Page 1 202406003 CPC(D)20-45 CPQYD20-38 FORKLIFT TRUCK ( 英语 ) OPERATION AND MAINTENANCE MANUAL...
Page 3: Important Safety Information
Operations that could cause damage to the machine are marked both in this manual and on the machine itself using the labels “Caution” or “Warning”. LiuGong cannot predict every hazard in the work environment; therefore the warnings in this manual and on the machine should not be considered exhaustive. When using a tool, procedure, working method, or operation technique that is not explicitly recommended by LiuGong, you must pay special attention to the safety of yourself and others.
Page 5: Table Of Contents
CONTENTS June 11, 2024 CPC(D)20-45/CPQYD20-38 CONTENTS Preface Applications and Technical Specifi- cations Frame Number & Machine Number ....4 Applications ............. 41 Main Structural Component .......5 Technical Specifications ........42 Safety Information Operation Manual Safety Decals and Decal Locations ....11 Before Operating the Machine ......68 General Safety Considerations ......18 Forklift Instrumentation and Controls ....
Page 6: Revision Table
CONTENTS June 11, 2024 CPC(D)20-45/CPQYD20-38 Revision Table...
Page 7: Operation
This section includes information on instrumentation, control equipment, control LiuGong provides a full warranty for users who levers, as well as transport and towing. This operate and maintain the machine in accordance section is suitable for new drivers to study and 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 16.Front wheel 5. Steering wheel 11.Rear wheel 17.Carriage 6. Overhead guard 12.Engine hood 18.Fork Component Serial Number Manufacturer Guangxi Liugong Machinery Co., Ltd Product Identification Number(PIN) Engine Serial Number Transmission Serial Number Front Axle Serial Number Rear Axle Serial Number...
Page 10: Frame Number & Machine Number
Preface June 11, 2024 Frame Number & Machine Number CPC(D)20-45/CPQYD20-38 Frame Number & Machine Number The frame number (1) is located above the pedal on the left side of the frame. The machine number (MEIN) (2) is located under the pedal on the left side of the frame.
Page 11: Main Structural Component
Preface June 11, 2024 Main Structural Component CPC(D)20-45/CPQYD20-38 Main Structural Component 1. Mast 2. Carriage 3. Fork 4. Frame...
Page 12 Preface June 11, 2024 Main Structural Component CPC(D)20-45/CPQYD20-38 Mast 1. Outer mast 2. Inner mast 3. Chains 4. Sprocket 5. Roller Fork arm carrier 1. Carriage 2. Main roller 3. Side roller...
Page 13 Preface June 11, 2024 Main Structural Component CPC(D)20-45/CPQYD20-38 Fork 1. Lock mechanism 2. Upper hook 3. Lower hook Frame 1. Frame 2. Carriage Bars 3. Antislip pedal 4. Fuel tank cap...
Page 14 Preface June 11, 2024 Main Structural Component CPC(D)20-45/CPQYD20-38 CE Marking CE Marking CE marking on nameplate (Only applies to machines marketed within the EU/EEA) The nameplate is attached on the front of the instrument frame.
Page 15 Preface June 11, 2024 Main Structural Component CPC(D)20-45/CPQYD20-38 EC DECLERATION OF CONFORMITY...
Page 16 Preface June 11, 2024 Main Structural Component CPC(D)20-45/CPQYD20-38...
Page 17: Safety Information
Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 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 18 Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 Safety Decals and Decal Locations FORKLIFT TRUCK Guang xi Liu gon g Machin ery Co., Ltd. N o.1Li u tai R oad, Liuz hou, Guan gx i 54 50 07, PR Chin a N o.694 Qing' an Road, Q ingpu D is tric t , Sh an gha i 2 017 00, PR Chin a Manufac tured B y Shanghai Liugon g Fork l i ft Truck Co.
Page 19 Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 Decal information 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 20 Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 Decal information Fig. 3 DANGER DECAL (Located on left side of mast.) No passengers on or under fork. 74A3301 Fig. 4 DANGER DECAL (Located on left side of mast.) CRUSH HAZARD.
Page 21 Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 Decal information Fig. 5 WARNING DECAL (Located on the engine housing) 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 22 Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 Decal information 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 23 Safety Information June 11, 2024 Safety Decals and Decal Locations CPC(D)20-45/CPQYD20-38 Decal information 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 24: General Safety Considerations
Safety Information June 11, 2024 General Safety Considerations CPC(D)20-45/CPQYD20-38 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. Wear a hard hat and eye protection, safety footwear, face mask, and gloves while operating or maintaining the machine.
Page 25 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 26: Preventing Crushing And Cutting
Safety Information June 11, 2024 Preventing Crushing and Cutting CPC(D)20-45/CPQYD20-38 Wear safety goggles and leather gloves when checking for leaks. Use wood or cardboard to check for leaks, never bare hands. Even leaks the size of a pinhole can pierce flesh, Preventing Crushing and causing serious injury or death.
Page 27: Burn Prevention
Safety Information June 11, 2024 Burn Prevention CPC(D)20-45/CPQYD20-38 Make sure that the engine fan blades are free of When checking the coolant level, shut off the debris and miscellaneous items. Fan blades can engine and wait until the water refilling cap is cut through or throw out tools or debris that fall cool to the touch before opening.
Page 28: Fire And Explosion Prevention
Do not weld or flame cut pipes that contain lubricant lines and hydraulic system hoses and flammable liquids. Clean up any flammable pipes. Leaks can cause fires. Contact a LiuGong liquids before welding or flame cutting. Machine Works authorized dealer for repairs or...
Page 29: Fire Extinguishers And First-Aid Kit
Safety Information June 11, 2024 Fire Extinguishers and First-Aid Kit CPC(D)20-45/CPQYD20-38 If any of the following problems are found, Prepare in advance the phone numbers of replacement is necessary. relevant personnel to contact in case of emergency (physicians, emergency services, fire Fittings are damaged or leaking.
Page 30: Fuel
Do not approach heated tires. Stay at least 50 feet (15 meters) away. Stand outside the shaded area (as shown). AT LEAST 15m(50ft) AT LEAST 500m(1500ft) LiuGong can provide pneumatic or solid tires according to your specific needs.
Page 31: Information On Attachments
Without authorization, any modification of attachments is strictly prohibited. Know Your Machine LiuGong is not responsible for any injuries, Be able to operate all equipment on the machine. accidents, or damage to the machine caused by the use of unauthorized attachments.
Page 32 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 Know Your Work Area Ensure that all windows on the cab are clean and that the wipers are working properly. Make every effort to learn about your work area Adjust the seat to the proper position and check in advance.
Page 33 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 After starting the engine, observe the pressure After any engine repairs or adjustments, re- gauges, instruments, and indicator lights to check the exhaust emission values and ensure ensure that they are working properly and that that they comply with the local government’s the readings are within operating range.
Page 34 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 Maintain proper posture on the seat. Accidents Use the rotary beacon (optional accessory) and can occur when you are not seated properly or reverse signal alarm to make others aware of the when you leave the seat to operate the machine.
Page 35 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 No one is ever allowed underneath a raised fork. Use appropriately-sized loading platforms. Before lowering the fork, check that no one else Check the loading platform’s condition, strength, is nearby. Whether or not the fork is loaded, no and safe loading capacity.
Page 36 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 The load must be balanced properly on the fork. Do not lift loads when the mast is tilted forward. When handling wide or lopsided loads, take The mast must be vertical or tilted backward special care to keep the machine from tipping when lifting, never forward.
Page 37 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 Tilt the mast backwards while driving, keeping Overtaking is prohibited. In dangerous areas the load against the backrest. Do not lift or lower such as intersections and places where vision is the load while driving.
Page 38 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 Drive slowly in areas with poor visibility. Mirrors Do not drive over any surface obstacles that are should be used where available. At stop signs, not firm. It is best to exit the vehicle, clear the bring the vehicle to a complete stop.
Page 39 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 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 the aisle to prevent harm to personnel or When loading and unloading, make sure that the equipment.
Page 40 Safety Information June 11, 2024 Operation Safety Information CPC(D)20-45/CPQYD20-38 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 41: Maintaining The Machine Safely
Safety Information June 11, 2024 Maintaining the Machine Safely CPC(D)20-45/CPQYD20-38 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 42 Safety Information June 11, 2024 Maintaining the Machine Safely CPC(D)20-45/CPQYD20-38 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 43: Stability And Center Of Gravity
Safety Information June 11, 2024 Stability and Center of Gravity CPC(D)20-45/CPQYD20-38 Stability and Center of Gravity Relationship Between Center of Gravity and Stability The forklift’s stability is determined by its center Load Center of gravity. When unloaded, that is the center of Confirm the position of center of gravity gravity of the vehicle itself.
Page 44: Noise Information
Emissions” is (see the following table): the rear axle. If the combined center of gravity is forward of the triangle, then the vehicle will tip 105dB CPC20/CPC25 E series forward. If the combined center of gravity is at 105dB CPCD20/CPCD25 E series the side of the triangle, it will tip to the side.
Page 45: Periodic Replacement Table For Safety-Critical Components
Safety Information June 11, 2024 Periodic Replacement Table for Safety-Critical Components CPC(D)20-45/CPQYD20-38 Periodic Replacement Table for Safety-Critical Components Safety-Critical Component Service Life (Years) Brake hoses and pipes Hydraulic hoses for lifting system Mast chains High-pressure hoses and pipes for hydraulic system Oil cup of brake liquid Brake pump, cover of the pump and dust cover Fuel hoses...
Page 46: Bolt Tightening Torque For Important Components
Safety Information June 11, 2024 Bolt Tightening Torque for Important Components CPC(D)20-45/CPQYD20-38 Bolt Tightening Torque for Important Components CPC(D)20/CPC(D)25 Component Torque (N.m) Bolt on the half shaft of drive axle 150~170 Mounting nut of front wheel (wheel hub) 470~550 Mounting nut brake drum 206~225 Mounting nut brake pedal 210~235...
Page 47: Applications And Technical Specifications
Applications and Technical Specifications June 11, 2024 Applications CPC(D)20-45/CPQYD20-38 Applications and Technical Specifications Applications This machine is an industrial vehicle used to transport goods over short distances. It is suitable for driving on smooth and hard surfaces (asphalt, cement, etc.). The machine is intended for use in warehouses, railway stations, shipping ports, construction sites, open-air freight yards, etc.
Page 48: Technical Specifications
Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications All rated operating/lifting capacities are based on the machine working from a solid, level support surface. If the machine is operated in an environment different from the above reference conditions (e.g. on soft, uneven, or inclined surfaces), then the operator must take these conditions into consideration.
Page 49 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 1 1 Model CPC(D)20/CPQYD20 CPC(D)25/CPQYD25 Power Diesel Diesel General Rated lift capacity at rated load center 2000 2500 Rated load center Unload mass Without load 3355 3555 Fully loaded/without 4680/1470 5300/1360 Weights...
Page 50: Vehicle Specifications
Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 1 Service brake Foot brake / hydraulic Braking Parking brake Manual/mechanical Xinchai 4D29V41 Xinchai 4D29V41 Xinchai 4D29X41 Xinchai 4D29X41 Quanchai V29-50V42 Quanchai V29-50V42 Systems Quanchai V29-50C42 Quanchai V29-50C42 Engine Model C490BPG...
Page 51 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 2 1 Model CPC(D)20/CPQYD20 CPC(D)25/CPQYD25 Power Diesel Diesel General Rated lift capacity at rated load center 2000 2500 Rated load center Unload mass Without load 3355 3555 Fully loaded/without 4680/1470 5300/1360 Weights...
Page 52 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 2 Service brake Foot brake / hydraulic Braking Parking brake Manual/mechanical Systems Xinchai A498BPG Xinchai A498BPG Engine Model Xinchai A498BT1 Xinchai A498BT1 Xinchai 4D27LPG Xinchai 4D27LPG...
Page 53 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 3 CPC(D)30/ CPC(D)35/ 1 Model CPC(D)38 CPQYD30 CPQYD35 Diesel/ Diesel/ General Power Diesel LPG(GAS) LPG(GAS) 3000 3500 Rated lift capacity at rated load center 3800 Rated load center Unload mass Without load 4200...
Page 54 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 3 Service brake Foot brake / hydraulic Braking Parking brake Manual/mechanical Xinchai (4D29V41, Xinchai 4D29X41,4D3 (4D29V41, Xinchai 2V41,4D32X4 4D29X41,4D3 (4D29V41, 2V41,4D32X41 4D29X41,4D32 Quanchai V41,4D32X41) (V29-50V42, Quanchai Quanchai V29-50C42, (V29-50V42, (V29-50V42, V32-50V42,...
Page 55 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 4 1 Model CPC(D)40 CPC(D)45 Power Diesel Diesel General Rated lift capacity at rated load center 4000 4500 Rated load center Unload mass Without load 5450 5770 Fully loaded/without 8320 / 2210 9050 / 2190 Weights...
Page 56 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 5 1 Model CPCD20 CPCD25 Power Diesel Diesel General Rated lift capacity at rated load center 2000 2500 Rated load center Unload mass Without load 3355 3555 Fully loaded/without 4680/1470 5300/1360 Weights...
Page 57 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 6 1 Model CPCD30 CPCD35 Power Diesel Diesel General Rated lift capacity at rated load center 3000 3500 Rated load center Unload mass Without load 4200 4630 Fully loaded/without 6400 / 1630 7310 / 1765 Weights...
Page 58 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Vehicle Specifications 7 Model CPD25-SRT Power Diesel General Rated lift capacity at rated load center 2500 Rated load center Unload mass Without load 3800 Fully loaded/without load, front 5550/1450 Weights axle Axle Load Fully loaded/without load, rear...
Page 59: Technical Specification
Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications Of Main Components--1 Component Item Technical Specification Xinchai Xinchai Xinchai Xinchai Model 4D29V41 4D29X41 V29-50V42 V29-50C42 4-stroke, direct 4-stroke in line, 4-stroke, direct 4-stroke in line, injection, direct injection, injection, direct injection, Type...
Page 60 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications Of Main Components--2 Component Item Technical Specification Xinchai Xinchai Xinchai Xinchai Model 4D32V41 4D32X41 V32-50V42 V32-50C42 4-stroke, direct 4-stroke in line, 4-stroke, direct 4-stroke in line, injection, direct injection, injection, direct injection, Type...
Page 61 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications Of Main Components--3 Component Item Technical Specification Xinchai Model 3E22YG51 Type 4-stroke, direct injection Cooling Water-cooled Order of ignition 1-3-2 Cylinder bore.x stroke 3-94mm×107mm Displacement 2. 23L Compression ratio 17.5:1 Rated power 44.8kW/2400r/min...
Page 62 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications Of Main Components--4 Component Item Technical Specification Model Xinchai C490BPG Xinchai A498BPG Xinchai A498BT1 4-stroke, direct injection, 4-stroke, direct injection, 4-stroke, direct injection, Type overhead valve overhead valve overhead valve Cooling Water cooling...
Page 63 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications Of Main Components--5 Component Item Technical Specification ISUZU C240- ISUZU 4JG2-B-A- Model YANMAR 4TNE92 YANMAR 4TNE98 NBKEG-01-C3 05-C2 4-stroke, non- 4-stroke, direct 4-stroke, direct 4-stroke, direct direct injection, Type injection, injection, overhead...
Page 64 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Technical Specifications Of Main Components--6 Component Item Technical Specification Model NISSAN K25 Xinchai 4D27LPG 4-stroke, direct injection, water 4-stroke, non-direct injection, water Type cooling, overhead valve cooling, overhead valve Cooling Water cooling Water cooling Order of ignition...
Page 65: Operating Range
Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 Operating Range Always operate the forklift in accordance with its load curve profile! (This figure is for use with the CPC20 / CPCD20 / CPQYD20 mast.) (This figure is for use with the CPC25 / CPCD25 / CPQYD25 mast.)
Page 66 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC30 / CPCD30, 3-stage mast, triple valve.) (This figure is for use with the CPC30 / CPCD30, 2-stage mast, double valve.)
Page 67 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC30 / CPCD30, 2-stage mast, triple valve.) (This figure is for use with the CPC30 / CPCD30, 3-stage mast, double valve.)
Page 68 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC35 / CPCD35, 3-stage mast, triple valve.) (This figure is for use with the CPC35 / CPCD35, 2-stage mast, double valve.)
Page 69 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC35 / CPCD35, 2-stage mast, triple valve.) (This figure is for use with the CPC35 / CPCD35, 3-stage mast, double valve.)
Page 70 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC38 / CPCD38, 3-stage mast, full free, with sideshifter.) (This figure is for use with the CPC38 / CPCD38, 2-stage mast, full free.)
Page 71 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC38 / CPCD38, 2-stage mast, full free, with sideshifter.) (This figure is for use with the CPC38 / CPCD38, 3-stage mast, full free.)
Page 72 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPC40 / CPCD40, 2-stage mast.)
Page 73 Applications and Technical Specifications June 11, 2024 Technical Specifications CPC(D)20-45/CPQYD20-38 (This figure is for use with the CPCD45, 2-stage mast) (This figure is for use with the CPCD45, 2-stage mast, with sideshifter.)
Page 74: Operation Manual
Operation Manual June 11, 2024 Before Operating the Machine CPC(D)20-45/CPQYD20-38 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, Mounting and Exiting the Machine contacts, and connections, and ensure that they are secure.
Page 75: Forklift Instrumentation And Controls
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Forklift Instrumentation and Controls Mechanical Forklift 1. Steering wheel 7. Fwd / Bwd shift lever (Mechanical) 2. Instrument 8. Accelerator pedal 3. Turn signal light switch 9. Clutch pedal (Mechanical) 4.
Page 76 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Hydraulic Forklift (electronic shift gears) 1. Fwd / Bwd shift lever 7. Lift lever 2. Steering wheel 8. Accelerator pedal 3. Instrument 9. Fine adjustment pedal 4. Light switches 10.Steering column adjust lever 5.
Page 77 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Hydraulic Forklift (manual shift gears) 1. Steering wheel 7. Accelerator pedal 2. Instrument 8. Fine adjustment pedal 3. Turn signal light switch 9. Steering column adjust lever 4. Lift lever 10.Gear control lever 5.
Page 78: Ignition Switch
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Ignition Switch START---- Turn the switch from ON to START to start the engine. After releasing the switch, it will automatically return to the ON position. The ignition switch (also known as “key switch”) is located on the right side of the steering column, as indicated by the arrow below, and has four positions (progressing in a clockwise...
Page 79: Battery Terminal
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Fuel Conversion Switch (NISSAN GAS------Press the GAS position of the switch, and then turn on the start/ choke switch, the engine--double fuel systems only) engine uses GAS at this time. Only the machine collocated with NISSAN engine and double fuel systems has the fuel conversion switch, which is located at the right...
Page 80: Instrument Panel
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Instrument Panel ON: parking regeneration is needed to activated. The machine enters the limit mode after 4 hours. It is recommended to regenerate when the machine does not work. Flash slowly (can be calibrated): the machine has entered the limit mode and park the machine to regenerate.
Page 81: Torque (N
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Left Turn Signal Driver alert indicator The indicator illuminates when the When detects the aftertreatment fault, machine turns left, and the front and the driver alert indicator will light. rear left turn signal lights will also Engine intake air filter alert indicator illuminate at the same time.
Page 82 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 The illuminating of this indicator means the water LCD Screen in fuel is too high. If the indicator goes on lighting The LCD screen is driven by single-chip or flashing, you should park the machine and microcomputer, which can display: service hour drain out the water in the fuel.
Page 83: Torque (N
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Instrument Panel (for China II& EU Warmup Indicator Stage III & EU Stage IIIA) The warmup indicator will turn on when the ignition switch is turned to PREHEAT position. After the indicator goes off, turn the ignition switch to START position to start the machine.
Page 84 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Fuel Gauge Engine alert indicator When detects the engine fault, the Indicates the amount of fuel in the fuel engine alert indicator will light. tank. When the display (or pointer) is on the left side, the tank is nearly empty.
Page 85: Operator Controls
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Operator Controls Place the lever in the middle position, it’s in neutral. Shift Lever (Mechanical) Always put the shift lever in the NEUTRAL position before starting the engine. Otherwise, the engine will not start. Stop the machine completely before switching from FOWARD to REVERSE.
Page 86: Parking Brake Lever
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Driving with the parking brake applied is dangerous and will damage the braking performance. Always release the parking brake before starting to drive. Do not lift the load too quickly. When the hydraulic cylinders are lifted to near the maximum height, lift the load slowly.
Page 87: Accelerator Pedal
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Fine Adjustment Pedal (Hydraulic) Accelerator Pedal The fine adjustment pedal is located in front of The accelerator pedal is located in front of the the operator’s seat, on the left side. operator’s seat, on the right side Press the accelerator pedal to open the throttle, increase the fuel supplied to the engine, and thus...
Page 88: Steering Column
Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 The forklift uses fully-hydraulic steering gear, Switch of Position Lights and Front which is powered by the engine. Because of this, Floodlights it is very difficult to steer the machine when the engine is off.
Page 89: Overhead Guard
In addition, loosened installation, and using. Replace it when necessary. Contact your use after disassembly may cause serious LiuGong dealer for seat belt replacements. accident too. Adjust length of the seat belt before use in order to ensure safety and comfortability. Length of the...
Page 90 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 The seat belt buckle is on the right side of the Whenever the truck is switched-on and in drive seat. Insert the tongue of the seat belt into the mode, a visual warning will indicate to the opening in the buckle, and the buckle will latch.
Page 91 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 As for those attachments with rotating function (such as paper roll clamp, bale clamp, multi- purpose clamp and drum clamp), weld two stop blocks to the both sides where the top carriage bar is connected with the attachment after installing to prevent the attachment from moving left and right during working.
Page 92 6. Do not engage brake suddenly during driving. Drive slowly when carrying with a load. 7. It is prohibited to modify the attachment without the technical permission of LiuGong as the modification could cause safety problem and change the attachment function. "Attachment Capacity" stated by the...
Page 93 Operation Manual June 11, 2024 Forklift Instrumentation and Controls CPC(D)20-45/CPQYD20-38 Safety in LPG Forklift Use 2. Quality and Component of LPG Fuel The purity of the LPG has a direct impact on the 1. LPG Charging Cautions operation and use of the forklift. if there are impurities, foreign matter, moisture or excessive There are two ways to add fuel for LPG forklift, tar components in the LPG, which will block the...
Page 94: Starting The Engine
Operation Manual June 11, 2024 Starting the Engine CPC(D)20-45/CPQYD20-38 In the event of accident: 6. Carry out regular maintenance according to the manner suggested by the original 1. Stop the forklift immediately, and turn off the gasoline engine manufacturer, including the engine.
Page 95 Operation Manual June 11, 2024 Starting the Engine CPC(D)20-45/CPQYD20-38 4. Insert the key and turn the key switch clockwise one click to the “ON” position to connect electrical power for the entire vehicle. Make sure that no other personnel are near the machine. The engine can only be started when the shift lever is in the NEUTRAL position.
Page 96: Operation Techniques
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 Operation Techniques Driving Without load, second gear can be used for the initial acceleration or driving of the vehicle. With load, only first gear can be used for the initial acceleration of the vehicle.
Page 97: Brake Operation
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 Steering 4. Press down the accelerator pedal to reach the desired speed. 1. Release the accelerator pedal to reduce the engine speed. 1. Press down on the service brake pedal to Do not turn on slopes. This will cause the slow down the machine.
Page 98: Operating On Slopes
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 Operating on Slopes Approach the load slowly, aligning the center of the forks with the center of the load. Move slowly to avoid colliding with the load. Select a suitable gear before starting the descent.
Page 99: Cold Weather Operation
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 When driving downhill with a load, drive in When handling wide loads, the forklift must be reverse and go slowly. equipped with a fork carriage suitable for wide or long loads. The capacity of the widened fork arm carrier should be the same with the standard carrier and within the stimulated load center.
Page 100: Hot-Weather Operation
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 5. Use cold-resistant batteries in cold-weather 2. Check that the fan belt is not loose, and regions. adjust the tension as necessary. 6. The battery electrolyte may freeze at low 3. If the engine overheats and the coolant is temperatures.
Page 101: Storing The Machine
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 Storing the Machine Shutting Off the Engine Before Storing The engine, chassis, and undercarriage of the Do not shut off the engine immediately after vehicle should be cleaned, repaired, and free of operating under load to prevent overheating rust.
Page 102 This will prevent the machine from moving during loading and transport. 3. Before transporting, make sure the trailer 8. For components removed for transport, floor is strong enough. contact an LiuGong authorized service center for reassembly.
Page 103 Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 9. If it is necessary to remove the mast and 7. Place blocks on both sides of the front of the counterweight, remove the mast first and forklift chassis to support the vehicle, then then the counterweight.
Page 104 Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 13. Adjust the tire pressure to the specified 5. Use the jack to raise the forklift slowly until value. the rear wheels are lifted completely off the ground. As shown below, support the forklift Rear Wheels by placing blocks under both sides of the rear part of the frame.
Page 105: Torque (N
Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 9. Tighten the nuts to the specified torque alternately from one side of the wheel to the Figure 1 other. Refer to “Bolt Tightening Torque for Important Components”. 10. Adjust the tire pressure to the specified value.
Page 106 Operation Manual June 11, 2024 Operation Techniques CPC(D)20-45/CPQYD20-38 Installing the Forks Towing or Moving a Malfunctioning Machine Move the fork and carriage so the top hook on the fork can engage the upper carriage bar. 1. If the machine breaks down, use a trailer to Raise the carriage to move the lower hook move the machine elsewhere.
Page 107: Maintenance Manual
Maintenance Manual June 11, 2024 Breaking In a New Vehicle CPC(D)20-45/CPQYD20-38 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 Breaking In a New Vehicle that the alternator, lights, and turn signals are working properly.
Page 108: Periodic Maintenance Schedule
Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Periodic Maintenance Schedule Read and understand all safety information, warnings, and instructions before performing any operation, maintenance, or servicing tasks. In extremely harsh, dusty, corroding, continuous heavy-load or humid working environments, properly shorten the maintenance intervals.
Page 109 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Check the engine for ○ ○ ○ ○ ○ oil leaks Check oil level and ○ ○...
Page 110 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Coolant level ○ ○ ○ ○ ○ Check for leaks ○ ○ ○ ○ ○ Check for hose aging ○...
Page 111: Drive Train
Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Drive Train Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Check for leaks ○ ○ ○ ○ ○ Check the oil level ○ ● and change if Check every ○...
Page 112 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Wheels Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Pressure Inflation pressure ○ ○ ○ ○ ○ gauge Check for cracks ○ ○ ○ ○...
Page 113: Steering System
Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Steering System Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Check clearance ○ ○ ○ ○ ○ Check for axial ○ ○ ○ ○ ○...
Page 114: Braking System
Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Braking System Daily Monthly 3 Months 6 Months Item Task Tools Annually (8h) (250h) (500h) (1,000h) (2,000h) Free travel ○ ○ ○ ○ ○ Pedal travel Scale ○ ○ ○ ○ ○...
Page 115 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Daily Monthly 3 Months 6 Months Item Task Tools Annually (8h) (250h) (500h) (1,000h) (2,000h) Brake drum Test attaching parts ○ ○ ○ ○ hammer loose or not Friction disc wear Vernier ○...
Page 116: Lift System
Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Lift System Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Check the forks for damage, deformation, ○ ○ ○ ○ ○ or wear Check the dowel pin Forks ○...
Page 117 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Check the chain tension. Check for ○ ○ ○ ○ ○ deformation, damage, or corrosion. Lubricate the chains ○...
Page 118: Electrical System
Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Electrical System Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Starter Check the gear ○ ○ ○ motor engagement Check the harnesses for ○ ○...
Page 119 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 Safety Devices and Attachments Daily Monthly 3 Months 6 Months Annually Item Task Tools (8h) (250h) (500h) (1,000h) (2,000h) Check for secure Test Overhead mounting hammer guards Check for and load deformation, cracks, ○...
Page 120 Maintenance Manual June 11, 2024 Periodic Maintenance Schedule CPC(D)20-45/CPQYD20-38 When using any oil, coolant, or antifreeze different from those specified for the machine in this manual, the replacement periods will not be the same. High-viscosity oils have a wide operating temperature range, but still need to be replaced frequently.
Page 121: General Torque Specifications
Maintenance Manual June 11, 2024 General Torque Specifications CPC(D)20-45/CPQYD20-38 General Torque Specifications Unless otherwise stated, all bolts used in this machine should be tightened to the torques listed in the table below. lbf·ft (Nm) Nominal Size Property Class 8.8 Property Class 10.9 7.7±1.1(10.5±1.5) 19±2.9(26±4) 38±5(52±7)
Page 122: Tire Inflation
Maintenance Manual June 11, 2024 General Torque Specifications CPC(D)20-45/CPQYD20-38 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 large load capacity, but are not suitable for high driving speeds due to their high rolling resistance.
Page 123: Working Device System
These 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 124 Maintenance Manual June 11, 2024 Working Device System CPC(D)20-45/CPQYD20-38 Collapse prevention measures for ordinary 2- stage masts The sprocket rotates when the inner mast is lifted, and the movement speed ratio of the fork Adjusting the mast chains: with the mast vertical, the forks lowered to the ground, carriage to the inner mast is 2:1.
Page 125 Maintenance Manual June 11, 2024 Working Device System CPC(D)20-45/CPQYD20-38 3. Slowly lower the inner mast until it is caught by the chain. 4. Lower the fork carriage completely. Select the appropriate chains according to the mast height. Do not exceed the maximum lift height.
Page 126: Oil And Fuel Specifications
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Oil and Fuel Specifications To ensure normal operation of the machine, use only the types and specifications of oils and fuels listed in the tables below. Recommended Oils and Fuels Oil/Fuel Type Quantity Product...
Page 127 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Oil Change Intervals and Approximate Volumes Always prepare a suitable container to collect any liquids before inspecting, servicing, testing, or adjusting the machine, or removing or disassembling any hydraulic parts or any liquid- containing components.
Page 128 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Power System Maintenance Coolant Level--Check This machine’s engine cooling system is located in the middle of the machine. It can be seen by loosening the screw of cover. While the machine is operating, the coolant is hotter and under higher pressure.
Page 129 500 working hours or every six system. months, whichever comes first. Refill the additives by regularly changing the coolant filter. LiuGong recommends the following brands and specifications of antifreeze: Refer to the specifications in the “Engine Operation and Maintenance Manual” for details...
Page 130 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Do not use a solution of more than 60% 4. Keeping the radiator cap open, start the antifreeze, as this will reduce its effectiveness. engine. Let the engine run at low idle for 5 minutes, and then at high idle for another 5 Coolant--Add minutes, allowing the coolant temperature to...
Page 131 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 To clean the cooling system: 5. Fill the cooling system with a flushing solution of water and sodium carbonate. Use a ratio 1. Insert the key into the key switch and turn it of 1.1lb (0.5 kg) of sodium carbonate for clockwise to the “ON”...
Page 132: Engine Air Filter Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Engine Air Filter Maintenance Coolant--Drain Out Engine Air Filter--Clean Do not drain the coolant before the engine is cooled down and when the system is under pressure. Otherwise, draining the hot and Check the air filter regularly, and perform pressurized coolant is extremely any necessary maintenance if a blockage is...
Page 133 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 3. Remove the primary air filter element and Wash with detergent (soak the filter element in inspect it. If the pleats, gaskets, or seals are water containing a mild detergent for about 30 damaged, then the primary filter element minutes, then clean it);...
Page 134 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 8. Clean and re-install the air filter cover, Oil-Bath Air Filter--Maintain ensuring that the air filter cover gasket makes contact evenly with the air filter housing. Periodically replace the engine oil according to working conditions.
Page 135 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 4. Pour some clean diesel fuel into the wash 8. Pour the diesel fuel used for cleaning the tub. strainer into the oil pan, and then clean the oil pan. 5.
Page 136: Fuel System Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 11. Add clean engine oil (about 3.8L) to the clean oil pan until the oil level reaches the top of the oil pan. No smoking and stay away from fire and spark area when cleaning with diesel fuel.
Page 137 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Start the engine and check that it is operating 3. Remember to re-tighten the fuel tank cap normally. Check the fuel level on the fuel level/ after refueling to prevent water and dirt from voltmeter gauge.
Page 138 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Fuel System Moisture and Impurities-- Fuel System Air--Remove (for China II Remove Xinchai Engine) If any dust or moisture is present in the fuel, the Under the normal work condition, air can enter fuel pump and injectors will not function properly the fuel system in the following ways: and wear will be accelerated.
Page 139 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 2. Loosen the air bleed port 2 or 3 turns. 3. Operate the charging pump until the fuel coming out of the air bleed port is free of bubbles. 4. Tighten the air bleed port. 5.
Page 140 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 3. Remove the gasket on the thread connector 5. Install the filter to the support by hand. After of the support. Clean the sealing surface of the gasket of the filter contacts with the the support with a non-fibrous cloth.
Page 141 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Fuel Filter--Replace (for YANMAR 5. Carefully open the oil drain plug to drain fuel from the fuel filter. Engine) Figure 2 Do not refuel before installing the fuel filter. Fuel contamination will quicken the damage of the parts of the fuel system.
Page 142 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 13. Carefully install the new in-line fuel filter into Fuel Filter--Replace (for NISSAN the output nipple. Engine--Double Fuel System) 14. Carefully install the fuel filter sensor assembly in the new fuel filter with the new O-ring supplied with the fuel filter (Fig.
Page 143 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Fuel-Water Separator--Maintain (ISUZU Oil Build-up of the LPG Forklift Truck-- Engine) Drain The fuel-water separator is provided to separate Preparation: the water contained in the fuel. 1. The surrounding environment should be well- ventilated.
Page 144 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 5. Remove the gas inlet hose (low pressure gas Open the gas outlet hose at the joint of the hose) clamp from the liquid gas pressure pressure reducing valve and mixer. A lot of black reducing valve to mixer;...
Page 145 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Diesel Particulate Filter (DPF) An industrial vacuum cleaner or a dust/ash collecting device. Introduction Cleaning Process through “HEATING IN ELECTRICAL OVEN”: Diesel Particular Filters remove particulate matter and inorganic ash from diesel exhaust. 1.
Page 146 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Cleaning process Temperature Duration Step Ramp shape (min) ( ℃ ) Using compressed dry air: Stop Before removing the DPF filter center-body for cleaning, mark the exhaust side (outlet) of the Remove the DPF center body from the oven.
Page 147 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 The torque of DPF filter screws is 25 Nm. ● In certain conditions it could be necessary to clean the filter earlier than normal scheduled maintenance interval filter cleaning, as in event of faster soot accumulation with consequent clogging of the filter.
Page 148 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 DPF Regeneration Strategy (for Xinchai E Series) 1. DPF regeneration mode DPF can realize regeneration in the following three ways: passive regeneration, traveling regeneration and parking regeneration. Passive regeneration occurs naturally during vehicle operation and does not require any operation conducted by the operator.
Page 149 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 In order to ensure that the engine can trigger regeneration in time under some harsh conditions, flow resistance is taken as the protective trigger condition. When the engine running time/ accumulated fuel consumption or flow resistance reaches the corresponding triggering threshold, the regeneration reminder light will illuminate to remind the operator that DPF regeneration is needed.
Page 150 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 4. DPF indicator There are 4 types of DPF lights available in the software, namely the DPF regeneration reminder light, the DPF regeneration state indicator light, the DPF regeneration disable light and the high exhaust temperature alarm light.
Page 151 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 DPF active regeneration not activated In the process of Normally ON traveling regeneration, (available for calibration) the exhaust temperature is 580- 600°C, and it should be confirmed whether the current environment is suitable for regeneration.
Page 152 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 4. Pull up the hand brake or press the hand brake switch "P" (press the "P" switch on the cab, so that "P" will appear on the instrument); 5. Shift the transmission to "N" position (press the "N" switch on the cab, so that "N" will appear on the instrument);...
Page 153: Engine Oil Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Engine Oil Maintenance 4. If the oil level is below the “L” mark, the oil must be replenished. If it is above the "H" mark, then loosen the drain plug at the Engine Oil Level--Check bottom of the oil pan and drain out some of the oil.
Page 154 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Engine Oil--Replace 4. Re-tighten the drain plug bolt. Add clean oil from the engine oil refilling port, up to the “H” mark on the dipstick. Run the engine at idle and check the oil filter and drain plug for any leaks.
Page 155 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Engine Oil Filter--Replace 5. Install the oil filter on the mounting base and tighten it by hand until the gasket makes contact with the mounting base, then use a 1. Clean the area around the oil filter’s band wrench to tighten it according to the mounting base.
Page 156 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Transmission Fluid--Replace The transmission fluid must be changed after the machine reaches its first 100 work hours. Change the transmission fluid every 1,000 work To prevent personal injury, wear protective hours thereafter.
Page 157: Axle Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 9. Start the engine and run it at idle speed. 3. Use a clean cloth to clean the contact Check the level again and add transmission surfaces of the mounting base. fluid until the oil level is above Low 4.
Page 158: Hydraulic System Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 4. Re-tighten the fill plug of the oil level hole. 6. Re-tighten the fill plug at the top of the drive axle. Drive Axle Oil--Replace Hydraulic System Maintenance Hydraulic Oil Level--Check Always prepare a suitable container to collect any liquids before inspecting, servicing, testing, or adjusting the machine,...
Page 159 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Hydraulic Oil--Replace Hydraulic oil tank drain port Always prepare a suitable container to collect any liquids before inspecting, servicing, testing, or adjusting the machine, or removing or disassembling any hydraulic parts or any liquid-containing components.
Page 160: Brake System Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 7. Fill the hydraulic tank with clean hydraulic oil Check the level of the brake fluid in the oil cup. from the refilling port until the oil level The oil level should be within 5 mm of the bottom reaches 1/2 between the middle mark and of the mesh.
Page 161: Electrical System Maintenance
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Electrical System Maintenance 4. Pull up the parking brake handle, then slowly release the service brake pedal. Check that the machine remains in place. Never place a lit cigarette or any open flame Personal injury may result if the machine near the batteries.
Page 162 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Battery--Install Battery indicator eye 1. Turn the ignition (also known as “key switch”) to the OFF position and remove the key. 2. Use a clean cloth to clean off the battery terminals and battery surface.
Page 163 Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 Battery--Charge a) Do not charge if the battery case is cracked or leaking acid. Dispose of the battery properly. Causes of battery power loss: b) Do not charge if the battery terminals are Improper use such as the vehicle’s electrical ●...
Page 164: Disposing Of Batteries
Maintenance Manual June 11, 2024 Oil and Fuel Specifications CPC(D)20-45/CPQYD20-38 If the battery’s voltage is below 11 V, it may Maintaining the Battery When the ● not charge initially. When the battery is Machine is in Storage severely depleted, the specific gravity of sulfuric acid in the battery is near that of pure If the machine is to be stored for more than ●...
Page 165: Other Maintenance
After a fuse is blown, it can be replaced with a fuse from a different manufacturer, but of the same series and specifications. If fuses need to be replaced frequently, then there may be a circuit malfunction. Please contact a LiuGong dealer for more information.
Page 166: Overhead Guard Disassembly And Assembly Procedures
7. Remove the fixed bolts of the front and rear Contact your LiuGong dealer for seat belt pillars. (For LPG forklift trucks, also need to replacements. remove the air ducts.) Schematic Diagrams for the Vehicle's 8.
Page 167: Machine Assembly Procedure
Maintenance Manual June 11, 2024 Machine Assembly Procedure CPC(D)20-45/CPQYD20-38 Machine Assembly Procedure Assemble steering axle, the Assemble tilting cylinders, Chassis assembly oil pines, radiators, control drive axle, transmission and valves, chassis wires etc. engine to the chassis Transmission, engine and drive axle assembly Assemble parking brake lever, brake assembly, flexible shafts, wires etc.
Page 168: Troubleshooting
Maintenance Manual June 11, 2024 Troubleshooting CPC(D)20-45/CPQYD20-38 Troubleshooting Power Loss Parts Cause Method of inspection Solution A. Oil pressure is too low: (1) Oil level is too low Check the oil level Refill (2) Air is taken into the oil suction Retighten the connector and Check connector and oil pipe side...
Page 169 Maintenance Manual June 11, 2024 Troubleshooting CPC(D)20-45/CPQYD20-38 Parts Cause Method of inspection Solution 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 170: Oil Leaks
Maintenance Manual June 11, 2024 Troubleshooting CPC(D)20-45/CPQYD20-38 Noisy Transmission Parts Cause of malfunction Method of inspection Troubleshooting Check the sounds when it is in (1) Break in spring plate Replace the spring plate operation (2) Bearing is worn or damaged Remove and check Replace Torque...
Page 171 Maintenance Manual June 11, 2024 Troubleshooting CPC(D)20-45/CPQYD20-38 Low Transmission Efficiency Parts Cause of malfunction Method of inspection Trouble shooting Check the sounds when it is in (1) Break in spring plate Replace operation. (2) Oil storage is not enough Inspection of the oil level Add oil Torque (3) Malfunction of drive system oil...
Page 172: Troubleshooting For Each System And Component
Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Troubleshooting for Each System and Component Parking Brake Troubleshooting Problem Cause Solution 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...
Page 173 Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Drive Axle Troubleshooting Problem Cause Solution 1. Over abrasion of the bevel gear or the joggle Replace the gear or adjust the joggle clearance clearance is too large 2.
Page 174 Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Mechanical Transmission Troubleshooting Problem Cause Solution Vibrate greatly The installed coupling bolt loosened Screw down High temperature Alterative oil or oil level is too high, or too low Replace new oil or adjust oil level Oil leakage The combined side bolt loosened, and seal ring aging...
Page 175: Clutch Troubleshooting
Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Clutch Troubleshooting Problem Cause Solution 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 176 Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Lifting System Troubleshooting Problem Cause Solution 1. Wear and tear of the gear pump, and too much Replace the wearing parts or oil clearance in movement pump 2. Seal piece failure of lift cylinder, there is in-leakage Replace the seal piece 3.
Page 177 Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Steering Gear Troubleshooting Problem Cause Symptom Solution 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...
Page 178 Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Problem Cause Symptom Solution 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...
Page 179 Maintenance Manual June 11, 2024 Troubleshooting for Each System and Component CPC(D)20-45/CPQYD20-38 Steering System Troubleshooting Problem Cause Solution 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.
Page 180: Maintenance Note Table
Maintenance Manual June 11, 2024 Maintenance Note Table CPC(D)20-45/CPQYD20-38 Maintenance Note Table...
Page 181: Index
Depositing Loads ..........93 Axle Oil Level--Check ........151 Diesel Particulate Filter (DPF) ...... 139 Disassembling the Forks ........ 99 Disposing of Batteries ........158 DPF Regeneration Strategy (for Xinchai E Series) ............... 142 Battery Terminal ..........73 Drawbar ............83 Battery--Charge ..........157 Drive Axle Oil--Replace ........
Page 182 INDEX June 11, 2024 CPC(D)20-45/CPQYD20-38 Forklift Instrumentation and Controls ....69 Installing the Forks ........100 Frame Number & Machine Number ....4 Instrument Panel (for China II& EU Stage III & EU Fuel ..............24 Stage IIIA) ............77 Fuel Conversion Switch (NISSAN engine--double Instrument ............
Page 183 INDEX June 11, 2024 CPC(D)20-45/CPQYD20-38 Overhead Guard ..........83 Solid Tires--Change ........116 Overhead Guard Disassembly and Assembly Stability and Center of Gravity ......37 Procedures ............160 Stacking Loads ..........92 Starting the Engine ......... 88 Steering ............91 Steering Column ..........82 Steering Gear Troubleshooting ....
Page 184 INDEX June 11, 2024 CPC(D)20-45/CPQYD20-38...
Page 185 June 11, 2024 CPC(D)20-45/CPQYD20-38 Revision Table Revision Table Revision Version no. Date Note 202303000 2023.03.06. The first print 202306001 2023.06.01. The first print 202310002 2023.10.19. The first print 202406003 2024.06.11. The first print...
Page 186 Revision Table June 11, 2024 CPC(D)20-45/CPQYD20-38...
Page 187 June 11, 2024 CPC(D)20-45/CPQYD20-38 Hydraulic Schematic Diagram Hydraulic Schematic Diagram 50Y1470 CPC(D)1.5T-2.5T, 4.5T, 4.7T, 5T...
Page 188 June 11, 2024 CPC(D)20-45/CPQYD20-38 Hydraulic Schematic Diagram 50Y1471 CPC(D)1.5-2.5T OPS...
Page 189 June 11, 2024 CPC(D)20-45/CPQYD20-38 Hydraulic Schematic Diagram 50Y1475 CPC(D)3.0-3.8...
Page 190 June 11, 2024 CPC(D)20-45/CPQYD20-38 Hydraulic Schematic Diagram 50Y1476 CPC(D)3.0-3.8T OPS...
Page 191 June 11, 2024 CPC(D)20-45/CPQYD20-38 Hydraulic Schematic Diagram 50Y1470 CPC(D) 1.5-2.5T, 4.5T, 4.7T, 5.0T...
Page 192 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram Electrical Schematic Diagram Quanchai High pressure common rail...
Page 193 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram Quanchai/Xinchai/VP pump...
Page 194 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram Xinchai, High pressure common rail...
Page 195 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50E1042 Xinchai 485 China II / Xinchai 490 China II / Xinchai 495 China Ⅱ...
Page 196 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50E1043 Xinchai 498 China II...
Page 197 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50E1045 Isuzu C240...
Page 198 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50Y0491 NISSAN Single & Double Fuel...
Page 199 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50Y1095 NISSAN OPS...
Page 200 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50Y0953 Yanmar OPS...
Page 201 June 11, 2024 CPC(D)20-45/CPQYD20-38 Electrical Schematic Diagram 50Y1104 Yanmar 4TNE92, 4TNE98...
Page 202 June 11, 2024 CPC(D)20-45/CPQYD20-38 Brake Schematic Diagram Brake Schematic Diagram 50Y1497 1.5T-3.8T...

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