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LiuGong CPCD15 Manual

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Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown following.
The meaning of this safety alert symbol is as follows:
Attention. Be alert. Your safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
LiuGong cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by LiuGong is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged or
made unsafe by the operation, lubrication, maintenance or require procedures you choose.
The information, specification, and illustrations in this publication are on the basis of information
available at the time when it was written. The specification, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service
given to the product. Obtain the complete and most current information before starting any job. LiuGong
has the most current information available.
CALIFORNIA PROPOSITION 65
Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.

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Summary of Contents for LiuGong CPCD15

  • Page 1 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 2: Table Of Contents

    CONTENTS CONTENTS Preface Operation Manual Main Components of the Machine ....3 Before Operation ..........45 Serial Number of the Machine and Parts ...3 Operator Controls and Instrument Panels ..46 General Hazard Information ......12 Main Parts of the Forklift Body ......52 Crushing and Cutting Prevention .....15 Engine Starting ..........
  • Page 3 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 4 8 service hours or daily. All the information, figures, tables and specifications are the latest product information obtainable at the time of publication. Guangxi Liugong Company will reserve the right to make change without notice. Certified Engine Maintenance Correct maintenance and repair methods are essential to keeping the engine and machine systems operating correctly.

  • Page 5: Preface

    8. Steering axle 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 6: Safety Information

    Safety Information Safety Decals and Decal Locations Safety Information "Caution" is also used to indicate safety information relating to unsafe operations which may cause personal injuries. "Danger" represents the most dangerous conditions. The Safety Symbol safety signs "Danger" or "Warning" are placed near particular dangerous places.
  • Page 7 Preface Serial Number of the Machine and Parts Used for 1.5t forklifts 1. WARNING DECAL 7. WARNING DECAL 2. NOTICE DECAL 8. WARNING DECAL 3. DANGER DECAL 9. CAUTION DECAL 4. DANGER DECAL 10. WARNING DECAL 5. WARNING DECAL 11. DANGER DECAL 6.
  • Page 8 Preface Serial Number of the Machine and Parts Used for 2t, 2.5t, 3t, 3.5t forklifs FO R K LI F T TR U C K G u a n g x i L i u g o n g M a c h i n e r y C o . , L t d . N o .
  • Page 9 Preface Serial Number of the Machine and Parts Safety labels Fig. 1 WARNING DECAL (Located on the instrument stand) 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 10 Preface Serial Number of the Machine and Parts Safety labels Fig. 3 DANGER DECAL (Located on left side of mast) CRUSH HAZARD. Do not enter working area of forklift. 74A3293 Fig. 4 DANGER DECAL (Located on left side of mast) No passengers on or under fork.
  • Page 11 Preface Serial Number of the Machine and Parts Safety labels Fig. 5 WARNING DECAL (Located on the engine hood) 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 12 Preface Serial Number of the Machine and Parts Safety labels Fig. 6 WARNING DECAL (Located near the tire) IMPACT HAZARD. During inflation of tire, stand forward or behind wheel. Release pressure before repair. Read and understand Operation& Maintenance Manual for proper procedure.
  • Page 13 Preface Serial Number of the Machine and Parts Safety labels Fig. 9 CAUTION DECAL (Located on the counterweight) Hot surface, keep clear 74A3625 Fig. 10 WARNING DECAL (Located on the middle beam of mast) CRUSH HAZARD. Keep clear of mast. 74A3303 Fig.

  • Page 14: General Hazard Information

    Preface 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 15 Secure all loose items such as lunch boxes, tools and others. Report all required repairs in time. Do not allow unauthorized personnel on or around the machine . Guangxi Liugong bear no resposibility for failures caused by modifications to machine structure without Liugong’s permission.
  • Page 16 Preface General Hazard Information Compressed Air Even a pin-hole size leak can cause serious injury, If you are hit by spraying high-pressure oil, Compressed air can cause personal injury. When see a doctor for treatment at once. using compressed air for cleaning, wear a protective face shield, protective clothing, hearing protection and protective shoes.

  • Page 17: Crushing And Cutting Prevention

    Check all protective devices for safety such as your health. Equipment and replacement parts doors, safety guards and covers. Ensure they shipped from Liugong have no asbestos in them. have been installed correctly so as to avoid any Liugong recommends the use of genuine factory possible injury caused by moving parts, for spare parts only.

  • Page 18: Burn Prevention

    Preface Burn Prevention Keep hands and objects away from moving fan Check the coolant level only after the engine has blades. They can throw or cut any object that been stopped and the coolant filler cap is cool contacts the moving blades. enough to remove with your bare hand.

  • Page 19: Fire & Explosion Prevention

    Keep all fuels and lubrications stored in properly system tubes or hoses. Repair any damaged fuel marked containers and away from all or oil lines, tubes or hoses. Leaks can cause unauthorized persons. fires. Contact Liugong or your Liugong Dealer for factory authorized replacement parts.

  • Page 20: Fire Extinguishers And First-Aid Kit

    Preface 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 21: Fuel

    Preface Fuel Fuel Tire Explosion Prevention Use the correct fuel type for your forklift. If the Maintenance, removal, repair and installation of use of the wrong fuel will impair forklift the tires and wheel rims must be performed with performance and lead to unpredictable faults or special equipment and a trained repairer.

  • Page 22: Attachment Cautions

    Understand Your Machine attachments without permission from your Liugong dealer. Be able to operate all the equipment on your Liugong bears no responsibility for injuries, machine. accidents or machine damage resulting from the Understand the purpose of all control systems, use of unauthorized attachments.
  • Page 23 Preface Cautions about Machine Operation Understand Your Working Area Replace all damaged or lost parts and carry out lubrication according to the maintenance interval Before starting, inspect the area where you will schedule. be working. You should check: adequate Remove all loose objects from the cab. Loose ventilation, the position of any slopes, visible objects may affect the operation and cause ditches, falling or hanging objects, conditions of...
  • Page 24 Preface Cautions about Machine Operation Ensure the hydraulic control levers are all in the Check the emission value in a safety outdoor NEUTRAL position and the shift control lever is area periodically. Pay attention to avoid fire, in the NEUTRAL position before starting the especially the leakage of oil or fuel when engine.
  • Page 25 Preface Cautions about Machine Operation Keep a correct posture on the seat. There may Don't overload. Make sure weights of loads are be an accident if you sit on the seat incorrectly or within the rated capacity of the forklift truck. operate the machine without sitting on the seat.
  • Page 26 Preface Cautions about Machine Operation Do not use this machine to lift personnel. Do not Adjust the fork width as wide as possbile. before allow anybody to ride on the fork. Use it for loading goods onto the fork, make sure that the carrying goods only.
  • Page 27 Preface Cautions about Machine Operation Never raise the goods on a rough road surface, Carry loads as close to the ground as possible. pay attention to road conditions all the time when Keep the forks 15 to 20mm off the ground in driving on a rough road surface.
  • Page 28 Preface Cautions about Machine Operation Keep a safe distance between machines so as to Slow down the forklift when driving on a wet road be able to stop the machine safely under any surface and slippery ground. circumstance. In the areas where the visibility is not good, you Never overtake other machines.
  • Page 29 Preface Cautions about Machine Operation It is not allowed to drive across unsolidified obstacles on the road. It is better to remove the obstacles before going across to avoid loosening the loads. Watch left and right side clearance, especially with wide loads. Where possible, drive in the center of the aisle to avoid endangering Pay attention to the plate hardness when driving personnel or equipment.
  • Page 30 Preface Cautions about Machine Operation When carrying goods with huge size and the front sight has been blocked, you should drive with reverse gear, or move forwards under a signalman’s help. Shut down the forklift truck when leaving it. Always park on flat ground with the forks lowered.

  • Page 31: Cautions About Machine Maintenance

    Preface Cautions about Machine Maintenance Parking the Machine Lowering the Attachment/ Implement with Engine Stopped When possible, choose flat level ground to park the machine, apply the parking brake (if CAUTION: For a machine controlled by equipped), always lower any attachment to the electro-hydraulically control lever, in order to ground and ensure the machine will not move, lower the implement, the engine start switch...
  • Page 32 Preface Cautions about Machine Maintenance Do not work under any part of the machine or Welding Operation attachment that is not adequately supported. Do not rely on hydraulic systems as support. Use Any personnel engaging in welding operations stands or other measures that are secure and must have occupational certificates and carry out can support the weight being applied to them.

  • Page 33: Stability And Barycenter

    Preface Stability and Barycenter When carrying out the cleaning operation, wear Forklift Stability suitable PPE. Consider exposure to: chemicals, slippery surfaces, high pressure water spray and Use front wheel as a pivot, two side weights keep material splash. in balance. Barycenter of the forklift and load determines the forklift stability.
  • Page 34 Preface Stability and Barycenter Stable Range of Barycenter In order to keep the forklift in stable condition, the barycenter should be in the triangle stable range surrounded by the grounding points of two front wheels and the pivot of rear axle (three points). If the complex barycenter is loacted in front of the triangle, the forklift will tipover forward, and it will tipover sideward if the complex barycenter is...

  • Page 35: Sound

    “EN12053:2001+A1: 2008 Safety of industrial trucks-Test methods for measuring noise emissions” is 104.8dB (CPC15/CPCD15), 105.3dB (CPC20), 105.8dB (CPCD20), 105.3dB (CPC25), 106.6dB (CPCD25), 106.1dB (CPC30/ CPC35), 106dB (CPCD30/CPCD35), 97dB (CPCD25 LPG).

  • Page 36: Key Spare Parts To Be Periodically Changed

    Preface Key Spare Parts to be Periodically Changed 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 High pressure hose or tube of hydraulic system Oil cup of brake liquid Brake pump, cover of the pump and dust cover Fuel hose...

  • Page 37: Applications And Specifications

    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 38: Main Specifications

    Applications and Specifications 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 39 Applications and Specifications Main Specifications Machine Specifications CPCD CPCD Type Unit CPCD15 CPC15 20/25 20/25 20/25 20/25 (ISUZU) (ISUZU) Rated capacity 1500 2000(2T)/2500(2.5T) Load center Max. lifting height 3000 3000 Fork free lift height Max. lifting speed (full-loaded) mm/s Tilt angle (fwd / bwd) 6°/ 12°...
  • Page 40 Applications and Specifications Main Specifications Machine Specifications Type Unit CPCD20(LPG)/CPCD25(LPG) Rated capacity 2000(2T)/2500(2.5T) Load center Max. lifting height 3000 Fork free lift height Max. lifting speed (full-loaded) mm/s Tilt angle (fwd / bwd) 6°/ 12° Transmission type Hydraulic Max. travel speed (full-loaded) km/h Max.
  • Page 41 Applications and Specifications Main Specifications Machine Specifications CPCD30/ CPC30/ Type Unit CPCD30/35 CPC30/35 35(ISUZU) 35(ISUZU) Rated capacity 3000/3500 Load center Max. lifting height 3000 Fork free lift height Max. lifting speed (full-loaded) mm/s 420(3t)/440(3.5t) Tilt angle (fwd / bwd) 6°/ 12° Transmissions type Hydraulic Mechanical...
  • Page 42 Applications and Specifications Main Specifications Main Components Specifications Xinchang490BPG/A490BPG Diesel Model NB485BPG-4 Diesel engine engine 4-stroke, direct injection, water 4-stroke, direct injection, water cooling, Type cooling, overhead valve overhead valve Type of cooling Closed, pressure water cooling Closed, pressure water cooling Order of ignition 1-3-4-2 1-3-4-2...
  • Page 43 Applications and Specifications Main Specifications Main Components Specifications Pump CBHZ-F32-ALH6L System maximum flow 32L/min Main overflow valve set pressure 20 MPa Safety valve set pressure: lifting and tilting 17.5 MPa Switch-over overflow valve set pressure 8.5MPa Hydraulic System Lifting cylinder quantity, bore × rod 2-Φ50×Φ45×1495 mm diameter ×...
  • Page 44 Applications and Specifications Main Specifications Work scope P lease operate the machine according to the rated load capacity in the load curve chart . (The load chart used for 1.5t forklift.) (The load chart used for 2t forklift.)
  • Page 45 Applications and Specifications Main Specifications (The load chart used for 2.5t forklift.) (The load chart used for 3t forklift.)
  • Page 46 Applications and Specifications Main Specifications (The load chart used for 3.5 forklift.) External Dimension and Weight of Dismountable Components External Dimension Components Weight (kg) length×width×height (mm) Standard mast (no fork) 550×808×1975 Counterweight (3t)) 680×1230×890 1760 Counterweight (3.5t) 740×1230×890 2040 Overhead guard 1392×1110×1450...

  • Page 47: Operation Manual

    Operation Manual Before Operation Operation Manual Daily Inspection For a maximum service life of the machine, complete a through walk-around inspection Before Operation before you mound the machine and before you start the engine. Inspect the area around and under the machine. Mounting and Dismounting Look for loose bolts, trash buildup, oil, and coolant leakage, broken parts, or worn parts.

  • Page 48: Operator Controls And Instrument Panels

    Operation Manual Operator Controls and Instrument Panels Operator Controls and Instrument Panels 1. Parking brake lever 7. Accelerator pedal 2. Steering wheel 8. Turn signal light switch 3. Fine adjustment pedal (Fluid drive) / clutch pedal 9. Fwd / Bwd shift control lever(Mechanical) (Mechanical) 10.

  • Page 49: Engine Start Switch

    Operation Manual Operator Controls and Instrument Panels Engine Start Switch CAUTION: 1. Do not turn the start switch to the PREHEAT position after stopping the engine, to do this will discharge the battery. The start switch is located on the right side of the steering column, and has four positions 2.

  • Page 50: Instrument Panel

    Operation Manual Operator Controls and Instrument Panels Instrument Panel If the indicator turns on during operation, that indicates that there is a fault in the charge circuit, you should park the machine on a safe and convenient place for repair at once. Engine oil pressure alert indicator When the start switch is at the PREHEAT position, the indicator will...
  • Page 51 Operation Manual Operator Controls and Instrument Panels Shift Control Lever (Mechanical) Control Valve Lever The control valve lever is used to lift and lower the fork. 1. Forward /Backward shift control lever 2. I/ II shift control lever 1. Lifting lever Forward: Push the handle forward, the machine 2.

  • Page 52: Parking Brake Lever

    Operation Manual Operator Controls and Instrument Panels Parking Brake Lever Service Brake Pedal The parking brake lever is located at the left side The service brake pedal is located in the front of the steering wheel. right side of the operator’s seat. Depress this pedal to engage the brake of the front axel, the brake lights will turn on.

  • Page 53: Steering Wheel

    Operation Manual Operator Controls and Instrument Panels Clutch Pedal (Mechanical) Steering Wheel The clutch pedal is located in the front left side of the operator’s seat. An ordinary steering wheel is provided for this machine. The steering wheel is located inside To change gear, you must depress down the the cab (a closed cab is optional) and connected clutch pedal first then operate the shift control...

  • Page 54: Choke Switch

    If the machine is equipped with an ISUZU diesel Before using the seat belt, check it for good engine (imported), you can stop the engine by condition. Replace it, if necessary. turning the start switch to “OFF” position. For seat belt replacement, consult with your Liugong dealer.

  • Page 55: Overhead Guard

    Operation Manual Main Parts of the Forklift Body Overhead Guard Adjust the length of the seat belt before using in order to ensure safety and comfortability. Length of the seat belt can be adjusted by moving the The overhead guard is an important safety part position of the catch on the seat belt.

  • Page 56: Engine Hood

    Operation Manual Main Parts of the Forklift Body Engine Hood Fork Lift and loosen the locking pins on both sides of the fork to adjust the fork left or right, tighten the locking pins to lock the fork. Keep the load center in he middle line of the machine when adjusting the fork.
  • Page 57 7. It is prohibited to modify the attachment moving left and right during operation. without the technical permission of Liugong As for those attachments with a position hook, as the modification could cause safety...

  • Page 58: Engine Starting

    Operation Manual Engine Starting Engine Starting 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 CAUTION: Clear personnel from around personnel that the machine will be starting the machine.

  • Page 59: Operation Techniques

    Operation Manual Operation Techniques Operation Techniques CAUTION: In the unloaded condition, 2nd gear may be used for start and travel, but in the loaded condition, 1st gear should always Traveling Operation of the be used to start. Machine 3. Turn the steering wheel and check the machine’s ability to turn in both directions.

  • Page 60: Downhill Operation

    Operation Manual Operation Techniques Brake Operation of the Machine When parking the machine, first release the accelerator pedal, then depress the brake pedal smoothly to perform service brake operations. WARNING: When the machine is running at high speed, unless an urgent situation develops, do not rapidly fully depress the brake pedal as this could cause an accident and damage of the machine and personal...

  • Page 61: Loading Operation

    Operation Manual Operation Techniques Loading Operation 1. Before loading, confirm whether the width of the pallet or the goods is suitablely matched with the opening degree of two forks. If it isn’t suitable, adjust the space between the two forks manually (or adjust the space through operating the control valve if the forklift is equipped with a fork positioner).

  • Page 62: Operation During Cold Weather

    Operation Manual Operation Techniques Operation during Cold Weather 10. Before operating, you should idle the engine to warm up it. CAUTION: If the ambient temperature is Operation during Hot Weather too low, the engine can not be started easily, and the radiator will be frozen. Pay attention to the following points when you 1.
  • Page 63 Operation Manual Operation Techniques Parking 3. If there is no anti-freeze in the machine, when the machine is parked in the winter, to prevent the water from freezing, open all Stop the Machine water valves of the engine and discharge the coolant in the cooling system and air 1.

  • Page 64: During Storage

    CAUTION: If the machine has not received an antirust additive each month 5. Drive onto and off the trailer at low speed. during storage, consult with your Liugong Never attempt to change direction while on dealer. the ramps, and carry out this operation by following the signlaman's instruction.
  • Page 65 6. Tilt the mast forward until the front wheels 8. Ask your Liugong dealer to install those parts being lifted off ground. that removed before transportation. CAUTION: Do not remove the nuts of the 9.
  • Page 66 Operation Manual Transportation Information 9. Install the nuts in turn as illustrated, and 4. Loosen the nuts of the wheels tighten the nuts temporarily. counterclockwise 1-2 turns. CAUTION: Do not remove the nuts of the wheels before the rear wheels being lifted off ground.

  • Page 67: Fork Removal

    Operation Manual Transportation Information 8. Remove the blocks under the frame. Lower the forklift slowly on to the ground, and then Figure 1 remove the wedges at the front wheels and the jack under the counterweight. 9. Tighten the bolts of the wheels in turn to specified torque, refer to "Tightening Torque of the Bolts"...

  • Page 68: Towing Information

    Operation Manual Transportation Information Fork Install Lift the machine Move the fork and carriage so the top hook on WARNING: Improper lifting or securing the fork can engage the upper carriage bar. could cause the machine to move Raise the carriage to move the lower hook accidentally and cause machine damage, through the fork removal notch.
  • Page 69 Operation Manual Transportation Information 4. The lifting device should be installed on the lift eyes with lifting decals on the machine. Ensure that the lifting ropes have strong enough capacity to lift the forklift. CAUTION: Ensure that the lifting devices do not interfere with the overhead guard and lights during lifting.

  • Page 70: Maintenance Manual

    Maintenance Manual Run-in Maintenance Manual 3. Check the oil levels of the transmission, axles and engine. 4. Check the hydraulic system and brake system for leakage. CAUTION: Perform the maintenance 5. Check temperatures and connections of the procedures at the intervals according to this electric system, power supply of the manual.

  • Page 71: 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 72 Maintenance Manual Maintenance Interval Schedule Engine leaks oil or ○ ○ ○ ○ ○ Check oil level, ○ ○ ○ ○ ○ cleanliness Lubrication system ● Replace engine oil ● ● ● First 50 hours Replace engine oil ● ● ●...
  • Page 73 Maintenance Manual Maintenance Interval Schedule Power Train Check Every day Every month 3 months 6 months Every year Content Tool Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr) Leak conditions ○ ○ ○ ○ ○ Check oil level or ○ ○ ● ●...
  • Page 74 Maintenance Manual Maintenance Interval Schedule Wheel rim, wheel Wheel rim, arm, and hub ○ ○ ○ ○ ○ wheel arm damage condition Check loose conditions and ○ ○ ○ ○ Axle noise bearing Clean and ● ● lubricate Check axle body distortion, cracks Axle ○...
  • Page 75 Maintenance Manual Maintenance Interval Schedule Brake System Check Every day Every month 3 months 6 months Every year Content Tool Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr) Free travel ○ ○ ○ ○ ○ Pedal travel Scale ○ ○ ○ ○ ○...
  • Page 76 Maintenance Manual Maintenance Interval Schedule Brake drum Detect attaching parts ○ ○ ○ ○ hammer loose or not Friction disc wear Vernier ○ condition scale Brake shoe movement ○ condition Anchor pin ○ corroded or not Brake drum Return spring and brake damage Scale...
  • Page 77 Maintenance Manual Maintenance Interval Schedule The welding part between crossbeam and ○ ○ ○ ○ inner mast, outer mast cracked, damaged or not Welding between tilting cylinder bracket and mast ○ ○ ○ ○ is not good, cracked or damaged Inner mast and outer mast welding is not...
  • Page 78 Maintenance Manual Maintenance Interval Schedule Check the tension condition of chain, ○ ○ ○ ○ ○ distorted, damaged, rusted or not Lubricate the ○ ○ ○ ○ chain Chain, sprockets Rivet pin loose ○ ○ ○ ○ condition Sprockets distorted, ○...
  • Page 79 Maintenance Manual Maintenance Interval Schedule Electrical System Check Every day Every month 3 months 6 months Every year Content Tool Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr) Pinion Starter ○ ○ ○ engagement motor condition Harness damage, ○ ○ ○ ○ loose conditions Wire Circuit...
  • Page 80 Maintenance Manual Maintenance Interval Schedule Safety Devices and Attachment Check Every day Every month 3 months 6 months Every year Content Tool Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr) Installation is stable Detect Overhead or not hammer guard and Check for distortion, load ○...

  • Page 81: General Torque Specifications

    Maintenance Manual General Torque Specifications General Torque Specifications Tighten bolts used in the machine according to the torque requirements shown in the following table unless others are specified: Standard Torque lbf. ft (N·m) Thread Size 8.8 Grade Strength 10.9 Grade Strength 7.7±1.1 (10.5±1.5) 19±...

  • Page 82: Tire Information

    The inflation pressure for nitrogen and air are the same when charing the tires. Consult your tire dealer for operating pressures. Liugong recommends the use of dry nitrogen for tire inflation and for tire pressure adjustments. It About the tire inflation pressures under normal includes all machines with rubber tires.
  • Page 83 Maintenance Manual Tire Information Cushion Tire--Replace 2. In order to offer a better installation, spray or apply lubricant such as soapsuds etc onto the surface of wheel hub and wheel rim to Replace the cusion tire as follows with a new one reduce the friction possibility between wheel if the tire is less than 3/4 thick.

  • Page 84: Working Implement System

    3. Lower the inner mast slowly till it is hung by chain and so on that needs further safety the chain. measures, please contact the Liugong forklift dealer. CAUTION: After maintenance, when the forks are lowered on to the ground, the two chains must be in tension state at the same time, otherwise please adjust the chain bolts.
  • Page 85 Maintenance Manual Working Implement System Drop-resistant Measures of Full Free Two Drop-resistant Measures of Three Stage Mast Stage Mast The middle lift cylinder firstly raises the fork to a Even operated in a very low space, this kind of particular free height through chain wheel, with mast can still raise freely .

  • Page 86: Lubrication Specifications

    Maintenance Manual Lubrication Specifications Lubrication Specifications Oil Change Intervals and Refill Capacities CAUTION: Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the equipment. Collect the fluid with a suitable container before opening any compartment or disassembling any component that contains fluids.

  • Page 87: Oil Specifications

    Maintenance Manual Lubrication Specifications Oil Specifications Oils that are 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 Tonnage 2~3.5t Lubricant engine 6# /8# hydraulic transmission oil (Fluid drive) crankcase...

  • Page 88: Important Maintenance Procedures

    Checking Method for Coolant Level Check the ROPS (if equipped) for visible damage. Consult with your Liugong dealer for 1. Stop the engine and loosen the screw on the repair information, if there is damage. plate.
  • Page 89 Maintenance Manual Important Maintenance Procedures Brand and performance of antifreeze recommended by Liugong are as follows: Min. suitable Mobil antifreeze environmental (concentration) temperature (°c) 3. Check the level of the coolant. It is normal when the coolant level is 10mm below the When adding antifreeze, use the same brand of water inlet.
  • Page 90 Maintenance Manual Important Maintenance Procedures Coolant--Replenish 4. Keep the radiator cap open, start the engine and run at idle speed for 5 minutes and then run at high speed for another 5 minutes until the coolant temperature reaches over 80 degrees Celsius.
  • Page 91 Maintenance Manual Important Maintenance Procedures 2. Start the engine, run at idle speed for 5 10. Replace with a new coolant filter, close the minutes, and then stop the engine. Slowly drain valve and refill the radiator with new screw out the radiator cap to release coolant according to the operation steps pressure after the coolant temperature is described in "...
  • Page 92 Maintenance Manual Important Maintenance Procedures Air Filter--Clean 4. Clean the main filter element, if it is good. First blow it out along the pleats inside the main filter element. Then repeat blowing air CAUTION: Check the air filter termly, along the pleats inside and outside of the replace the air filter when blocked happened.
  • Page 93 Maintenance Manual Important Maintenance Procedures 7. Secure a clean main filter element inside the 7. Secure a new main filter element, allowing air filter to ensure the even contact of the end even contact and good sealing of the seal face of the main filter element.
  • Page 94 Maintenance Manual Important Maintenance Procedures Fuel--Replenish CAUTION: Replenish the fuel tank before it is completely emptied. Any residual diesel fuel at the bottom of the tank contains water and moisture that will affect the proper running of the engine. 1. The fuel cap is located on the left side of the machine.
  • Page 95 Maintenance Manual Important Maintenance Procedures Air--Remove (XINCHANG Engine) Air--Remove (YANMAR Engine) Under normal work conditions, air can enter into The fuel system needs to be primed under fuel system as follows: certain conditions: 1. Drain out oil when the machine working. Before starting the engine for the first time.
  • Page 96 Maintenance Manual Important Maintenance Procedures Fuel Filter and Pre-filter--Replace 4. Install a new gasket on the thread connector of the support of the fuel filter. Apply a coat of (XINCHANG Engine) engine oil on the sealing surface of the filter. Preparing new filter CAUTION: Do not fill with fuel before the fuel filter is installed.
  • Page 97 Maintenance Manual Important Maintenance Procedures Fuel Filter and Pre-filter--Replace 3. Turn left 4. O-ring (YANMAR Engine) 5. Fuel filter sensor assembly 6. Seal 7. In-line fuel filter CAUTION: Do not fill fuel before the fuel 8. Output nipple filter is installed. Fuel contamination will 9.
  • Page 98 Maintenance Manual Important Maintenance Procedures 4. If the oil level is below “L”, replenish the oil. If Fuel--Heat the oil level is above the “H”, screw out the oil release plug on the bottom of the engine oil If it is necessary to heat the fuel due to low pan and drain excessive oil.
  • Page 99 Maintenance Manual Important Maintenance Procedures Engine Oil Filter--Replace (XINCHANG Engine) 1. Clean the area around the support of the engine oil filter. 2. Remove the engine oil filter with a belt spanner. 3. Clean the contact surface of the gasket of the support with a clean cloth.
  • Page 100 Maintenance Manual Important Maintenance Procedures Engine Oil-- Replenish(YANMAR 5. Secure the engine oil filter on the support and tighten the support of the engine oil filter Engine) gasket. Tighten engine oil filter according to the specified requirements. 1. Drive the machine to a flat area, stop the engine.
  • Page 101 Maintenance Manual Important Maintenance Procedures 4. Put a suitable container under the engine to collect the waste oil. 1. Engine oil filter 2. Turn anticlockwise 1. Container 3. Turn clockwise 2. Oil drain plug 5. Replenish new engine oil refer to the “Oil 5.
  • Page 102 Maintenance Manual Important Maintenance Procedures Engine Oil--Replace (NON-CERTIFIED 3. Open the engine hood, take out the dipstick. Wipe it with a clean cloth and completely GM3.0) reinsert the dipstick into the end of the oil filler of the engine. Take the dipstick again CAUTION: Care must be taken to ensure and check the oil level.

  • Page 103: Power Train System

    Maintenance Manual Important Maintenance Procedures Engine Oil Filter--Replace (NON- CAUTION: Excessive tightening the engine oil filter could result in damage to the CERTIFIED GM3.0) thread or the seal of engine oil filter element. 1. Clean the area around the support of the engine oil filter.
  • Page 104 Maintenance Manual Important Maintenance Procedures 1. Park the machine on flat ground and turn the 7. Take out the dipstick of the transmission; shift control lever to NEUTRAL. Hold the replenish clean transmission oil until the level parking brake lever and lower the fork on the is above High (H) graduation mark.
  • Page 105 Maintenance Manual Important Maintenance Procedures Transmission Secondary Filter-- Replace The secondary filter of the transmission is located at the top of the transmission. When changing the transmission fluid, also change the secondary filter. 2. Turn the shift control lever to NEUTRAL; set the parking brake lever to prevent movement of the machine.

  • Page 106: Hydraulic System

    Maintenance Manual Important Maintenance Procedures 2. Stop the engine, turn the shift control lever to The hydraulic tank is located on the right side of NEUTRAL, and set the parking brake lever to the seat. You can see two cover front and rear prevent movement of the machine.
  • Page 107 Maintenance Manual Important Maintenance Procedures If the working conditions are severe or the hydraulic oil becomes deteriorated due to pollution, such as black color and bubbles in the oil, change the the hydraulic oil. Because the hydraulic oil temperature is still high when draining, wear protective clothing 1.

  • Page 108: Brake System

    Maintenance Manual Important Maintenance Procedures Brake System Parking Brake Performance--Inspect CAUTION: Check the parking brake Brake oil Level--Check performance frequently to ensure the machine can safely stop and ensure its emergency braking capability. 1. Adjust the air pressure of the machine’s tires to the specified value, raise the fork 15-20cm above the ground and confirm the service brake is performing satisfactorily.

  • Page 109: Electrical System

    Maintenance Manual Important Maintenance Procedures Service Brake Performance--Inspect Battery--Check The battery is located under the engine hood and CAUTION: To ensure safety and on top of the hydraulic oil tank. accuracy, the service brake performance test only can be carried out by professional personnel.
  • Page 110 Maintenance Manual Important Maintenance Procedures Battery--Charge Tighten the locknut in the center of the hold- down to prevent a loose battery. Check the battery terminals for loosen frequently. Battery--Install Keep ventilated when charging. Charge the battery under normal temperature. 1. Turn the engine start switch key OFF and remove the key.
  • Page 111 Maintenance Manual Important Maintenance Procedures 2. Do not charge a battery with cracked (a) Select a charge current with rated terminal, find out the reason and replace the capacity of 7A. battery. (b) Refer to the following table for the 3.
  • Page 112 Maintenance Manual Important Maintenance Procedures 10. Check the battery hydrometer condition once 5. For the machine which is stored over one every hour during the charging process. If the year, replace with a new battery and dispose battery hydrometer turns green, the voltage the old one if the above mentioned of the battery comes to 16.0VDC voltage and requirement can not be followed.

  • Page 113: Other Maintenance

    4. Install the cover of the fuse box. the seat belt according to it. Other Maintenance For further information of the seat belt replacement, refer to your Liugong dealer. Backup Alarm--Test Machine Electrical Schematic Refer to Parts Manual of this machine for the electrical schematic.

  • Page 114: Troubleshooting

    Maintenance Manual Troubleshooting Troubleshooting Power Loss Parts Cause of malfunction Method of inspection Troubleshooting A. Oil pressure is too low: (1) Oil level is too low Check the oil level Refilling (2) Air is taken into the oil suction Retighten the connector and Check connector and oil pipe side replace the seals...
  • Page 115 Maintenance Manual Troubleshooting There is dirt in the clutch; The clutch plates are not engaged Removal and clean fully; Removal and adjust clutch The clutch plates are worn; Repair or replace The clutch plate spring is too Adjust or replace weak;...

  • Page 116: Oil Leaks

    Maintenance Manual Troubleshooting Noisy Transmission Parts Cause of malfunction Method of inspection Troubleshooting (1) Break in spring plate Check the sounds when it operates Replace the spring plate (2) Bearing is worn or damaged Remove and check Replace (3) Broken gear Remove and check Replace Torque...
  • Page 117 Maintenance Manual Troubleshooting Low Transmission Efficiency Parts Cause of malfunction Method of inspection Trouble shooting (1) Break in spring plate Check the sounds when it operates. Replace (2) Oil storage is not enough Inspection of the oil level Add oil Torque (3) Malfunction of drive system oil Removal and inspection...

  • Page 118: Malfunction Analysis And Troubleshooting

    Maintenance Manual Malfunction Analysis and Troubleshooting Malfunction Analysis and Troubleshooting Parking Brake Malfunction Causes Troubleshooting Leakage of brake fluid in brake system Repair The friction plate clearance is adjusted incorrectly. Adjust Brake is overheated Check for any slip Brake force is The contact between the brake drum and friction plate is not Adjust not enough...

  • Page 119: Steering Gear

    Maintenance Manual Malfunction Analysis and Troubleshooting Steering Gear Malfunction Cause Symptom Troubleshooting Leakage of oil from valve Dirt on the joint surface body, partition, stator and the Wash it again joint surface of rear cover Leakage of oil at the neck of the Leakage of oil shaft because of a damaged Replace the rubber ring...
  • Page 120 Maintenance Manual Malfunction Analysis and 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 large Pressure oscillation increases obviously, and the Break or distortion of pin Replace the pin turning movement can not be...

  • Page 121: Steering System

    Maintenance Manual Malfunction Analysis and Troubleshooting Steering System Malfunction Causes Troubleshooting 1. The pressure of the flow divider valve is too low Regulate the pressure:4~5t is 12Mpa. Discharge the air, and check whether there 2. Air exists in steering system is leakage in the oil suction pipeline 3.

  • Page 122: Mechanical Transmission

    Maintenance Manual Malfunction Analysis and Troubleshooting Clutch Malfunction Causes Troubleshooting 1. There is dirt in the clutch Removal and clean 2. The clutch pieces are not engaged fully Removal and adjust Clutch 3. The clutch pieces are worn Repair or replace 4.

  • Page 123: Drive Axle

    Maintenance Manual Malfunction Analysis and Troubleshooting Hydraulic Transmission Malfunction Causes Troubleshooting 1. The friction plate is locked up or worn; the friction plate agglutination is touched or warped Adjust or replace unevenly. 2. Wear of the oil feed pump or too low of the oil level causes the oil feed insufficiency of the oil Replace, or renew oil Efficiency has...

  • Page 124: Braking System

    Maintenance Manual Malfunction Analysis and Troubleshooting Braking System Malfunction Causes Troubleshooting 1. The clearance between the brake drum and the friction shoe linings is too large, or the friction Adjust the clearance plate clearance is adjusted unevenly. 2. Leakage of the secondary pump Replace the rubber cup 3.

  • Page 125: Lifting System

    Maintenance Manual Malfunction Analysis and Troubleshooting Lifting System 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.
  • Page 126 Maintenance Manual Malfunction Analysis and Troubleshooting...

  • Page 127: Index

    INDEX INDEX Coolant--Replenish ........88 Crushing and Cutting Prevention ....15 Cushion Tire--Replace ........81 Abnormal Oil Temperature ......113 Accelerator Pedal ...........51 Air Filter Safety Element--Replace ....91 Air Filter--Clean ..........90 Air--Remove (Xinchang Engine) ....93 Daily Inspection ..........86 Air--Remove (YANMAR Engine) ....93 Downhill Operation ........
  • Page 128 INDEX Fuel Filter and Pre-filter--Replace (Xinchang Main Components of the Machine ....3 Engine) ............94 Main Parts of the Forklift Body ...... 52 Fuel Level--Check ..........91 Main Specifications ........36 Fuel Tank--Clean ...........92 Maintenance beside the Mast and Fork ..82 Fuel ..............19 Maintenance Interval Schedule .....
  • Page 129 INDEX Safety Information ..........4 Safety Signs .............4 Safety Symbol ..........4 Seat Belt--Inspect ........111 Seat ..............52 Seatbelt (Optional) .........52 Service Brake Pedal ........50 Service Brake Performance--Inspect ...107 Shift Control Lever (Mechanical) ....49 Sound .............33 Stability and Barycenter .........31 Steering Column Adjust Lever .......51 Steering Gear ..........117 Steering Operation of the Machine ....57 Steering System Troubleshooting ....119...

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