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LiuGong CLG2100H Operation And Maintenance Manual

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202206000
CLG2100H/2120H
FORKLIFT TRUCK
( 英语 )
OPERATION AND
MAINTENANCE MANUAL

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Summary of Contents for LiuGong CLG2100H

  • Page 1 202206000 CLG2100H/2120H 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

    June 29, 2022 CLG2100H/2120H CONTENTS Preface Operation Manual Before Operating the Machine ......46 Safety Information Operator Controls and Instrument Panels ..47 Safety Decals and Decal Locations ....4 Engine Starting ..........60 General Safety Considerations ......16 Operation Techniques ........61 Preventing Crushing and Cutting .....19...
  • Page 6 June 29, 2022 CLG2100H/2120H...

  • 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 Parts Of The Machine

    18. Fork 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: Safety Information

    Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H 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 11 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Decal location 1. DANGER DECAL 6. WARNING DECAL 2. DANGER DECAL 7. WARNING DECAL 3. NOTICE DECAL 8. WARNING DECAL 4. WARNING DECAL 9. WARNING DECAL 5. CAUTION DECAL...
  • Page 12 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in ISO Standard Market) Fig. 1 DANGER DECAL (Located at crush area) CRUSH HAZARD. Do not enter working area of forklift. 74A 3293 Fig. 2 DANGER DECAL (Located on left side of mast) No passengers on or under fork.
  • Page 13 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in ISO Standard Market) Fig. 3 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.
  • Page 14 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in ISO Standard Market) Fig. 4 WARNING DECAL (Located on the instrument stand) Before starting: Only trained qualified operators should operate forklift truck. Check every control and alarm system before operating forklift truck.
  • Page 15 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in ISO Standard Market) Fig. 5 CAUTION DECAL (Located on the top of the engine hood) Hot surface, keep clear 74A3735 Fig. 6 WARNING DECAL (Located near the engine fan) CUTTING HAZARD.
  • Page 16 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in ISO Standard Market) Fig. 8 WARNING DECAL (Located in front of frame) CRUSH HAZARD. Keep clear of mast. 74A3303 Fig. 9 DANGER DECAL (Located on right side of mast) No passengers on or under fork.
  • Page 17 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in the USA Market) Fig.1 DANGER DECAL ( Located at crush area ) CRUSH HAZARD. Do not enter working area of forklift. 74A3229 Fig. 2 DANGER DECAL (Located on left side of mast) No passengers on or under fork.
  • Page 18 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in the USA Market) Fig. 3 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.
  • Page 19 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in the USA Market) Fig. 4 WARNING DECAL (Located on the instrument stand) Before starting: Only trained qualified operators should operate forklift truck. Check every control and alarm system before operating forklift truck.
  • Page 20 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in the USA Market) Fig. 5 CAUTION DECAL (Located on the top of the engine hood) Hot surface, keep clear. 74A3734 Fig. 6 WARNING DECAL (Located near the engine fan) CUTTING HAZARD.
  • Page 21 Safety Information June 29, 2022 Safety Decals and Decal Locations CLG2100H/2120H Safety Decals (Used in the USA Market) Fig. 8 WARNING DECAL (Located in front of frame) CRUSH HAZARD. Keep clear of mast. 74A3136 Fig. 9 DANGER DECAL (Located on right side of mast) No passengers on or under fork.

  • Page 22: General Safety Considerations

    Safety Information June 29, 2022 General Safety Considerations CLG2100H/2120H 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 23 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 24 Safety Information June 29, 2022 General Safety Considerations CLG2100H/2120H 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, Information on Using Accumulators causing serious injury or death.

  • Page 25: Preventing Crushing And Cutting

    This product does not contain asbestos, and guard afterwards. LiuGong recommends using only genuine Spinning engine fan blades can cut fingers. Keep LiuGong parts. If you need to handle materials a safe distance or turn off the engine when that contain asbestos, follow these guidelines: servicing.

  • Page 26: Fire And Explosion Prevention

    Safety Information June 29, 2022 Fire and Explosion Prevention CLG2100H/2120H Coolant Release system pressure before removing any hoses, fittings, or similar parts. At operating temperature, the engine coolant is very hot and under pressure. Hot water and Batteries steam are present in the radiator and all hoses attached to it.

  • Page 27: Fire Extinguishers And First-Aid Kit

    Promptly repair any loose or damaged fuel or lubricant lines and hydraulic system hoses and Do not weld or flame cut pipes that contain pipes. Leaks can cause fires. Contact a LiuGong flammable liquids. Clean up any flammable Machine Works authorized dealer for repairs or liquids before welding or flame cutting.

  • Page 28: Electrical Storm Injury Prevention

    Safety Information June 29, 2022 Electrical Storm Injury Prevention CLG2100H/2120H Prepare in advance the phone numbers of Fuel should be supplied from designated fuel relevant personnel to contact in case of stations. Ensure that fuel stations are well- emergency (physicians, emergency services, fire ventilated, free of sparks and flames, and department, etc.).

  • Page 29: Information On Attachments

    1640 feet (500 attachments is strictly prohibited. meters) from the machine, and may result in LiuGong is not responsible for any injuries, personal injury or death, or damage to property. accidents, or damage to the machine caused by Do not approach heated tires.
  • Page 30 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Know Your Machine Check whether any fasteners are loose or missing. Be able to operate all equipment on the machine. Check the wiring harnesses for wear or abrasion. Understand the purpose of all control systems, Check that fuses are intact and all connections instruments, and indicator lights.
  • Page 31 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Engine exhaust can cause illness or death. If you need to start the engine in a closed or poorly- ventilated area, open doors and windows to ensure adequate ventilation and prevent gas poisoning.
  • Page 32 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Operating the Machine The driver has an important responsibility to protect the safety of pedestrians. Pedestrians Before driving on public roads, check that the often have the right-of-way. Pay special machine meets the requirements of local traffic attention, especially when turning corners.
  • Page 33 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Use appropriately-sized loading platforms. No one is ever allowed underneath a raised fork. Check the loading platform’s condition, strength, Before lowering the fork, check that no one else and safe loading capacity.
  • Page 34 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Check whether the load on the loading platform Always use the load backrest and overhead is loose. Strap down the load securely before guard when stacking loads up high. Pay special transporting it.
  • Page 35 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Maintain a safe distance so that you can stop the vehicle safely under any conditions. Tilt the mast backwards while driving, keeping the load against the backrest. Do not lift or lower Overtaking is prohibited.
  • Page 36 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Slow down on wet or slippery surfaces. 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 37 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H When the load is so large that it blocks the view in front, drive in reverse or have an assistant guide you. When moving wide loads, be mindful of clearances on both sides. Drive in the middle of...
  • Page 38 Safety Information June 29, 2022 Cautions about Machine Operation CLG2100H/2120H Parking the Machine Park the machine on a level surface where there is no danger of falling stones or landslides. If the ground is low, make sure there is no danger of flooding.

  • Page 39: Maintaining The Machine Safely

    Safety Information June 29, 2022 Maintaining the Machine Safely CLG2100H/2120H Lowering Working Devices when the Engine Transporting the Machine is Off When transporting the machine, follow all Before lowering the working device, ensure that national and local regulations regarding limits on no one else is near the machine.

  • Page 40: Stability And Center Of Gravity

    Safety Information June 29, 2022 Stability and Center of Gravity CLG2100H/2120H When welding on the machine, disconnect the Wear non-slip shoes when cleaning to prevent master power switch and instrumentation system slipping on wet surfaces. plug. Otherwise, burn damage to the instrument panel components may occur.
  • Page 41 Safety Information June 29, 2022 Stability and Center of Gravity CLG2100H/2120H Forklift Stability The weight at both ends is balanced with the front axle as the fulcrum. The forklift’s stability is determined by the centers of gravity of both the load and the vehicle.

  • Page 42: Sound And Vibration

    Safety Information June 29, 2022 Sound and Vibration CLG2100H/2120H Sound and Vibration Center of Gravity Stability Range For the forklift to be stable, the center of gravity Sound must be within the “stability triangle” formed by 3 points: the two points where each of the front...

  • Page 43: Key Spare Parts To Be Periodically Changed

    Safety Information June 29, 2022 Key Spare Parts to be Periodically Changed CLG2100H/2120H 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 44: 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 45: Main Specifications

    Application and Specification June 29, 2022 Main Specifications CLG2100H/2120H Main Specifications All rated operation 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 46 Application and Specification June 29, 2022 Main Specifications CLG2100H/2120H Machine specifications (CLG2100H) CLG2100H CLG2100H Model Item Unit Power Type Diesel Diesel General Base Capacity rated load center 10000 10000 Load Center Service Weight unloaded 11800 11800 Weights loaded/unloaded, front 19750/4750...
  • Page 47 Application and Specification June 29, 2022 Main Specifications CLG2100H/2120H service Foot / Hyd Foot / Hyd Brakes parking Hand / Mech Hand / Mech manufacturer Yuchai Cummins model YC4A125-T300 QSF3.8 China Tier II, China Tier II, emission compliance Stage III...
  • Page 48 Application and Specification June 29, 2022 Main Specifications CLG2100H/2120H 22 Length to Fork Face with std 2-stage mast 4460 4460 23 Overall Width 2000 2000 24 Overhead Guard Height 2225 2225 25 Turning Radius minimum outside 4350 4350 with std 2-stage mast (with...

  • Page 49: Specifications

    Application and Specification June 29, 2022 Main Specifications CLG2100H/2120H Main Parts Specifications Parts Item Specifications Yu Chai YC4A125-T300 diesel Model Cummins QSF3.8 diesel engine engine Vertical type, in-line, 4-stroke, Vertical type, in-line, 4-stroke, turbocharged & air-cooled, turbocharged & air-cooled, Type...
  • Page 50 Work Scope Operate the machine according to the rated load capacity in the load curve chart . (The load chart used for CLG2100H forklift, 2-stage mast.) (The load chart used for CLG2120H forklift, 2-stage mast.) Note: Under standard condition (load center: 600mm), the rated load capacity is 10000kg and 12000kg.
  • Page 51 Application and Specification June 29, 2022 Main Specifications CLG2100H/2120H External Dimension and Weight of Dismountable Components External Dimension Components Weight (kg) Note length × width × height (mm) Equipped with Mast 896 × 1803 × 2205 2200 standard carriage Counterweight (10T) 1373 ×...

  • Page 52: Operation Manual

    Operation Manual June 29, 2022 Before Operating the Machine CLG2100H/2120H 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 53: Operator Controls And Instrument Panels

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Operator Controls and Instrument Panels 1. Central instrument panel 9. Seat 2. Steering wheel 10. Switch panel 3. Shift control lever 11. Start witch 4. Parking brake lever 12. Combination switch 5.

  • Page 54: Start Switch

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Start Switch PREHEAT------Turn the start switch key counterclockwise from OFF to PREHEAT position to preheat the engine. When the start The start switch (also called ignition switch) is switch key is released, the key will return to OFF located on the right side of the steering column.

  • Page 55: Battery Disconnect Switch

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Battery Disconnect Switch Instrument Panel This switch connects the negative terminal of the battery to the cable of the frame. Turn the start switch to OFF position before turn on or turn off the disconnect switch.
  • Page 56 Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Neutral Indicator Engine Intake Air Filter Alert Indicator (Not available in this It is illuminated when the machine is in model) Neutral position after turn on the start switch, and it goes out when the start switch is in It is illuminated when the air filter is blocked to other positions.

  • Page 57: Operator Controls

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Operator Controls Control Valve Lever The control valve lever is used to lift and lower Shift control lever the forks.. 1. Lift lever Push the lever forwards, the machine drives 2.

  • Page 58: Parking Brake Lever

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Pull the Positioner Lever-LH Parking Brake Lever backwards, the hydraulic oil will go into the small cavity of right fork-shifter cylinder, the cylinder retracts, the left fork moves to right.

  • Page 59: Brake Pedal

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Brake Pedal Use your hand to press down the fine adjustment pedal to check the free stroke until you feel the resistance. Depress the fine adjustment pedal The brake pedal is located at the front right side and check for any obstacle or abnormality.

  • Page 60: Combination Switch

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H An ordinary steering wheel is provided for this Combination Switch machine. The steering wheel is located inside the cab and connected with the hydraulic The combination switch is located at the right metering pump.
  • Page 61 Replace it when necessary. Contact your when any one of the fault indicators turns on. LiuGong dealer for seat belt replacements. Stop the machine to repair until the fault is Adjust length of the seat belt before use in order eliminated.

  • Page 62: Engine Hood

    Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Engine Hood Fastening the seat belt reduces the risk of injury or death in the event of a tipover. To prevent serious injury or death of the driver due to a tipover, keep the seat belt fastened when driving the machine.
  • Page 63 Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Engine Rear Hood Fork Forks are installed on the fork arm carrier through the shaft. The forks can be adjusted according to the configuration of the machine. To the machine equipped with cylinder forkshift...
  • Page 64 Operation Manual June 29, 2022 Operator Controls and Instrument Panels CLG2100H/2120H Forkshift Attachment Drawbar Two forkshift cylinders drive the forks smoothly to The drawbar is located behind the counterweight carry out the clearance adjustment of the forks, is only used to tow the machine when the wheels as shown below.
  • Page 65 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 66: Engine Starting

    Operation Manual June 29, 2022 Engine Starting CLG2100H/2120H The bucket (if equipped) can only be used to shovel, load and unload loose material with small density, e.g. loose sediment, chemical fertilizer, wood flour and vegetables etc. Estimate loading Start the engine only after the shift control...

  • Page 67: Operation Techniques

    Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H 6. After starting from cold, allow the engine to warm at idle speed (650-750r/min). Do not ISUZU Engine Start Switch apply load to the engine until the temperature has risen to normal on the temperature gauge.

  • Page 68: Steering Operation

    Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H Steering Operation 2. Use the shift control lever to get the desired speed and the direction. 1. Release the accelerator pedal to reduce the speed of the engine firstly. 2. Depress the brake pedal to reduce the speed In the unloaded condition, 2nd gear may be of the machine.

  • Page 69: Brake Operation

    Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H Downhill Operation 5. Turn the turn indicator switch to NEUTRAL after finish steering operation. Then the turn signal lights and turn indicator will go out. 1. Always select the lowest acceptable gear 6.
  • Page 70 Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H 2. Drive the forklift slowly to approach the 6. When drive the forklift with a load down the goods. Align the forks with the center line of hill, it is better to drive the machine reversely goods at a slow speed to avoid damaging the at a slow speed.

  • Page 71: Cold Weather Operation

    Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H Transporting Wide or Long Loads 4. The coolant must contain antifreeze. Adjust the concentration of antifreeze in the coolant based on the local minimum temperature. It Be especially careful when transporting wide or is best to prepare the coolant for long loads.

  • Page 72: Hot-Weather Operation

    Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H Hot-Weather Operation Parking the Machine Stopping the Machine When driving the machine in hot weather, pay attention to the following: Park the machine on level ground. If it is necessary to park the machine on a slope, then place blocks under the wheels.

  • Page 73: Storing The Machine

    Operation Manual June 29, 2022 Operation Techniques CLG2100H/2120H Leaving the Machine While Stored 1. Close the left and right cab doors (if The vehicle should be started once per month. equipped). The mast should be lifted, lowered, and tilted forward and backward three or more times each 2.

  • Page 74: Transporting And Hoisting The Machine

    This will prevent the machine from moving during loading and transport. 8. For components removed for transport, 3. Before transporting, make sure the trailer contact an LiuGong authorized service center floor is strong enough. for reassembly. 4. The trailer must be fully braked, with the 9.
  • Page 75 Operation Manual June 29, 2022 Transporting and Hoisting the Machine CLG2100H/2120H 5. Tilt the mast backward and place blocks 9. Install the nuts alternately from one side of under both sides of it. the wheel to the other. Tighten the nuts temporarily.
  • Page 76 Operation Manual June 29, 2022 Transporting and Hoisting the Machine CLG2100H/2120H 7. Install the nuts alternately from one side of the wheel to the other. Tighten the nuts temporarily. Make sure that the jack’s capacity is at least 2/3 of the forklift’s total weight.
  • Page 77 Operation Manual June 29, 2022 Transporting and Hoisting the Machine CLG2100H/2120H Equipped with hydraulic fork positioners 3. To disassemble the connection between the (without sideshifter): fork and the fork positioner cylinder, remove components (5), (6), and (7) as shown in the...

  • Page 78: Hoisting The Machine

    Operation Manual June 29, 2022 Transporting and Hoisting the Machine CLG2100H/2120H 2. Move the fork so that the hook passes through the fork carriage, then slowly adjust the fork until the fork pin (1) can be installed. 1. Fork pin 2.
  • Page 79 Operation Manual June 29, 2022 Transporting and Hoisting the Machine CLG2100H/2120H 2. When hoisting, ensure that the four hoist 4. The hoisting device must be fixed securely to hooks bear weight evenly, and that the the hoisting eyes marked on the machine, hoisting point is directly above the machine’s...

  • Page 80: Maintenance Manual

    Maintenance Manual June 29, 2022 Breaking In a New Vehicle CLG2100H/2120H 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 81: 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 82 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Engine Every Every Every month 3 months 6 months Check Item Content Tool year (200Hr) (500Hr) (1000Hr) (8Hr) (2000Hr) Observe and check engine running ○ ○ ○ ○ ○ condition Engine noise ○...
  • Page 83 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Every Every Every month 3 months 6 months Check Item Content Tool year (200Hr) (500Hr) (1000Hr) (8Hr) (2000Hr) Observe and check oil ○ ○ ○ ○ ○ tube, oil pump, and oil...

  • Page 84: Power Train

    Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Power Train Every Check Every 3 Month 6 Month Every year Content Tool month Item day (8 Hr) (500 Hr) (1000 Hr) (2000 Hr) (200 Hr) Leakage ○ ○ ○ ○...
  • Page 85 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Wheels Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) Charge pressure Barometer ○ ○ ○ ○ ○...

  • Page 86: Steering System

    Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Steering System Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) ○ ○ ○ ○ ○ Check clearance Check axial ○...
  • Page 87 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Brake System Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) Free travel ○ ○ ○ ○ ○...
  • Page 88 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) Brake drum attaching Detect ○ ○ ○ ○ parts loose or not...

  • Page 89: Lift System

    Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Lift System Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) Fork damage, distortion, wear ○ ○ ○...
  • Page 90 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) Check the tension condition of chain, ○ ○ ○...
  • Page 91 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Hydraulic System Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) ○ ○ ○ ○ ○ Check oil level ●...
  • Page 92 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H Safety Devices and Attachment Check Every day Every month 3 Month 6 Month Every year Content Tool Item (8Hr) (200Hr) (500 Hr) (1000 Hr) (2000 Hr) Installation is Detect Overhead stable or not...
  • Page 93 Maintenance Manual June 29, 2022 Maintenance Interval Schedule CLG2100H/2120H When using the 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 94: General Torque Specifications

    Maintenance Manual June 29, 2022 General Torque Specifications CLG2100H/2120H General Torque Specifications Tighten the bolts used in the machine according to the torque requirements shown in the following table unless other specified: Metric Thread Standard Torque Standard Torque lb.ft (N·m) Thread Size 8.8 Grade Strength...

  • Page 95: Oil Specifications

    Maintenance Manual June 29, 2022 Oil Specifications CLG2100H/2120H Oil Specifications Oil Specifications Oils those used in this machine should meet the following specifications when refilling or replacing to ensure the normal use of the machine. Type of oil Capacity Oil type and classification...
  • Page 96 Maintenance Manual June 29, 2022 Oil Specifications CLG2100H/2120H 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 97: Tires

    Maintenance Manual June 29, 2022 Tires CLG2100H/2120H 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

    These to prevent injuries from tipping over. safety measures apply only to general inspection and lubrication tasks. Further safety measures are required for repairing the mast or replacing the cylinders or chains. Contact your LiuGong dealer for details.
  • Page 99 Maintenance Manual June 29, 2022 Working Device System CLG2100H/2120H Collapse prevention measures for ordinary 2- stage masts The sprocket rotates when the inner mast is Adjusting the mast chains: with the mast lifted, and the movement speed ratio of the fork vertical, the forks lowered to the ground, carriage to the inner mast is 2:1.
  • Page 100 Maintenance Manual June 29, 2022 Working Device System CLG2100H/2120H 2. Use chains to bind the outer mast’s upper cross member (A) to the inner mast’s lower cross member (B). 3. Slowly lower the inner mast until it is caught Select the appropriate chains according to by the chain.

  • Page 101: Important Maintenance Procedures

    Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Important Maintenance 2. Wait until the engine coolant temperature drops to 122 °F (50 °C), then slowly unscrew Procedures the cap on the radiator to release the pressure in order to prevent burns from hot vapor or hot coolant spraying out.
  • Page 102 Radiator coolant can damage paint. If any LiuGong recommends the following brands and splashes out, rinse it off quickly. specifications of antifreeze: Only soft water (demineralized water) should be...
  • Page 103 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 2. Insert the key in the start switch and turn Coolant--Replace clockwise to the “ON” position to turn on the power of the machine. Care must be taken in order to ensure that...
  • Page 104 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 4. After draining out coolant of the engine, close Coolant--Drain Out the water release valve on the bottom of the water radiator. 5. Replenish cleanser mixed with water and sodium carbonate into the cooling system of Do not drain the coolant before the engine is the engine, its proportion is 0.5 kilograms of...
  • Page 105 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Engine Air Filter--Clean 2. Remove the cover of the air filter. Check the air filter termly, replace the air filter when blocked happened. The engine intake air filter alert indicator on the instrument panel will illuminate when the air filter is blocked to some extent.
  • Page 106 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H (3). Detergent (Dip the element in the neuter 9. Replace the main filter element after it has detergent about 30 minutes and wash it.) been cleaned up to six times. Replace once every year even if it hasn’t been cleaned six...
  • Page 107 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Fuel Level--Check Fuel--Replenish Do not refill the fuel tank if 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 June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Fuel Tank--Clean Fuel System Moisture and Impurities-- Remove If any dust or moisture is present in the fuel, the fuel pump and injectors will not function properly Care must be taken to ensure that fluids are and wear will be accelerated.
  • Page 109 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Fuel System Air--Drain out Fuel Filter and Pre-filter--Replace Under normal work conditions, air can enter into the fuel system in the following ways: 1. Drain out fuel when the machine is working.
  • Page 110 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 4. Install a new gasket on the thread connector Engine Oil Level--Check of the support of the fuel filter. Apply a coat of engine oil on the seal surface of the filter. Fill the fuel filter with clean fuel.
  • Page 111 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Engine Oil--Replace 4. Tighten the oil drain plug and replenish clean engine oil from the oil filler of the engine until the engine oil is at H on the oil dipstick. Run the engine at idle speed to check the engine oil filter and oil drain plug for leakage.

  • Page 112: Power Train System

    Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Engine Oil Filter--Replace 5. Secure the engine oil filter on the support and tighten the gasket of the engine oil filter until it contacts with the support.Tighten engine oil 1. Clean the area around the support of the filter to 3/4~1 turn with the spanner.
  • Page 113 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Transmission Oil--Replace 2. Oil drain plug Replace the transmission oil after the first 100 service hours. After that, change the Because the transmission oil temperature is transmission oil every 1000 service hours at still high when draining, wear protective least once a year.
  • Page 114 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 9. When the transmission oil reaches the Transmission primary filter operating temperature (80~90 °C), check the level again. The level should be between High (H) and Low (L) graduation of the dipstick.
  • Page 115 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 3. Clean the seal surface of the support with a 3. Remove the oil drain plug. The oil level of the clean cloth and install with a new primary axles should be just below the oil drain outlet.

  • Page 116: Hydraulic System

    Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 5. Replenish with clean axle oil at the oil filler plug on the top of the front axle until the oil level reaches the lower side of the oil release outlet. Observe for about 5 minutes after replenishing.

  • Page 117: Brake System

    Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 4. Clean the hydraulic oil tank drain plug. Screw 7. Replenish clean hydraulic oil at the oil inlet of out the oil drain plug to drain out hydraulic oil the hydraulic tank until the oil level reaches and collect with a waste container.
  • Page 118 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 2. Accumulator Pressure-- Release Ensure the parking brake system works normally before check the service brake performance so that the parking brake lever can work properly if an emergency happens. Drive the forklift on a flat and dry road at a speed of 20 kilometers/hour.

  • Page 119: Electrical System

    Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Electrical System 2. Start the machine and drive it onto a slope with 15% (8.53°) grade. The slope surface should be flat and dry. Battery Never let burning cigarette or open fire close to the batteries.
  • Page 120 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Open the cover of the battery, clean the battery Battery--Install terminals and the battery surface with a clean cloth. Check the battery electric charge state with 1. Turn the ignition (also known as “key switch”) eyeballing when the ray is bright enough.
  • Page 121 Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H 4. Tighten each nut securely. Remove the battery from the machine. When ● removing the battery, disconnect the negative cable from the battery first. Use a clean cloth to clean off the battery ●...

  • Page 122: Disposing Of Batteries

    Maintenance Manual June 29, 2022 Important Maintenance Procedures CLG2100H/2120H Maintaining the Battery When the 11.50-11.30 Machine is in Storage 11.30-11.00 < 11.00 If the machine is to be stored for more than ● If the battery’s voltage is below 11 V, it may ●...

  • Page 123: Other Maintenance

    Forward position, t he backup alarm should stop hooting. Replacing the broken fuse with a new one with same specification and series from different manufactures is allowed. There may be a circuit failure if frequent fuse replacement occurs. Please contact LiuGong dealer if necessary.

  • Page 124: Machine Electrical Schematic

    3. No matter how well the seat belt looks like, replace it every three years. 4. Consult your LiuGong dealer for the replacement of the seat belt. Machine Electrical Schematic Refer to the end of this manual for electrical...

  • Page 125: Troubleshooting

    Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Troubleshooting Power Loss Parts Cause of malfunction Method of inspection Troubleshooting A. Oil pressure is too low: (1) oil level is too low Check the oil level Refilling (2)Air is taken into the oil suction...
  • Page 126 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Abnormal Oil Temperature Parts Cause of malfunction Method of inspection Troubleshooting (1) Oil level is low Check the oil level Refilling (2) Filter is blocked Remove and check Clean and replace Discharge the oil from filter or oil...

  • Page 127: Oil Leakage

    Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Oil Leakage 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 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Parking Brake Malfunction Analysis Malfunction Causes Troubleshooting Brake rod is not in position Adjust The friction plate clearance is adjusted incorrectly. Adjust Brake is overheated Check for any slip Brake force is The contact between brake drum and friction plate is not...
  • Page 129 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Steering Gear Malfunction and Troubleshooting Malfunction Cause Symptom Troubleshooting Leakage of oil from valve body, Dirt on the joint surface partition, stator and the joint Wash it again surface of rear cover Leakage of oil at the neck of the...
  • Page 130 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Malfunction Cause Symptom Troubleshooting (1) The steering column is different from the valve core The pressure drop at middle Steering wheel (2) The steering column pushes position becomes increasingly can not return to...
  • Page 131 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Steering System Troubleshooting Malfunction Causes Troubleshooting Flow control valve lever is blocked Take it out for repair or replace it The steering wheel is stagnant when fast turn is made Flow control valve lever is worn...
  • Page 132 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Brake System Troubleshooting Malfunction Causes Troubleshooting 1. The clearance between the brake drum and the friction shoe linings is too large, or the friction plate clearance is adjusted Adjust the clearance unevenly. 2.Leakage of the secondary pump Replace the rubber cup 3.Leakage of the braking system, and mixed with air...
  • Page 133 Maintenance Manual June 29, 2022 Troubleshooting CLG2100H/2120H Lifting System Troubleshooting Malfunction Causes Troubleshooting 1.Wear and tear of the gear pump, and too much clearance in Replace the wearing parts or movement oil pump 2.Seal piece failure of lifting cylinder, there is in-leakage Replace the seal piece 3.Main relief valve spring failure of the control valve...

  • Page 134: Maintenance Note Table

    Maintenance Manual June 29, 2022 Maintenance Note Table CLG2100H/2120H Maintenance Note Table...

  • Page 135: Index

    INDEX June 29, 2022 CLG2100H/2120H INDEX Abnormal Oil Temperature ......120 Daily Inspection ..........95 Accelerator Pedal ..........53 Depositing Loads ..........64 Accumulator ..........111 Disassembling the Forks ........ 70 Air Filter Safety Element--Replace ....100 Disposing of Batteries ........116 Application and Specification ......38 Downhill Operation .........
  • Page 136 INDEX June 29, 2022 CLG2100H/2120H Storage ............116 Maintaining the Machine Safely ...... 33 Maintenance Interval Schedule ...... 75 General Safety Considerations .......16 Maintenance Manual ........74 General Torque Specifications ......88 Maintenance Note Table ......128 Malfunction Analysis ........122 Mast--Lubricate ..........
  • Page 137 INDEX June 29, 2022 CLG2100H/2120H Safety Decals and Decal Locations ....4 Wheels ............79 Safety Devices and Attachment ......86 Wheels--Change ..........68 Safety in Attachment Installation, Adjustment and While Stored ........... 67 Use ..............58 Working Device System ......... 92 Safety Information ..........4 Safety Warning Labels ........4...
  • Page 138 INDEX June 29, 2022 CLG2100H/2120H...
  • Page 139 June 29, 2022 CLG2100H/2120H Hydraulic Schematic Diagram Hydraulic Schematic Diagram 50Y1490...
  • Page 140 June 29, 2022 CLG2100H/2120H Electrical Schematic Diagram Electrical Schematic Diagram 50Y0989 Yuchai YC4A125-T300 engine...
  • Page 141 June 29, 2022 CLG2100H/2120H Electrical Schematic Diagram Electrical Schematic Diagram 50Y0924 Cummins QSF3.8 engine...
  • Page 142 June 29, 2022 CLG2100H/2120H Brake Schematic Diagram Brake Schematic Diagram 50Y1495 disk type brake...

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