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.
 1

CONTENTS

Preface Operation Manual

Machine Introduction......................................... 3 Before Operation ............................................ 34

Serial Number of the Machine and Parts .......... 3 Operator Controls and Instrument Panels ...... 34

Main Parts of Forklift Body ............................. 40

Safety Information
Operation Techniques .................................... 46
Safety Decals and Decal Locations .................. 4
Transportation Information ............................. 52
General Hazard Information............................ 11

Crushing and Cutting Prevention .................... 14 Maintenance Manual

Burn Prevention .............................................. 14 Maintenance Interval Schedule ...................... 58

Fire & Explosion Prevention............................ 15 General Torque Specifications ....................... 70

Fire Extinguishers and First-aid Kit ................. 16 Lubricant Specifications.................................. 72

Electrical Storm Injury Prevention ................... 17 Tire Information .............................................. 74

Tire Explosion Prevention ............................... 17 Working Implement System............................ 75

Attachment Cautions....................................... 17 Maintenance of drive axle............................... 77

Cautions about Machine Operation ................ 18 Maintenance of Hydraulic System .................. 78

Cautions about Machine Maintenance............ 26 Brake System Maintenance............................ 81

Stability and Barycenter .................................. 28 Battery Maintenance....................................... 82

Key Spare Parts to be Periodically Changed .. 30 Electrical System ............................................ 85

Tightening Torque of the Bolts ........................ 30 Other Maintenance ......................................... 89

Maintenance Record .................................... 110

Applications and Specifications
Applications..................................................... 31 INDEX
Main Specifications ......................................... 32

Preface
This manual includes important instructions
concerning operation, lubrication, checking
testing, adjusting the machine and permanent
key components.
This manual should always be kept safe, clean
and with the machine where it is convenient to
find for operators to use. This manual should not
be separated from the machine even when
reselling or leasing.
Some photographs and illustrations in this
manual show deatils of attachments that may be
different from your machine. Guards and covers
may have been removed for the purpose of
illustration.
Read this manual carefully and follow all
instructions for proper operation and
maintainance of this machine. Instructions in this
manual should help the reader avoid possible
personal injury or damage to the machine. The
operator should proficiently and correctly operate
the machine to ensure safety.
Use this machine only for the purpose described
in this manual. Contact your LiuGong dealer for
approval before making any modifications or
adding attachments to the machine. The addition
of any unauthorized attachment may cause
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi
LiuGong accepts no liability for any damage
resulting from the use of unapproved
attachments or working practices.
Only trained or experienced personnel should be
allowed to operate or maintain this machine.
Correctly record the machine type, serial
number, engine serial number and all major
component serial numbers for your reference
when ordering parts or in the event of theft.
Record the correct numbers to both the
operators manual and a secure place outside the
machine.
1
Preface
Safety
The safety section lists basic safety precautions.
In addition this section identifies the text and
locations of warning signs and labels used on the
machine.
Read and understand the basic precautions
listed in the safety section before operating or
performing lubrication, maintenance or repairs
on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. Read, understand and reference it
whenever neccessary. This section includes a
description of gauges, machine controls,
switches and other controls at the operators
station. It also provides transportation and towing
information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication
are basic. Skill and techniques develop as the
operator gains knowledge of the machine and its
capabilities.
Maintenance
The maintenance section is a guide for
equipment care. The illustrated, step-by-step
instructions are grouped by servicing intervals.
Items without specific intervals are listed under
the "When Required" service interval. Items in
the "Maintenance Intervals" are referenced to
detailed instructions that follow.
2
Preface

Maintenance Intervals

Use the service hour meter to determine

servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 8 service hours or daily.
All the information, figures, tables and
specifications are the latest product information
obtainable at the time of publication. Guangxi
LiuGong Company will reserve the right to make
change without notice.

Certified Engine Maintenance

Correct maintenance and repair methods are

essential to keeping the engine and machine
systems operating correctly. As the owner, you
are responsible for performance of required
maintenace listed in the Maintenance Manual for
this machine. It is prohibited for person engaged
in the business of repairing, serviceing, selling,
leasing or trading engines or machines to
remove, alter or render inoperative any
emmissions related device or element of design
installed on or in an engine or machine that is in
compliance with the regulations. Certain
elements of the machine such as exhaust
system, fuel system, electrical system, air intake
system and cooling system may be emmision
related and should not be altered unless
approved by LiuGong.
 3
Preface
Machine Introduction

Machine Introduction

Applicable Models

This manual is applicable to CPD10, CPD15, CPD20, CPD25, CPD30, CPD30-AS.

Models Instruction (CPD15)

Operating weight: 1.5t

D: Battery
CP: Counterbalance forklift

Electrical Controller of Machine

Model Electrical Control Abbreviation

CURTIS 1244 traction controller
CPD10
1253-4802 pump controller
CURTIS 1244 traction controller
CPD15
1253-4802 pump controller

CPD20/CPD25/CPD30 H2B MOS chopper H2B

CPD30-AS SME ACM2 72/48V 450A+450A

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 Battery
Serial Number of Reduction Box
Serial Number of Rear Axle
Serial Number of Frame
Serial Number of Travel Motor
Serial Number of Oil Pump Motor
4
Safety Information
Safety Decals and Decal Locations
Safety Information
Safety Symbol
The symbol for safety alerting appears
on machines, safety signs, manuals or
for important safety information at
other places. When you see this
symbol, you should follow the instructions in the
safety information, guarding against any
possibility of personal injuries or death.
Safety Signs
Definitions of the safety signs with the words
"Danger", "Warning" and "Caution" which appear
in this manual and on the machine are as
follows:
● Danger: this word denotes an impending
danger, failure to observe instructions could
result in death or serious injuries.
● Warning: this word denotes potential danger,
failure to observe instructions could result in
death or serious injuries.
● Caution: this word denotes potential danger,
failure to observe instructions could result in
minor to medium degree of injury.
"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 signs "Danger" or "Warning" are placed
near particular dangerous places. General notice
information is placed on the safety sign
"Caution."
Safety Decals and Decal
Locations
There are several specific safety decals on your
machine. The exact location of and description of
the hazards are reviewed in this section. Please
take time to read, understand and familiarize
yourself with each and every one of these safety
decals.
Make sure that you can read all safety decals.
Clean or replace if you cannot read the words or
see the pictures. When cleaning the decals use a
cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the
safety decals. Solvents, gasoline or harsh
chemicals could loosen the adhesive backing of
decals causing them to fall off the machine.
You must replace a decal if it is damaged,
missing or cannot be read. If a decal is on a part
that is replaced, make sure a new decal is
installed on the replacement part. Pay attention
to the instructional and safety decals located in
the cab before starting.
 5
Safety Information
Safety Decals and Decal Locations

Decal Location

VIEW
VIEW A A

1. DANGER DECAL 6. WARNING DECAL

2. NOTICE DECAL 7. WARNING DECAL
3. WARNING DECAL 8. CAUTION DECAL
4. WARNING DECAL 9. DANGER DECAL
5. WARNING DECAL
6
Safety Information
Safety Decals and Decal Locations

Decal Information

Fig.1 DANGER DECAL

(Located on left side of mast)
No passengers on or under fork.

74A3301
Fig. 2 NOTICE DECAL
(Located on the instrument stand)
Inspect before starting the forklift.
Check hydraulic oil level. The level should
reach the mark at the middle of the sight
glass.
Check hoses, pipes, fittings, pump and valves
for leakage and damage.
Check service brake:
1. The idle stroke of service brake pedal
should be between 20-30 mm (0.8 in-1.2 in).
2. The clearance between the front bottom
plate and service brake pedal should be more
than 20 mm (0.8 in) after applying service
brake.
Check parking brake:
Machine should be able to park stably on a
slope with 20% gradient without load when
pulling the brake lever to its maximum stroke. 74H2070
Check instruments, lights, terminal plugs,
switches and other electrical wirings for
normal working condition.
 7
Safety Information
Safety Decals and Decal Locations

Decal Information
Fig.3 WARNING DECAL
(Located on the cover of battery)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations. 74A3302
Fig.4 WARNING DECAL
(Located on the cover of battery)
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.
2.Lift load with mast tilted back from straight
position. Lift load to required height only at
location to be placed, move machine slowly
into position and only tilt load forward when
load is over location to be placed.
3.Side shift operation: Always ensure side
shift is referenced on load chart. Rated load
will be reduced from standard with side shift
fitted. Never adjust side shift with forks on the
ground. Caution should be used when
operating side shift with load raised, sudden
movement of load may cause forklift 74A3294
instability.
8
Safety Information
Safety Decals and Decal Locations

Decal Information
Fig.5 WARNING DECAL
(Located at the right rear side of seat)
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. Always
consider the weight of any device or
attachment being used when calculating load.
When loading or unloading materials: Never
exceed forklift rated load capacity. Always
ensure the security of goods being lifted. Fully
insert fork under load before lifting clear of
load bearing surface. Never operate any part
of the machine from outside of operator's
seat. Never load with a single fork. Observe
overhead clearance when passing under
height limitations. Mast forward tilt
movements should be minimized when mast
is raised and a load applied. Beware load
may fall towards truck with mast raised.
When operating: Never carry passengers on
any part of the forklift truck. Slow down in wet
or slippery areas and when turning. Use
caution when driving on a ramp or slope.
Always travel straight up and down a ramp or
slope. Never attempt to turn forklift when
travelling on a ramp or slope. When travelling
on a gradient of 1/10, travel up gradient
forwards travel down gradient backwards.
Special attention is required when travelling
on uneven or temporary surfaces. Loads
should be carried as close to ground as
possible with mast rolled back to provide
stability. 74A3305
When parking machine: Lower forks to
ground and apply parking brake, place
transmission in neutral and stop engine.
When parking machine on gradient or slope
apply parking brake and choke the wheels.
 9
Safety Information
Safety Decals and Decal Locations

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.
74A3304

Fig.7 WARNING DECAL

(Located on the front of the frame)
CRUSH HAZARD. Keep clear of mast.

74A3303

Fig.8 CAUTION DECAL

(Located on mast)
Do not mount machine from right side.

74A3292
10
Safety Information
Safety Decals and Decal Locations

Decal Information

Fig.9 DANGER DECAL

(Located on right side of mast)
No passengers on or under fork.

74A3300
 11
Safety Information
General Hazard Information

General Hazard Information

Be familiar with all safety cautions, failure to

observe could result in property damage, serious
injury or even death.
Only trained and qualified personnel should be
allowed to operate or maintain the machine.

Wear relevant personal protective equipment

(PPE) such as a hard hat, ear protection, safety
glasses, safety shoes and gloves when
operating or servicing the machine.

Do not operate the machine if you feel sick,

sleepy or after taking some medication. Check
with your doctor if unsure. Never operate
machinery while under the influence of drugs or
alcohol.
Attach a DO NOT OPERATE or similar warning
tag to start switch or control levers before
servicing or repairing the machine.

Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high
G
N

pressure liquids, when maintaining storage

NI
AR
W

er ot

batteries, by flying scraps when the engine is in

!

op o n

e
at

operation or you are using tools to strike objects,

d

remove springs or resilient parts, add acid/

ter:
ra
pe

electrolyte to batteries, you should wear a full

O

:
te
Da

face protective mask. When carrying out welding

operations or gas cutting operations with a
Do not wear loose fitting clothing, dangling
welding torch, wear specific safety goggles
jewelry or long hair that can catch on controls or
suitable for the task being performed. Consult
in other moving parts of the machine.
your welding equipment dealer for more
information.
12
Safety Information
General Hazard Information

When working under high noise conditions, wear
appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high
noise on your hearing.
Know the appropriate worksite hand signals and
who gives them. Accept signals from one person
only.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
other materials.
Use all cleaning solutions with care. Do not use
any flammable material to wash components, for
example, diesel oil or gasoline. They may easily
catch fire.

Make sure all protective guards and covers are

secured in place on the machine. Always replace
protective guards and covers removed for
servicing or maintenance. Repair damaged
guards and covers before operation.
Keep the machine, especially the panels,
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Report all required repairs in time.
Secure all loose items such as lunch boxes, tools
and others. Do not allow unauthorized personnel on or
around the machine.
Pay attention when opening fluid compartments
to prevent foreign materials from entering the Guangxi Liugong bears no responsibility for
system. Always remove loose materials from failures caused by modifications to machine
near caps and plugs. structure without Liugong’s permission.
 13
Safety Information
General Hazard Information

Compressed Air

Compressed air can cause personal injury. When

using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. Never
aim compressed air at yourself or others.
Compressed air could penetrate your skin and
cause serious injury or death. The maximum air
pressure used should not exceed 25psi
(0.2Mpa).
Disposal of Waste Fluids
High-pressure Fluid
Improper handling of the waste fluid will cause
WARNING: Avoid injury from high-
pollution of the environment. Obey all local
pressure oil. When repairing hydraulic lines,
regulations for disposal of waste fluids.
ensure that system pressure is completely
released before beginning the repair. Collect all waste fluids when performing
Hydraulic oil under pressure contacting the inspections, maintenance, testing, adjusting and
skin could cause serious injury or damage. repairs to the machine.
Prepare to collect fluids with suitable containers
Use caution before disconnecting hydraulic lines
before opening any compartment or
or connectors. High pressure oil that is released
disassembling any component that contains
can cause a hose to whip.
fluids.
Wear safety glasses and leather gloves. Never
Use suitable containers to collect waste fluids.
check for high-pressure leaks with your
Do not use food containers or beverage bottles
unprotected hand. Use a board or cardboard
as they could mislead people to drink the
when checking for leaks.
contents.

Even a pin-hole size leak can cause serious

injury, If you are hit by spraying high-pressure oil,
see a doctor for treatment at once.
14
Safety Information
Crushing and Cutting Prevention

Asbestos Danger If it is necessary to remove shields in order to

perform maintenance, always install the shields
Breathing asbestos dust can be hazardous to after the maintenance is performed.
your health. Equipment and replacement parts
Keep hands and objects away from moving fan
shipped from Liugong have no asbestos in them.
blades. They can throw or cut any object that
Liugong recommends the use of genuine factory
contacts the moving blades.
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
Never use compressed air to clean up asbestos.
Use a wet method in order to clean up asbestos
materials. Water the area down to clear asbestos
dust.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Never attempt adjustments while the machine is
Do not grind materials that contain asbestos. moving or the engine is running unless otherwise
specified.
Obey environmental regulations for the disposal
of asbestos. If the machine must be repaired with engine
running, make sure that a qualified operator is
Shower after contact with asbestos.
available in the cab to shut down the engine if
Wear an approved respirator if there is no other required.
way to control the dust..
Do not use a kinked or frayed wire cable. Wear
gloves when handling wire cables.
Retainer pins, when struck with force, can fly out
and injure nearby persons. Make sure the area is
clear of people when driving retainer pins. Wear
protective glasses when striking a retainer pin to
avoid injury to your eyes.
Chips or other debris can fly off objects when
struck. Make sure no one can be injured by flying
debris before striking any object.

Crushing and Cutting

Prevention Burn Prevention

Some parts of the machine become hot during

Don't put hands, arms, or any other parts of the
normal operation. Use caution when maintaining
body in the way of removable parts.
the engine and hydraulics. Allow the machine to
Support equipment and attachments properly cool after it has been operating for a long period
when working beneath them. Do not depend on of time.
hydraulic cylinders to hold up the implement/
attachment. The implement/attachment can fall if
a control lever is accidentally moved, or if a
hydraulic line breaks.

Oil
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact the skin.
At operating temperature the hydraulic oil tank is
hot and can be under pressure.
Remove the hydraulic oil tank cap only after the
engine has been stopped and the cap is cool
enough to remove with your bare hand.
Remove the hydraulic oil tank oil filling cap
slowly to relieve pressure.
Relieve all residual pressure in air, oil, fuel or
cooling systems before any lines, connectors or
related items are disconnected or removed.
Batteries
Batteries give off flammable fumes which can
explode.
Do not smoke when observing the battery
electrolyte levels.
Electrolyte is an acid and causes personal injury
if it contacts skin or eyes. If contact occurs flush
with water and seek medical attention right away.
Always wear protective glasses and gloves when
checking batteries.
15
Safety Information
Fire & Explosion Prevention
Fire & Explosion Prevention
All fuels, most lubrication and some coolant
mixtures are flammable.
Fuel leaked or split onto hot surfaces or electrical
components can cause a fire.
Do not smoke while refueling or in a refueling
area, or where flammable materials are stored.
Clean and tighten all electrical connections.
Check daily for loose or frayed electrical wires.
Have all loose or frayed electrical wires
tightened, repaired or replaced before operating
the machine.
Check the electric circuit periodically to avoid fire
caused by overload or short circuit.
Keep all fuels and lubrications stored in properly
marked containers and away from all
unauthorized persons.
Store all oily rags or other flammable materials in
a protective container away from naked flames
or other sources of ignition. Do not weld or flame
cut pipes that contain flammable fluids. Remove
them from the machine and clean them
thoroughly with nonflammable solvent before
welding or flame cutting on them.
Remove all flammable materials such as fuel,
lubrication and other debris before they
accumulate on the machine.
Do not operate the machine near an open flame.
Keep all open flames or sparks away from the
battery. Do not smoke in battery charging areas.
Do not charge a frozen battery. This may cause
an explosion.
16
Safety Information
Fire Extinguishers and First-aid Kit
Ether
WARNING: EXPLOSION HAZARD. Do
not use ether. Machine is equipped with
electrical cold weather start aid device.
Starting the machine by use of ether could result
in serious damage to the engine or personal
injury or death.
Cautions Concerning Lines, Tubes and
Hoses
Do not bend or strike high-pressure lines. Do not
install bent or damaged tubes or hoses.
Tighten any loose fuel or oil pipes, hydraulic
system tubes or hoses. Repair any damaged fuel
or oil lines, tubes or hoses. Leaks can cause
fires. Contact Liugong or your Liugong Dealer for
factory authorized replacement parts.
If you see evidence of any of the following
situations, replace the part before using:
● Connectors damaged or leaking.
● Outer covering frayed or cut and reinforcing
wire exposed.
● Outer covering ballooning.
● Evidence of kinking or crushing.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
Make sure that all clamps, guards and heat
shields are properly installed. During operation
this will prevent vibration, abrasion, friction with
other parts and guard from excessive heat.
Before removing or servicing any lines of the air
conditioning system, always ensure there is not
an open fire nearby; any escaping gas coming
into contact with fire could result in poisonous
fumes. Never smoke when servicing or repairing
the air conditioning system, any escaping gas
that burns and inhaled can cause bodily harm or
death.
Fire Extinguishers and First-
aid Kit
A fire extinguisher that meets with all local fire
extinguisher laws and regulations should be
available on the machine.
Maintain the fire extinguisher in accordance with
all local laws and regulations. Contact your local
fire department for further information.
Know how to use the fire extinguisher and first-
aid kit.
A first-aid kit should be available at the work site.
Periodically check the contents of the kit and
replace used medical supplies as necessary.
Keep telephone numbers of doctors, first-aid
centers or fire stations etc with you so you can
contact them in case of an emergency. Post the
contact telephone numbers in regulated places.
Ensure that all persons know where the
telephone numbers are located and know the
correct contact method.
Inspect and service the fire extinguisher
regularly. Obey the recommendations on the
instruction plate and all local laws and
regulations relating to fire extinguishers.

Electrical Storm Injury
Prevention
When lightning is striking in the vicinity of the
machine, the operator should never attempt to
mount and dismount the machine.
If you are in the cab during an electrical storm,
stay in the cab. If you are on the ground during
an electrical storm, stay away from the machine.
Tire Explosion Prevention
Maintenance, removal, repair and installation of
the tires and wheel rims must be performed with
special equipment and a trained repairer.
Therefore, it is better to repair and maintain the
tires in a tire service shop.
Explosions of tires have resulted from gas heat-
induced and combustion inside the tires.
Explosions can be caused by heat that is
generated by welding, by heating rim
components, by external fire, or by excessive
use of brakes.
17
Safety Information
Electrical Storm Injury Prevention
A tire explosion is much more violent than a
blowout. The explosion can propel the tire, the
rim components, and the drive train components
as far as 500 m (1500 ft) or more from the
machine. Both the force of the explosion and the
flying debris can cause property damage,
personal injury, or death.
Do not approach a warm tire. Maintain a
minimum distance, as shown. Stay outside the
shadow area.
AT LEAST 15m(50ft) AT LEAST 500m(1500ft)
Dry nitrogen is recommended for inflation of
tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the
pressure. Nitrogen mixes properly with air.
Nitrogen inflated tires reduce the potential of a
tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation
of the rubber, deterioration of rubber, and
corrosion of rim components.
Attachment Cautions
Attachments should only be installed by
authorized people who have been trained to
operate and maintain the attachment according
to the operator’s manual.
Refer to the instructions in the operation manual
and any other related information when installing
and using attachments.
Incorrect installation of attachments or optional
parts not only will result in safety problems, but
also will negatively influence the operation and
service life of the machine and the attatchments.
18
Safety Information
Cautions about Machine Operation
It is forbidden to modify the machine or any
attachments without permission from your
Liugong dealer.
Liugong bears no responsibility for injuries,
accidents or machine damage resulting from the
use of unauthorized attachments.
Cautions about Machine
Operation
Mounting and Dismounting
Before mounting or dismounting the machine,
check the condition of handrails, ladders and
steps. Clean them of grease, lubricants and dirt
before use. Repair any damaged parts and
tighten loose bolts.
Mount and dismount the machine only where
there are handrails, steps or ladders.
Face the machine when getting on or off, grab
the handrails with both hands and step onto the
steps or ladders. Touch three points
simultaneously (two feet and one hand or two
hands and one foot) to ensure stability of the
body.
Never jump off the machine.
Never get on or off a moving machine.
Be careful not to touch any control levers when
getting on or off the machine.
Do not try to climb on or off the machine when
carrying tools or supplies. Use a rope to pull
equipment up onto the platform or have an
assistant pass them to you.
Understand Your Machine
Be able to operate all the equipment on your
machine.
Understand the purpose of all control systems,
instruments and indicators.
Understand the rated load, speed range, the
characteristics of braking and steering, turning
radius and the space clearance for operation.
Remember that rain, snow, ice, gravel and soft
earth may change the performance of the
machine.
Understand the safety signs on the machine
(Danger, Warning, Caution) and any other signs.
Understand Your Working Area
Before starting, inspect the area where you will
be working. You should check: adequate
ventilation, the position of any slopes, visible
ditches, falling or hanging objects, conditions of
soils (soft or hard), accumulated water and
swamp areas, rocks or stumps, hidden
groundwork, posts or the outer limits of walls, the
outer limits of the areas where garbage is buried
or that are filled in with earth, holes or openings,
obstacles, mud or ice, traffic, heavy dust, heavy
smoke, heavy fog, the exact locations of cables
or pipes for power supply, gas supply, phone
service, water supply, sewage disposal and other
utilities that are hidden or hung. If necessary
before starting work you should ask the utility
companies to mark out, close or move out these
utilities.
Before Starting the Engine
Inspect the machine carefully before starting the
engine, ensure all systems are in good
operational condition. Make sure nobody is on or
around the machine before starting the engine.
Keep the steps and handrail clean. Clear any dirt
and sand from your shoes before mounting the
machine.
Check all structural members, covers and
fenders for deformation or damage.
 19
Safety Information
Cautions about Machine Operation

Check the condition of safety items such as

doors, guards and covers. Repair any damage
as necessary.
Check the hydraulic system for oil leakage.
Check the condition of hoses and pipes.
Check all fasteners for security.
Check the condition of the electrical wiring
harness and fuses, replace or repair as
necessary. Also check the connectors for good
connection.
Replace all damaged or lost parts and carry out Before Operating the Machine
lubrication according to the maintenance interval
schedule. Make sure the machine is clear of personnel and
fasten the seat belt before operation.
Check all the illumination equipment before
operation in low light, and ensure that the Keep all the windows, lightshades and rearview
illumination system is in good condition. mirrors clean. Secure doors and windows in
either the open or shut position.
Engine Starting Adjust the rearview mirrors for best vision,
especially close to the machine.
Do not start the engine if there is a DO NOT
Clear all obstacles from where the machine will
OPERATE or similar tag attached to the start
switch or control levers. be working. Be aware of hazards such as high
voltage wires, ditches, etc.
Make sure the horn, backup alarm (if equipped)
and all other alert devices are working properly.
G
IN
N
AR

Machine Operation
W

er ot
!

op o n
e
at
d

Before operating the machine on roads, check

whether the machine meets the requirements of
r:
te
ra
pe
O

the local laws and regulations for road operation.

:
ate
D

Make sure that you get the road operating

Sound the horn to alert personnel before starting permission from relevant road administration
the engine. offices. Observe the local traffic regulations when
driving the machine on roads.
After the engine is started, you should observe,
instruments and warning lights, and make sure Before operation, check the conditions of the
that they work and every reading is within forklift. If any fault is found, report to relevant
working range. personnel immediately or get it repaired. Do not
use the machine until the fault has been
Observe machine movements and listen
eliminated.
carefully for unusual noises. If there is any fault
or abnormality, you should stop the engine
immediately. Locate the source of the problem
and repair before further operation.
20
Safety Information
Cautions about Machine Operation

Keep a correct posture on the seat. There may
be an accident if you sit on the seat incorrectly or
operate the machine without sitting on the seat.
This machine is equipped with a service
interlocking device, it will not be able to run and
operate if you don't sit on the seat correctly.
Don't overload. Make sure weights of loads are
within the rated capacity of the forklift truck.
Before picking up a load, check the load weight
and gravity center.

Before starting, make sure that the surrounding While driving, do not reach your arms or legs
areas are safe, the reverse switch is in the outside the forklift truck or into the mast. Never
correct position and the load has been unloaded try to go over the mast to deal with work unless
completely. when the machine stops for repair.
The operator has a primary responsibility to
protect the safety of pedestrians. Priority must
always be given to pedestrians. Take particular
care when turning. Never deliberately frighten
pedestrians to give way by flashing the lights or
sounding the horn.

Nobody is allowed to go under a raised fork,

It would be better to use a rotating beacon and
backup alarm to make it easy for people to notice
the forklift. (rotating beacon is optional)
before raising the fork, make sure that there is
nobody around it. Whether the fork is loaded or
unloaded, nobody (you are not an exception) is
allowed to stand or go under the fork.
 21
Safety Information
Cautions about Machine Operation

Do not use this machine to lift personnel. Do not Adjust the fork width as wide as possible. before
allow anybody to ride on the fork. Use it for loading goods onto the fork, make sure that the
carrying goods only. width of the pallet or the goods matches well with
the width of the fork.

Make sure that the goods on pallet are secured.

Secure the goods with ropes before shipping.

Use the proper size pallet for loading. Check the

condition, strength and loading capacity of the
pallet.

The goods on the fork should be placed evenly

so as to be perfectly balanced. When loading the
goods in large size or with the center of gravity
on one side, you should be cautious not to
overturn the forklift when operating it, and also
cautious of the goods in long size such as a steel
bar or timber.
22
Safety Information
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. most cases. Never travel with the load raised
higher than necessary.

Always use the load backrest extension and Keep the load tightly against the backrest, with
overhead guard for high stacking, especially be the mast tilted backward. Never lift or lower loads
cautious of falling objects when stacking. Make with the forklift truck in motion. Make sure that
sure no loose articles are lying on top of the load. the length of the forks matches that of the load.

Do not lift the load with the mast tilted forward. Keep your forklift truck under control at all times,
The mast should be vertical or tilted backward always drive at a safe speed. Be sure you
when lifting a load. Never tilt forward when lifting understand your limitations.
a load. Tilt the mast forward only when putting
the load on a stack or directly over the unloading
area.

Keep a safe distance between machines so as to
be able to stop the machine safely under any
circumstance.
Never overtake other machines. Never pass
other machines moving in the same direction, at
intersections, blind spots and other dangerous
places. Be prepared for the unexpected
circumstances.
It is forbidden to operate the forklift in a playful
way. Concentrate and watch where the forklift is
going.
23
Safety Information
Cautions about Machine Operation
Slow down the forklift when driving on a wet road
surface and slippery ground.
In the areas where the visibility is not good, you
should drive the forklift at a low speed. If there is
rearview mirror, you should use it. If there is a
"Stop" sign, you should stop the forklift
completely, sound your horn if necessary, and
carefully drive forwards.
When taking a turn, pay attention to the swing of
its rear parts. The forklift uses the rear wheels for
steering which may cause swing when turning.
Especially be careful when operating at a narrow
road or place.
24
Safety Information
Cautions about Machine Operation

It is not allowed to drive across unsolidifield

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
Pay attention to the plate hardness when driving center of the aisle to avoid endangering
across a plate. Not all of the plate has enough personnel or equipment.
hardness to support the machine, which is
loaded or unloaded. Also pay attention to the
block hardness.

It is not allowed to make the tip of the fork bump

into any objects. When driving close to platforms,
stacks, or any fixtures, and the people nearby,
you should pay more attention and lower the fork
during driving.
Pay attention to the overhead goods and the
clearance between the mast and the obstacle.
The distance between the equipment at the
ceiling (such as lamp, cable, various
decorations, fire fighting system, door opening,
conveyor belt and head of machine) and the top
of the forklift should be large enough. In the
places where the ceiling is relatively low, lower
the mast.
 25
Safety Information
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. Make sure that the parking brake lever
is engaged and the reverse switch is in the
When loading and unloading goods, make sure
NEUTRAL position. Then take out the key and
that the truck has stopped securely and its
keep with you.
wheels have been blocked. Make sure that the
parking brake of the truck has been engaged and
secured enough, otherwise, an accident could
happen.

Check the condition of the forklift after finishing

work everyday. Report any faults of the machine
to relevant personnel if any fault is found.
Drive the machine forward when going up a hill
with a load. Drive the machine in reverse when
going down a hill with a load to avoid tipping
over. If your sight is affected by a bulky load, it is
recommended to drive the machine slowly under
the help of a signalman.
26
Safety Information
Cautions about Machine Maintenance
Parking the Machine
When possible, choose flat level ground to park
the machine, apply the parking brake (if
equipped), always lower any attachment to the
ground and ensure the machine will not move,
possibly causing damage or injury.
If it is necessary to park the machine on a slope
or incline, lower the implement to the ground,
engage the parking brake (if equipped) and shut
off the engine. Place chocks under the wheels or
tracks at the downhill side on both sides to
prevent the machine from moving.
Put the hydraulic control levers to the NEUTRAL
position and the shift control lever to the
NEUTRAL position.
Engage the parking brake (if equipped).
Keep the engine running at idle speed for five
minutes to let the engine cool down gradually.
Stop the engine, and take out the key from the
switch.
Turn the battery disconnect switch to OFF
position to avoid battery discharge.
When leaving the machine lock all equipment
covers and doors with the key. Remove the key
and keep it with you.
Cautions about Machine
Maintenance
Prepare the Working Area
Please choose a clean and flat area with
adequate space, enough light, and good
ventilation to carry out any repair work. Clean the
ground surface, wipe up fuel, lubricating oil and
water, and spread sands or other absorptive
materials on the slippery ground. Keep the work
area clean and dry.
Support the Machine Correctly
Lower to the ground or support any attachments
with stands or other methods. Ensure that any
attachment can not move during maintenance or
repair work, use wheel chocks or other devices
to prevent machine movement.
Do not work under any part of the machine or
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use
stands or other measures that are secure and
can support the weight being applied to them.
Transportation Information
Obey the appropriate laws that govern the
parameters of the load (weight, length, width,
and height).
Understand the correct procedures for loading
and unloading.
Carry out the loading and unloading operations
on flat ground.
 27
Safety Information
Cautions about Machine Maintenance

Chock the wheel of the trailer to make it unable Do not inhale smoke produced buy burning paint.
to move.
Never weld pipes, close to rubber hose and
electrical wires.
Always remove residual pressure from the
5 machine. Never weld pipes that are fitted to the
machine.
Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
of the operation being performed.
4
Ensure good ventilation.
2 3 1 Remove all the inflammable materials, supply
the work area with a fire extinguisher.
1. Wedge
2. Block
3. Angle (Max. angle is 15°)
4. Distance between the ramps
5. Ramp
Use loading ramps appropriate for the machine
being moved. Consider: size, strength, departure
angle and proper height. Make sure that the
loading ramp is anti-slip and free of mud and
snow.
Use chains and blocks to secure the machine to
the trailer.
Keep the bystanders away.
Clean the Equipment Periodically
Place all the working equipment in the
transportation position, secure all the equipment To avoid possible injury or damage to the
and attachments or additional equipment with machine, all the oil and scraps accumulated
chains or other secure methods to prevent should be removed. The engine, radiator,
accidental movement. storage battery, hydraulic hose, fuel tank and cab
should be kept clean.
Welding Operation

Any personnel engaging in welding operations

must have occupational certificates and carry out
the operation at a place with appropriate devices
equipped, When carrying out the welding
operation, the personnel must follow the
instructions below:
Before carrying out the welding operation, turn
off the battery isolator switch, disconnect the
battery, disconnect the controllers, GPS and
other electrical parts.
Remove all paint from the place to be welded, so
as to prevent harmful gas from being produced.
28
Safety Information
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.

Do not spray the water directly onto sensors,

connectors or instruments of the electrical
system. If water enters the electrical system
malfunction may occur.
Stability and Barycenter
Load Barycenter
Confirm the barycentric location according to the
shape of the goods. Because various goods
have different barycenters, so it is very important
to confirm the barycentric location.
Relations between Barycenter and Stability
Barycentric location determines the forklift
stability. It is the forklift barycentric location when
the forklift without load, but it is the complex
barycentric location of the forklift and goods
when the forklift with load. The barycenter will
move forward or backwards if the forks tilt
forward or backwards; similarly, the barycenter
will move if the forks move upwards or
downwards.

Barycenter
 29
Safety Information
Stability and Barycenter

Empty forklift is much easier to tipover

transversely than the full load forklift. The
following factors should be considered for empty Max. Lift Capacity
forklift:
Load center is the distance from the goods
● Mast up and down positions;
center on the forks to fork vertical. Max. lift
● Load size, weight, and shape; capacity is the max. weight that can be lifted at
the standard load center. Max. lift capacity was
● Loading position;
marked on the load curve. Load center moves
● Load lift height; forward, the relevant load capacity will decrease
gradually.
● Tilting angle (forward, backwards);
● Tire air pressure;
● Accelerate, stop, running condition;
● Road surface condition and slope.

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 located in front of the
triangle, the forklift will tipover forward, and it will
tipover sideward if the complex barycenter is
located on sides of the triangle.
30
Safety Information
Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically Changed

No. Key spare parts to be periodically changed Changing intervals (year)

Lift cylinder, tilt cylinder, rubber cup of steering cylinder
1 1
and dust-proof seal
2 Hydraulic oil tank filter element 1~2
3 Hydraulic oil tank or tubes 2~4
4 Steering hoses 2
5 Internal seals of steering system 2
6 Chain 2~4
7 Hose in lift system 1~2
8 Seals in brake cylinder 1~2
9 Electrical brush 1

Tightening Torque of the Bolts

CPD10/CPD15 CPD20/CPD25/CPD30
Position
Torque N.m Torque N.m
Bolt at half shaft of drive axle 96~111 150~170
Nut on front wheel (nut on wheel rim) 150~170 470~550
Brake drum mounting 120~140 206~225
Brake bottom plate mounting 120~140 210~235
Nut on rear wheel rim 118~137 125~145
 31
Applications and Specifications
Applications

Applications and
Specifications

Applications

The forklift is an industrial machine for carrying

goods over short distances and is suited to
operate on smooth and hard road surfaces. It
can be used in warehouses, railway stations,
docks, construction sites and large open paved
yards for loading and unloading, stacking
operations and short distance transportation.
This machine is a kind of common industrial
machine which is unsuitable to work in
flammable, explosive, dusty and air poisonous
environments.

Requirements of Work Environments

1. Air relative humidity: ≤90%(When the

environmental temperature is 20°C)
2. Environmental temperature: -10°C~40°C
(The cold starting Aid device is not available)
3. Wind speed: <5m/s

CAUTION: Preventive measures for

operation, maintenance and safety rules
outlined on this manual are only suitable for
the stipulated applications of the machine.
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.

WARNING: In windy condition, do not lift

the mast too high in order to prevent the
falling of goods and cause accidental body
injury.
32
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.
Exterior Drawing
 33
Applications and Specifications
Main Specifications

Machine Specifications

Model Unit CPD10/15 CPD20/25 CPD30 CPD30-AS

Rated capacity kg 1000/1500 2000/2500 3000 3000
Load center mm 500
Max. lifting height mm H 3000
Fork free lift height mm H5 135 140 145 145
Max. lifting speed (Loaded) mm/s 280 240 268 268
Tilt angle (fwd/bwd) 6°/12°
Power type Electrical
Max. travel speed km/h 12 13 14 14
Max. gradient (Loaded) % 10 12 12 12
Min. Turning radius mm R 1850 2065 2300 2300
Length mm L 2955 3580 3580 3580
Width mm W 1080 1260 1260 1260
Overall Mast lowered
mm H1 2015 2124 2124 2124
Dimension height
s Mast extended
mm H2 3925 4160 4160 4160
height
Overhead guard
mm H3 2110 2150 2150 2150
height
Min. Ground clearance mm H4 110 120 100 100
Fork size (length×width×thick) mm L2 925×100×35 1070×125×40 1070×125×45 1070×125×45
Fork length adjusting range mm W3 200~916 250~1020 250~1130 250~1130
Wheel base mm L1 1300 1510 1625 1625
Front wheel mm W1 890 1010 1010 1010
Track
Rear wheel mm W2 870 980 980 980
Front overhang mm L3 405 439 496 496
Width of min. intersecting aisle mm L4 1900 2000 2200 2200
Width of min. aisle for right
mm L5 3300 3700 3900 3900
angle stacking
Service weight kg 2646/2850 4000/4230 5200 5200
Front wheel 6.50-10-10PR 28×9-15-14PR 28×9-15-14PR 28×9-15-14PR
Tire
Rear wheel 5.00-8-8PR 18×7-8-14PR 18×7-8-14PR 18×7-8-14PR
D385-48/385(1t)
Model-voltage/
Battery V/Ah D400-48/ D630-48/630 D500-80/500 D500-80/500
capacity
400(1.5t)
Travel motor
KW 5 6.3 10 12
power
Motor Lift motor power KW 6.3 7.5 13 14
Steering motor
KW 0.85 0.85
power
CURTIS 1244 SME ACM2 80V
Electrical control type H2B H2B
1253-4802 450A+450A
34
Operation Manual
Before Operation

Operation Manual Operator Controls and

Instrument Panels
Before Operation

Mounting and Dismounting

● Before mounting or dismounting the

machine, check the condition of handrails,
ladders and steps. Clean them of grease,
lubricants and dirt before use. Repair any
damaged parts and tighten loose bolts.
● Mount and dismount the machine only where
there are handrails, steps or ladders.
● Never get on or off a moving machine.
● Be careful not to touch any control levers
when getting on or off the machine.
● Do not mount or dismount the machine from 1. Shift control lever
the right side. 2. Parking brake lever
3. Instrument panel
Daily inspection 4. Horn button
5. Steering wheel
6. Light switch
Check the condition of the battery, and the level 7. Lift lever
and the density of the electrolyte (see 8. Tilt lever
maintenance of the battery for details). 9. Turn signal light switch
10. Accelerator pedal
Check tire pressure (see maintenance 11. Start switch
12. Brake pedal
specification for details).
Check wheel nuts (see maintenance Start Switch
specification for details).
Check the level of the hydraulic oil. Start switch (also called ignition switch) is
located at the left side of the gauge which is used
Check of the steering system performance. to turn on the power for the machine. OFF and
Check of the brake system performance. ON positions are available.

Check of the mast system performance.

Check the connection and tightness of the wire
and connectors.
About more information, please refer to
"Maintenance Interval Schedule" on page 58.

Before operating the machine, turn the start
switch clockwise from OFF position to ON
position to turn on power.
OFF-- the position where the start switch key is
inserted into or taken out.Turn the start switch
key from ON to OFF position to stop the
machine.
ON-- turn the start switch key to this position to
turn on power for the machine. Then all of the
electrical appliances are connected with power.
CAUTION: Turn the start switch key to
OFF position when stop the machine. Take
out the start switch key and keep it to avoid
unauthorized personnel using the machine.
Battery Connector
The battery connector is located at the right side
of the frame. Open the battery box cover to
check the battery connector.
35
Operation Manual
Operator Controls and Instrument Panels
The battery connector is used to supply power
for the machine. Taking out the socket out of the
battery connector can disconnect the battery
connector.
1
2
1. Connector
2. Socket
WARNING: Turn the start switch key to
OFF position before disconnect the battery
connector to avoid damage to the electrical
units. Disconnect the battery connector
before check the electrical system. Also
disconnect the battery connector when
abnormal operation happens.
Parking Brake Lever
The parking brake lever is located at the right
side of the steering wheel.
Pull the parking brake lever backwards to
engage parking brake when parking the
machine. Before driving, push the lever forward
to disengage parking brake.
36
Operation Manual
Operator Controls and Instrument Panels

It is very dangerous to run the machine without Shift Control Lever

disengaging the brake as this will damage the
brake performance. Therefore, disengage the
parking brake before running the machine Shift control lever: Control the travel direction of
the forklift. There are three positions on the shift
CAUTION: Depress the brake pedal at the control lever: forward, neutral and reverse.
same time when engage parking brake. Hold
the parking brake lever in hand when the
machine is running on a slope. Place a wedge
under the tires when parking the machine on
the slope.

Steering Wheel

Push the shift control lever to F, the machine will

run forward.
Push the shift control lever to R, the machine will
run backward.
Push the shift control lever to N, the machine will
stop running.

CAUTION: Before starting the engine,

turn the shift control lever to Neutral position
An ordinary steering wheel is provided for this first, otherwise the machine can not start.
machine. The steering wheel is located inside Stop the machine before shifting from
the cab (a closed cab is optional) and connected Forward to Reverse.
with the hydraulic metering pump. The steering
wheel cannot automatically reset after released.
Therefore, reverse the steering wheel after
turning so that the machine can run straightly.
 37
Operation Manual
Operator Controls and Instrument Panels

Instrument Pane MDI (Multifunctional Digital Instrument) has three

functions:
Instrument Panel of CPD15 1. Display the battery discharge state
2. Display work hours
3. Display the system trouble
MDI instrument shows the battery discharge
state by the diode. There are five diodes in the
MDI instrument, 1 in red and four in green. All of
the four green diodes will illumine if battery
charging is finished. However, battery discharge
will happen after charge is finished. The four
green diodes will go out in sequence and the red
diode will flash when the electricity runs out and
the chopper will start under-voltage protection.
Digital code will be shown on the display to tell
the driver the controller trouble. The red diode
1. Service hour meter will flash to catch the attention of driver and
2. Coulometer spanner symbol will be shown in the display.
3. Brake indicator
4. Slow down indicator Instrument Panel of CPD30-AS
5. Turn indicator
6. Traction controller fault indicator
7. Pump controller fault indicator

Instrument Panel of H2B

1. Left turn indicator
2. Forward indicator
3. Brake indicator
4. Floodlight indicator
5. Reverse indicator
6. Right turn indicator
7. Battery electrolyte level indicator
8. Time display
9. Digital display
10. Control state display
11. Working state display
1. Alert indicator
2. Floodlight indicator (for spare use)
3. Electricity level
4. Travel speed/fault code
5. E-S-H symbol
6. Low speed symbol
7. E-S-H select button
8. Slow speed select button
9. ENTER key
10. DOWN key
11. Parking brake symbol
12. Seat switch symbol
13. Service symbol
14. Service hour meter
15. Temperature alert symbol
16. Rear wheel steering angle symbol
17. Brake oil low level alert indicator (for spare use)
18. Direction indicator (for spare use)
38
Operation Manual
Operator Controls and Instrument Panels
Alert indicator
The indicator will turn red when the
fault is found on machine.
Floodlight indicator (for spare use)
The indicator will turn green when the
floodlight is turned on.
Direction indicator (for spare use)
Brake oil low level alert indicator
(for spare use)
The indicator will turn red and alert the
operator when the brake oil level is too low.
Travel speed/fault code
To show the travelling speed of the
machine under the normal state; if the
fault occurs, it shows the fault code.
Parking brake symbol
The symbol illuminates when the
parking brake is engaged. At this time,
the machine stops running.
Seat switch symbol
The symbol illuminates when the
operator leaves the seat. At this time,
the machine stops running. Operate the machine
only when the operator is correctly sitting on the
seat.
Service hour meter
The meter indicates the total
operating time of the machine
in hours or the running mileage of the machine.
Press to shift between service hours and
service mileage.
Rear wheel steering angle symbol
The symbol indicates the steering
angle of the rear wheel of the machine
(if equipped with steering angle sensor).
Service symbol
The symbol is shown when the fault is
found or during the maintenance
intervals.
Low speed symbol
Press once, the machine goes
into low speed mode;
Press the button again, the machine goes into
normal speed mode.
Travel speed symbol
The symbol indicates the
travelling speed of the
machine.
Electricity level symbol
The symbol has 9 bars. The numbers
of bars indicate the level of electricity.
Work mode select button
Press to shift to economical
mode, standard mode or high speed
work mode.
Temperature alert indicator
The indicator illuminates when the
temperature of controller (100°C) and
motor reaches 155°C.

Brake Pedal
The brake pedal is located in front of the driver's
seat. Depressing down the brake pedal, the
brake of the gearbox will be actuated to engage
brake. Meanwhile, the brake light will illumine.
After release the brake pedal, the brake light will
go out.
Lift Lever
1 2
1. Lift lever
2. Tilt lever
The machine is not able to travel and operate if
you don't sit on the seat correctly.
Lift lever is used to raise and lower the fork.
Reverse switch and horn button are provided on
the lift lever.
Pull lift lever backwards to lift fork.
Adjust the lift speed by adjusting the
angle of the lift lever. Pull the lift lever
backwards slowly to lift the fork at a slow
speed and pull the lever backwards to a
maximum limit position when it needs to lift the
fork at a full speed.
Push the lift lever forwards to lower the
fork. Adjust the lowering speed by
adjusting the angle of the lift lever.
39
Operation Manual
Operator Controls and Instrument Panels
CAUTION: Never lift the goods at a fast
speed. To avoid damaging to the goods, lift
the goods slowly when the cylinder is getting
to the highest position, in additional, lower
the goods at a slow speed to when the goods
is about to lowering onto the ground. Never
use tilt lever when the goods is at the highest
position. Do not operate the lift lever and tilt
lever at the same time.
WARNING: It is strictly prohibited to carry
people on the forks.
Tilt Lever
Tilt control lever is used to tilt the mast forwards
and backwards.
Pull the tilting lever back to tilt the mast
backwards.
Push the tilting lever forward to tilt the
mast forward.
CAUTION: Do not stay or put your hands
and feet between the mast and overhead
guard when tilt the mast backwards,
otherwise, serious personnel injury and
death could be resulted.
40
Operation Manual
Main Parts of Forklift Body

Sideshift Lever (Optional)

Sideshift lever is used as an optional control

lever for the hydraulic system (for example the
fork moves by side).
The hydraulic cylinder (hydraulic motor) speed is
controlled by sideshift lever angle.

Aux Lever (Optional)

Aux lever is used as a optional control lever of

the hydraulic system (for example: logging fork
Armrest Angle Adjustment (Optional)
clamp rotates).
The hydraulic cylinder speed (hydraulic motor)
can be controlled by aux lever angle.

Main Parts of Forklift Body

Seat

The seat has suspended vibration-absorbing

function. It can be adjusted along fore-and-aft
direction and height direction, and the backrest
angle can also be adjusted to adapt itself to meet Backrest Angle Adjustment (Optional)
the needs of different drivers and occasions. The
seat shall be adjusted so that the pedal can be Rotating the adjusting handle clockwise to
stepped on to the full stroke. The seat shall be increase the tilt angle and counterclockwise to
adjusted when the driver sit against the backrest. decrease. Release the handle if it comes to a
desired angle and it will lock up automatically.
Fore-and-aft Adjustment

Push the adjusting handle gently to the seat

center, move the seat body forward and
backward to reach a desired position, and
release the handle and it will reset and
automatically lock.

Seat Belt (Optional)
Weight Adjustment and Suspension
(Optional)
Three positions are available for this weight
adjustment. Adjust according to the operator's
weight. Use the first position for 60 kg, the
second for 80 kg and the third for 95 kg..
WARNING: 1. It is prohibited to adjust
seat when machine is running to avoid
accident. 2. check the screws as well when
check the seat for good condition. Check
performance of the safety device if equipped.
3. Only the professional can be allowed to
install and repair the seat.
41
Operation Manual
Main Parts of Forklift Body
Service Interlocking Device
Service Interlocking Function
If your posture is incorrect while sitting on the
seat, such as standing up, tipsy and so on, these
postures makes the machine unable to run even
though the accelerator pedal is depressed or the
control lever is operated. This machine is
equipped with service interlocking device, it will
not run if you don't sit on the seat correctly.
Under incorrect posture, the interlocking function
will be activated within 3 seconds to cut off the
power supply.
Cancel the Service Interlocking Function
Sit on the seat correctly, then the service
interlocking function will be cancelled.
CAUTION: Do not use the service
interlocking function to force the forklift to
stop.
Seat Belt (Optional)
The seat belt provided for this machine is non-
retractable type.
Fasten the seat belt before driving the machine.
Before using the seat belt, check it for good
condition. Replace it in time if necessary.
For seat belt replacement, consult with Liugong
dealer.
42
Operation Manual
Main Parts of Forklift Body
Adjust length of the seat belt before using in
order to ensure safety and comfortability. Length
of the seat belt can be adjusted by moving
position of catch on the seat belt.
The buckle of the seat belt is located at the right
rear side of the seat. Insert catch of the seat belt
into the buckle to lock it.
A red button is provided by side of the buckle.
Press the button down, the catch will spring up
from the buckle.
Before using the seat belt, check whether the
buckle of the seat belt can lock and release
normally.
WARNING: Fastening seat belt can
reduce the risk of personnel injuries and
death when a turnover accident happens.
CAUTIOIN: To prevent the driver from
serious injury or death in the case of a
turnover accident, fasten the seat belt when
driving the machine. Stay in the seat when a
turnover happens. Do not jump out of the
machine. Hold the steering wheel tightly and
lean to the opposite direction when turnover
direction.
Overhead Guard
Overhead guard is an important safety
component designed to avoid injuries caused by
load falling from above. No drilling, welding or
modification is allowed on the guard, which can
reduce the safety and cause serious accidents.
Looseness or removing also has serious
consequences.
Load Backrest
Load backrest is an important safety component
designed to avoid possible falling of load towards
the operator. Any looseness, removing or
modification is dangerous.
Steering Wheel
Pull up the adjusting handle to adjust the
steering wheel forwards and backwards to
desired angle. Then fix the adjusting handle.
 43
Operation Manual
Main Parts of Forklift Body

CAUTION: Before drive the machine, 3. Turn signal light, with one set at each side
make sure that the steering wheel has been and color in yellow.
properly adjusted. Do not adjust the steering
4. Width/brake light, with one set at each side
wheel when the machine is running.
and color in red.
5. Reverse light, with one set at each side and
Steering Wheel--Check color in white.
6. Rotating beacon, one set strong magnet self-
Before starting the machine, carry out the gravitation light, color in yellow.
following inspection. If any abnormality happens,
repair it at once.
Side Shroud of the Hood
Adjust the rear wheel until the two wheels are in
a straight line, then check free stroke of the
steering wheel.
Turn the steering wheel in circles, move the
steering wheel upwards and downwards to
check for any looseness.
Press the horn button to check whether it works
normally.

Horn Button

The horn button is located in the center of the

steering wheel. Press the horn button in the
center of the steering wheel to sound the horn.

1. Screw
2. Battery box cover
3. Side shroud
When removing the side shroud, open the
battery box cover at first, unscrew the front two
screws and inside screw, and then remove the
side shroud.

Lighting System

The machine is equipped with the following

lights:
1. Front position light, with one set at each side
and color in yellow.
2. Front floodlight, with one set at each side and
color in white.
44
Operation Manual
Main Parts of Forklift Body
Rear Hood
Loosen the screws to open the cover of electric
control box.
CAUTION: It is very dangerous to operate
the machine with the side shroud and rear
hood unlocked. Before driving the machine,
make sure that the side shroud and rear hood
are locked.
Battery
The battery is located in the middle of the frame,
surrounded by shrouds and covered by the
battery box cover.
Battery Box Cover--Open/Close
Opening: Push the battery box cover upwards to
open it.
Closing: Close the battery box cover by pressing
until it contacts the rubber pads of the battery.
Fork
Pull up and unscrew lock pins at both ends of the
fork, and move the fork leftwards and rightwards.
Tighten lock pin to lock the fork after adjusting
the fork position.
When adjusting the fork position, keep load
center to the central line of the machine.
Before carrying the goods, make sure that the
fork has been locked securely by the lock pin.

Traction Pin
The traction pin is located behind the
counterweight. It is used to tow the machine
when the wheels get into trench or mud puddle.
Refer to the Machine specifications for detailed
values of towing capacity.
CAUTION: The forklift is not a towing
machine. Do not use the forklift to tow other
vehicles unless necessary.
Safety in Attachment Installation,
Adjustment and Use
Attachment Installation
Install the attachment securely to ensure that the
attachment will not move along the fork arm
carrier to lead to safety problems during working.
As for those attachments with hook, engage the
hook into the beam after installing to let the
deviation allowance from center line of the
attachment to the fork arm carrier center stay
within 50mm, otherwise lateral instability will be
resulted.
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 upper beam of
fork arm carrier is connected with the attachment
after installing to prevent the attachment from
moving left and right during working.
45
Operation Manual
Main Parts of Forklift Body
As for those attachments with position hook,
adjust the clearance between the hook and the
lower beam of the fork arm carrier.
Nearly all of the attachment for medium and
small ton forklift is installed with hook. In order to
ensure the installation safety, it's recommended
to select the appropriate attachment to the forklift
according to the ISO2328 standard Fork-Lift
Trucks-Hook-On Type Fork Arms and Fork Arm
Carriages-Mounting Dimensions
Attachment Use
1. Operating the fork attachment should be
based on the operation experience of the
forklift, instructions on the forklift nameplate
and familiarity on the operation manual
(especially operation and installation
manuals from the attachment company).
Know the performance and operation of the
attachment especially the allowable load, lift
height, goods dimension and application
range.
2. When operating a multi-purpose attachment
(with sideshift, clamp and rotating function,
etc), do not carry out two actions at the same
time. Change to second action only after the
first is finished.
3. Do not overload the attachment. It's better
not to load unevenly at high order (especially
for sideshift type clamp which is controlled by
combination valve, that is, the clamp used by
sideshift cylinder and positioning cylinder) as
high order operation is only suitable for
specified period and the deviation should be
within about 100mm for left and right.
4. Do not drive the forklift with attachment at
high order position.
5. No passengers is allowed to stand within
1.5m from the dashed area which covers the
right below part of the attachment and goods
(except for the position at driver's seat
protected by overhead guard) to avoid
accidents.
6. Do not engage brake suddenly during
driving. Drive slowly when carry with a load.
46
Operation Manual
Operation Techniques

7. It is prohibited to modify the attachment
without the technical permission of Liugong
as the modification could cause safety
problems and change the attachment
function.
CAUTION: The machine can start only
when the reverse switch is in NEUTRAL
position.This can avoid the accident
produced at the beginning of starting the
machine.

NOTICE: "Attachment Capacity" stated 4. Pull up the emergency switch correctly.

by the attachment company is only a
5. Insert the start switch key and turn it
reference value for the attachment, not the
clockwise to "ON" position to turn on power
maximum capacity value to the forklift.
for the machine. Hoot the horn to announce
that the machine is about to start and other
The rated capacity of the machine installed
people are not allowed to approach the
with attachment is the minimum value among
machine.
forklift capacity, attachment capacity or
integrated capacity. Generally, the integrated
capacity has the minimum rated capacity
value after calculation. The forklift can meet
the need in different operation condition as
long as the goods do not exceed the rated
capacity.

Machine Starting
6. Check all instruments, lightings, indicators,
CAUTION: Before starting the machine,
horn, windshield wiper (if a cab is equipped)
make sure that nobody is working on or near
and brake lights for good condition.
the machine. Make sure that the machine is
under control of the operator.
Operation Techniques
1. Open the battery cover and connect the
battery connector.
Traveling Operation

NOTICE: Before driving the machine onto

roads, make sure that the driver knows the
local traffic laws and regulations. Observe
the local road regulations when driving on
roads.

NOTICE: Raise the forks 15 to 20cm off

the ground.

2. Get on the machine, and fasten the seat belt.

3. Turn the reverse switch to NEUTRAL
position.

1. Keep the correct posture during operation,
always sitting on the seat correctly, don't put
your hands, foot and other parts of your body
out of the overhead guard.
2. Operate the reverse switch to select the
desired direction.
3. Release the parking brake lever to disengage
parking brake. Depress the accelerator
pedal, the forklift will start to run.
4. Turn the steering wheel to check whether the
forklift can make a spot turn.
5. Check service brake performance. Run the
forklift forwards. Release the accelerator
pedal and then gently depress the service
brake pedal, the forklift will be able to slow
down.
CAUTION: if you can not feel any obvious
slowdown in the forklift, then immediately
engage the parking brake lever so as to force
it to stop.
6. Check engagement conditions for front and
rear gear.
CAUTION: shut down the machine when
shift front gear to reverse gear during
checking the engagement
47
Operation Manual
Operation Techniques
Steering Operation
The forklift adopts a full-hydraulic steering
system. Move the steering wheel slightly when
operating.
1. Turn the light switch lever forwards when the
machine is turning leftwards, then the left
turn signal light will turn on; turn the light
switch lever backwards when the machine is
turning rightwards, then the right turn signal
and indicator on the instrument will turn on to
indicate that the machine is steering so that
the passerbys and neighboring cars can
keep away.
1. Turn left
2. Run straight
3. Turn right
2. Turn the steering wheel clockwise when the
machine turns rightwards; turn the steering
wheel counterclockwise while the machine
turns leftwards. Reverse the steering wheel
so that the forklift can run in the straight
direction after finish steering operation.
3. Turn the light switch to the NEUTRAL after
finish steering operation. Then the turn signal
light will go out.
4. Depress the accelerator pedal to obtain a
desired motor speed.
WARNING: Never turn the forklift
leftwards or rightwards on slope, otherwise,
the forklift may overturn. Steering of this
machine is controlled by rear wheel. Slowly
rotate the steering wheel when steering to
avoid shake caused by a sharp brake.
48
Operation Manual
Operation Techniques
Brake Operation
Service Brake
Before engage brake, please first release the
accelerator pedal, and then slowly depress the
service brake. The service brake is engaged by
friction discs.
WARNING: Never depress the brake
pedal to the maximum position when the
machine is running at high speed unless
emergency happens. Otherwise, a sharp
brake will damage the brake system and
cause safety accident quite easily.
Parking Brake
Pull the parking brake lever backwards to
engage parking brake. The lever will hold
automatically after brake is engaged. Wheels are
stopped mechanically by friction discs.
Press the lock button on top of the parking brake
lever, then push the parking brake lever forwards
to disengage brake.
CAUTION: An alert symbol will flash in
the forklift gauge to warn that the parking
brake is not disengaged before running. The
parking brake can hold the forklift with load
on a slope with 15% grade stably if the slope
surface is clean.
Regenerative Brake
When the accelerator pedal is released, the drive
motor will turn into an alternator to convert kinetic
energy into electric energy to charge the battery
through a controller, which is called as
regenerative brake. The machine will slow down
in a short distance until stops. This brake mode
can reduce energy consumption.
Reverse Brake
During driving, the drive motor can generate an
opposite force that can slow the forklift down
when turn the reverse switch to opposite running
direction. Then the machine will gradually reduce
its speed until it stops. After that, the forklift starts
to drive in the opposite direction.
Downhill Operation
● Before starting the downhill operation, please
choose a suitable speed. Do not turn the
machine when travel on the slope.
● Please keep a slow downhill speed as
possible. Depress the service brake to
control travel speed when drive down the hill.
Never depress the service brake when the
machine is running at a high speed,
otherwise the brake and drive axle will
overheat quickly and easily damage.
● Run the forklift reversely if it is full-loaded and
travel on a slope with a grade more than
10%.
CAUTION: Drive the machine reversely
when go down the hill with a load. Drive
forwards when go up the hill. Never attempt
to drive forwards without a signalman if the
visibility is poor caused by the big load.

Loading Operation
1. Before loading, please confirm whether the
width of the loading board or the goods is
suitably matched with the opening degree of
two forks.
2. Drive the forklift slowly to approach the
goods. Align the fork with the center line of
goods at a slow speed to avoid damage the
goods.
3. Slowly push the lift lever forwards to place
the goods to the ground. Then push the tilt
lever forwards to insert the fork into the
bottom of the goods.
4. After the fork is inserted into bottom of the
goods, pull the lift lever backwards to raise
the fork to a height of 15mm to 20cm or so.(If
operating in a room, pay attention not to
touch the ceiling). Then pull the tilt lever
backwards to tilt the mast backwards.
5. In order to main a balance, please load the
goods evenly. When loading large sizes or
heavy goods, please pay close attention to
operation to avoid an overturn of the forklift.
6. When driving with goods, please keep the
mast tilted backwards. Moreover, raise the
fork for 15mm to 20cm height from the
ground to carry the goods to the unload
destination.
7. When drive the forklift with a load down the
hill, it is better to drive the machine reversely
at a slow speed.
49
Operation Manual
Operation Techniques
WARNING: During running, never tilt the
mast forwards or raises the goods too high
from the ground; otherwise the machine will
lose its balance, which will cause an
overturn.
Unloading Operation
Drive the forklift slowly to approach the unloading
site. Then operate the lift lever to raise goods to
a desired position.
Push the tilt lever forwards to tilt the mast, then
unload the goods.
Please withdraw the fork after the goods is
unloaded. Then lift the or lower the fork to a
height of 15mm or 20cm from the ground to
prepare for next task. Keep the mast at vertical
or tilted position.
Move Oversize Goods
Drive with special attention when carry oversize
goods.
Drive slowly when turning or lifting or lowering
the goods to avoid movement of the goods.
Meanwhile, pay attention to the surrounding to
ensure safety.
Use appropriate size fork arm carrier and fork
when carry oversize goods. The capacity of the
widened fork arm carrier should be the same
with the standard carrier and within the
stimulated load center. Try to place the goods on
the load center of the forklift. The deviation
allowance from the load center should be within
100mm for 1-3.5t forklift and 150mm for 5-10t
forklift. The lengthened fork should work on the
load curve diagram strictly and the capacity of it
should be within the load center and the same
with the standard fork. Reduce the load when the
load center moves forward.
50
Operation Manual
Operation Techniques

Cold Weather Operation

CAUTION: Do not operate the forklift

when the environment temperature is below -
20°C.

● Use hydraulic oil and lubricant with low

viscosity. For details on oil brands, please
refer to "Oil Specifications" on page 71.
● Electrolyte in the battery could freeze if the
ambient temperature drops. To prevent the
batter capacity from being affected by the
frozen electrolyte, please cover the battery
with suitable guards or move it to a warm
place. Install it to the machine again next day.
● Remove and clear away silt, water, and snow Parking
completely every day after finish working.
Otherwise, silt, water or snow enters into the
seams which will freeze and damage to the
Stop the Machine
seams.
Stop the machine on a flat ground. If you have to
● To prevent the forklift from being frozen on park the machine on a slope, place a wedge
the ground, park the machine on a dry hard under the wheels to avoid movement of the
ground or woods boards. machine.
● Replace hydraulic oil and lubricant with
medium-viscosity after cold weather is gone. CAUTION: Park the machine on a road
For details on oil brands, please refer to "Oil which is free from other machines.
Specifications" on page 71.
1. Depress down the service brake pedal to
stop the machine.
Hot Weather Operation
2. Turn the reverse switch to NEUTRAL
position.
Pay attention to the following points when
3. Engage the parking brake lever.
operate the machine under a hot weather.
● Do not work under a hot weather for a long
time because a high temperature will result in
a low efficiency.
● Use hydraulic and lubricant with high
viscosity to improve the hydraulic system
efficiency. For details on oil brands, please
refer to "Oil Specifications" on page 71.

4. Lower the forks onto ground.


Shut down the Machine
1. Turn the start switch to OFF position and
take out the key.
2. Turn every switch or push every lever to OFF
or NEUTRAL position.
Leave the Machine
1. Close the cab door. (If a cab is equipped)
2. Use the steps and the handrails when you
get off the machine. Face the machine and
use both hands. Make sure that the steps are
clear of debris before you dismount.
3. Clean out any debris and paper in order to
avoid a fire.
4. Remove all flammable debris in order to
reduce a fire hazard. Dispose all debris
properly.
5. Install all covers, lock all devices, and take
away the key.
Forklift Storage
Park the machine in a good-ventilated place that
is clean, dry and free from frost if the forklift has
not been used for over a month. Store the
machine as follows.
Before Storage
Clean the machine thoroughly, but do not flush it
with water to avoid short circuit.
Fully raise and lower the fork and tilt the mast
forwards and backwards for several times. If
attachments are available, raise and lower them
for several times.
51
Operation Manual
Operation Techniques
Lower the fork arm carrier to the support block so
as to remove the chain.
Check hydraulic oil level. Fill with oil if necessary.
Apply a layer of oil grease on exposed surfaces
of parts and components.
Lubricate the specified lubrication points on
forklift according to the lubrication chart.
Check the battery and its electrolyte for good
condition. Apply non-acid lubricant to terminal
posts. (Please follow battery instructions from
the manufacturer)
A suitable spray is used to spray on all electric
contact points.
CAUTION: Lift and fix the forklift during
storage period to prevent the tires from
deforming. Never cover the forklift with films
because water vapor may accumulate.
Contact with liugong dealer for further
maintenance procedures if the forklift is
parked over three months.
In Storage
Start the machine once every month. Lift and
lower the forklift at least three times, and tilt the
mast forwards and backwards at least three
times too. Drive the forklift forwards and
backwards for at least 50 meters. Lubricate all
the movable parts such as pins and shafts.
Before starting the machine, wipe off the grease
from the hydraulic cylinder piston rods. After
operation, apply a new layer of grease to the
cylinder piston rods.
Apply antirust to parts that easily get rusty.
CAUTION: Open the doors and windows
periodically to exhaust toxic gas when apply
the anti-rust compound indoor.
52
Operation Manual
Transportation Information

Before Reuse

Clean the forklift truck fully, but do not flush it

with water.
Smear non-acid grease over the battery terminal
posts.
Check battery condition and its electrolyte level.
Check hydraulic oil for water or deterioration,
replace with clean oil if necessary.
Check and give service to the forklift before 5. Never turn the forklift when drive the forklift
reusing the machine. onto the trailer. Carry out this operation by
following the signalman's instructions

Transportation Information 6. Lower the fork or attachments onto ground

Transportation
CAUTION: Observe the national and local
laws and regulations on the goods weight,
length, width and height before shipping.
after the forklift parked on the trailer, then
engage parking brake.
7. Choke and fasten the forklift with ropes to fix
it in order to prevent the machine from
moving during transportation.

1. Investigate the travel route for overpass

clearances and the allowed weight. Make
sure that the total height, total width and total
weight of the transportation car with this
machine inside does not violate the
stipulations.
2. Remove ice, snow, or other slippery material
from the loading platform and trailer before lift
the machine. This will help to prevent the
machine from slipping and moving during
transportation.
3. Before the shipment, please ensure that the
trailer body is strong enough.
4. Engage parking brake when parking the
trailer on the ground. Chock the trailer wheels
with wedges.

8. For installing those parts that removed before

transportation, please contact with liugong
dealer to install.

9. When it is necessary to remove the mast and
counterweight before transportation, please
remove the mast firstly, then the
counterweight. When installing, first to install
the counterweight, then the mast.
Tires--Replace
Front tires
1. Park the forklift on flat and hard ground.
2. Start the engine, lift the mast about 100 mm
off ground.
3. Chock the rear wheels with wedges to
prevent the machine from moving.
4. Loosen the nuts of the wheels
counterclockwise 1-2 turns.
5. Tilt the mast backwards, place blocks under
two sides of the outer mast.
6. Tilt the mast forward until the front wheels
being lifted off ground.
CAUTION: Do not remove the nuts of the
wheels before the front wheels being lifted off
ground.
7. Place blocks under the front two sides of the
frame to support the machine, and then stop
the engine.
53
Operation Manual
Transportation Information
8. Remove the nuts of the wheels, replace the
front tires.
WARNING: 1. Take out the wheel rim
bolts and nuts only after deflation when
removing the tire from the wheel hub. 2. The
block should be one-piece and hard enough.
3. Do not enter into the bottom of machine
when it is supported only by blocks.
9. Install the nuts in turn as illustrated, and
tighten the nuts temporarily.
10. Start the engine, remove the blocks under
the frame.
11. Tilt the mast backwards, lower the forklift
slowly, and then remove all the blocks under
the mast and the wedges at the rear wheels.
12. Tighten the bolts of the wheels in turn.
13. Adjust the tire pressure to specified value.
54
Operation Manual
Transportation Information

Rear tires 6. Remove the nuts of the wheels, replace the

1. Park the forklift on flat and hard ground.
2. Engage the parking brake lever. Chock the
front wheels with wedges to prevent the
machine from moving.
3. Place a jack under the counterweight as
shown below.
rear tires.
WARNING: 1. Take out the wheel rim
bolts and nuts only after deflation when
removing the tire from the wheel hub. 2. The
block should be one-piece and hard enough.
3. Do not enter into the bottom of machine
when it is supported only by blocks.

7. Install the nuts in turn as illustrated, and

tighten the nuts temporarily.

NOTICE: Make sure the minimum

withstand weight of the jack is 2/3 of the
forklift total weight.
8. Remove the blocks under the frame. Lower
the forklift slowly on to the ground, and then
4. Loosen the nuts of the wheels
remove the wedges at the front wheels and
counterclockwise 1-2 turns.
the jack under the counterweight.
CAUTION: Do not remove the nuts of the 9. Tighten the bolts of the wheels in turn to
wheels before the rear wheels being lifted off specified torque, refer to "Tightening Torque
ground. of the Bolts" on page 30.
10. Adjust the tire pressure to specified value.
5. Lift the forklift slowly by the jack until the rear
wheels completely off the ground. Place
blocks under the rear two sides of the frame
to support the machine as illustrated.
 55
Operation Manual
Transportation Information

Fork Removal
Figure 2

The forks are held on the carriage by hooks. The

forks are kept in position by latch pins that fit
through the top fork hooks and into slots in the
top bar carriage. Always check that the latch pins
for the forks keep the forks in position on the
carriage. Replace damaged latch pins parts. The
forks can be removed from the carriage by
aligning the forks with the fork removal notch.
The fork removal notch is in the bottom bar of the
carriage.

WARNING: Do NOT try to remove a fork

without a lifting device. Each hook fork for
these lift trucks can weigh 45 to 115 kg(99 to
254 lb).

A fork can be removed from the carriage for

replacement of the fork or other maintenance.
Slide the fork to the fork removal notch in the 1. Forks
bottom bar of the carriage. See Figure 1and 2. Carriage
3. Load backrest extension
Figure 2. Lower the fork onto blocks so the 4. Fork removal notch
bottom hook of the fork moves through the fork 5. Latch pin assembly
removal notch. See Figure 3. Lower the carriage
further so the top hook of the fork is disengaged
from the top carriage bar. Move the carriage
Fork Install
away from the fork, or use a lifting device to
move the fork away from the carriage. Move the fork and carriage so the top hook on
Figure 1 the fork can engage the upper carriage bar.
Raise the carriage to move the lower hook
through the fork removal notch. Slide the fork on
the carriage so both upper and lower hooks
engage the carriage bars. Engage the latch pin
with a notch in the upper carriage bar.

1. Carriage Bars
2. Fork
3. Blocks
56
Operation Manual
Transportation Information

Towing Information Lifting Operation

Tow the machine to a safe place if the machine WARNING: Improper lifting and wrong
is disabled. fixing may cause the forklift falls down and
result in machine damage and personnel
The drawbar is located behind the
injury or death. Make sure that nobody is
counterweight. Use this drawbar to tow the
around when lifting the forklift.
machine out if the machine get trapped in mud or
is secured on a trailer. Never try to use the forklift
CAUTION: Do not lift the machine by
as a towing tractor to tow other disabled
hoisting the overhead guard.
machines.

1. Choose suitable crane and rope with

maximum capacity according to the
nameplate on the forklift to ensure safety
when lifting.
2. A lifting decal is sticked on the mast and
counterweight. Lift the machine by hoisting
the lifting eye according to the lifting decal.

Use moving equipment (for example, crane) to

move the disabled forklift.

3. The lifting crane should be fixed stably to the

lifting eye. Ensure that the lifting ropes have
strong enough capacity to lift the forklift.

4. Ensure that the four lifting hooks on the lifting
ropes are weighted with even force when
lifting.
5. This machine can be side lifted by a forklift.
Please choose a suitable forklift to lift this
machine according to the nameplate.
CAUTION: Ensure that the lifting device
do not interfere with overhead guard and
lights during lifting.
57
Operation Manual
Transportation Information
Attachment--Remove and Lift
The attachment of the machine is removable.
Refer to the following steps for removal.
Take sideshifter for example.
1. Remove the fork and the hydraulic lines
which connect to sideshifter.
2. Remove the fixed plate at the bottom of the
sideshifter.
3. Lift the sideshifter by the lift eye.
58
Maintenance Manual
Maintenance Interval Schedule

Maintenance Manual

Maintenance Interval Schedule

CAUTION: Read and understand all the safety information, warnings and illustrations before
any operation and maintenance procedures.

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.
Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in
the "Maintenance Intervals" chart may be necessary.
Perform service on items at multiples of the original requirement. For example, at every 600 service
hours or 3 months, also service those items listed under every 200 service hours or monthly, every 8
service hours or daily.
( " ● " means replacement).

Electrical System

Three
Every Day Every Month Half Year Every Year
Items Description Tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Check the motor
connections ○ ○

Check motor carbon

brush abrasion
condition (only for ○ ○ ○ ○
DC motors)

Clean the valve

plate groove and its
surface to remove ○ ○ ○
Motor carbon powder (only
for DC motors)

Clean the radiator

fins and motor cover ○ ○ ○

Clean or replace the

bearing ○ ○

Check the wires for

good connection ○ ○ ○ ○
 59
Maintenance Manual
Maintenance Interval Schedule

Check the
consistency and Hydrom
liquid level of eter
electrolyte, also Voltmet ○ ○ ○ ○ ○
check the voltage of er
the motor

Check if the cables

of the battery are
damaged, replacing ○ ○
them if necessary
Check if the terminal
is loosed ○ ○ ○ ○
Battery
Clean the battery
connector and check
if the connector ○ ○ ○ ○
connects tightly

Clean the surface of

battery ○ ○ ○ ○ ○

Check if the breather

cap is screwed
tightly and the air ○ ○ ○ ○
inlet is kept open.

Check the abrasion

condition of the ○ ○ ○
contacts

Check the contactor

for good mechanical ○ ○ ○
movements

Check the fault

Controller diagnosis system of
the controller for ○
normal state.

Check the
connections
between the motor,
battery and ○ ○ ○
controller are good
or not
60
Maintenance Manual
Maintenance Interval Schedule

Check the
instruments and
display for good ○ ○ ○
condition

Other Check if the alarm

electrical device and
emergency switch ○ ○ ○
units
are in good condition

Check the
specifications of the ○ ○
fuse.

Power train system

Three
Every Day Every Month Half Year Every Year
Items Description Tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Check for leakage ○ ○ ○ ○ ○
Check for abnormal
noise ○ ○ ○ ○ ○

Gear box Change oil ● ●

(only for Check the brake for
models good condition ○ ○ ○ ○ ○
equipped
with gear Check bolts that
box) secured the frames ○ ○ ○ ○
for looseness.
Check the tightening
Torque
torque of wheel hub
wrench ○ ○ ○ ○ ○
bolt
Check for leakage ○ ○ ○ ○ ○
Change oil ● ●
Check the tightening
Drive axle Torque
torque of wheel hub
wrench ○ ○ ○ ○ ○
(only for
bolt
models
equipped Check the bearings
with drive for looseness and ○ ○ ○ ○
axle) noise
Check the axles for
deformation, cracks ○ ○ ○ ○
or damages.
 61
Maintenance Manual
Maintenance Interval Schedule

Wheels

Three
Every Day Every Month Half Year Every Year
Items Description Tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Inflation pressure
Pressure
(only for pneumatic
gauge ○ ○ ○ ○ ○
tires)
Check for cracks or
damages ○ ○ ○ ○ ○

Check for ground Depth

wear meter ○ ○ ○ ○
Tires
Check for
abnormal wear and ○ ○ ○ ○ ○
tear

Check if there are

nails, stones or
other foreign ○ ○ ○ ○
matters on the
tires.

Check for loose Test

bolts Hammer ○ ○ ○ ○ ○
Tires
installation Check for
damages ○ ○ ○ ○ ○

Check the wheel

Wheel rim rims, wheel ribs
and spoke and disk wheel for ○ ○ ○ ○ ○
damages.

Steering system

Three
Every Day Every Month Half Year Every Year
Items Description Tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Check the
clearance ○ ○ ○ ○ ○

Check the axial

looseness ○ ○ ○ ○ ○
Steering
wheel Check the radial
looseness ○ ○ ○ ○ ○

Check the
operation condition ○ ○ ○ ○ ○
62
Maintenance Manual
Maintenance Interval Schedule

Check for loose

bolts ○ ○ ○ ○
Metering
pump Check the seals of
each connector ○ ○ ○ ○ ○

Check the main pin

for looseness or ○ ○ ○ ○
damages
The
steering Check for
knuckle of deformation, ○ ○ ○ ○
rear axle cracks or damages

Check for good Test

installation hammer ○ ○ ○ ○

Check for good

operation condition ○ ○ ○ ○ ○

Check for leakage ○ ○ ○ ○ ○

Check looseness
when installing and ○ ○ ○ ○
Steering steering
cylinder
Check
engagement
condition for the
rack (only for the ○ ○ ○
steering axles
equipped with
rack)

Braking system

Three
Every Day Every Month Half Year Every Year
Items Description Tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Empty stroke ○ ○ ○ ○ ○
Pedal stroke Scale ○ ○ ○ ○ ○

Brake pedal Operation ○ ○ ○ ○ ○

condition
Check for brake
circuits for air ○ ○ ○ ○ ○

Check if the
parking brake is
Parking safety and check ○ ○ ○ ○ ○
brake its stroke
handle
Operation
performance ○ ○ ○ ○ ○
 63
Maintenance Manual
Maintenance Interval Schedule

Operation
Bar, ropes performance ○ ○ ○ ○
and cables,
etc Check for
looseness ○ ○ ○ ○

Check for damage,

leakage and cracks ○ ○ ○ ○

Circuits Check those

connection parts
for good ○ ○ ○ ○
connection
Check for leakage ○ ○ ○ ○
Check oil level and
replace oil ○ ○ ○ ● ●

Check the
operation condition
of primary brake
pump and ○
secondary brake
Primary pump
brake
pump, Check the primary
Secondary brake pump and
brake pump secondary brake ○
pump for leakage
and damages.

Check the primary

brake pump, piston
leather cup and the
check valve for ●
wear condition,
replace if
necessary.
64
Maintenance Manual
Maintenance Interval Schedule

Check the
mounting bolts and
Test
screws of the
hammer ○ ○ ○ ○
brake pump for
looseness

Check the friction

plate for good Scale ○
condition
Check if the fixed
Brake drum pin is corroded ○
(Only for
drum type Check the return
brake) spring for good Scale ○
condition

Check the self

adjustment device
for proper ○
clearance when it
is operating.

Check the brake

drum for wear and ○
damages
Check if the bottom
plate deforms ○
Bottom
plate of Test the
Check for cracks
damage ○
brake (Only
for drum
Check for
type brake) Test
looseness when
hammer ○
installing

Lift system

Three
Every Day Every Month Half Year Every Year
Item Description Tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Check the fork for
damage,
deformation and ○ ○ ○ ○ ○
wear condition

Check the dowel

Fork
pin for damage and ○ ○ ○
wear condition

Check the welding

position at the
bottom of the fork ○ ○ ○ ○
for cracks and
wear.
 65
Maintenance Manual
Maintenance Interval Schedule

Check the welding

position among the
inner mast, outer
mast and the beam ○ ○ ○ ○
for cracks and
damages

Check the welding

position of tilt
cylinder bracket
and mast for poor ○ ○ ○ ○
welding, cracks or
damages

Check the inner

mast and outer
mast for poor ○ ○ ○ ○
welding, cracks or
damages

Check the fork arm

carrier for poor
Mast and
welding, cracks or ○ ○ ○ ○
fork arm
damages
carrier
Check the roller for
looseness ○ ○ ○ ○

check the mast

bushing for ○
damages

check the mast Test ○

bolts for looseness hammer
At the first ○ ○
time
check the bolts of
lift cylinder, piston Test ○
rod and clamps for hammer
At the first ○ ○
time
looseness

Check the roller,

roller shaft and
check their welding ○ ○ ○ ○
positions for cracks
and damages
66
Maintenance Manual
Maintenance Interval Schedule

Check if the chain

is tensioned and
deformed, damag- ○ ○ ○ ○ ○
ed corroded
Lubricate chain ○ ○ ○ ○
Check the rivet
pins for looseness ○ ○ ○ ○
Chain and
chain wheel
Check the chain
wheel for
deformation and ○ ○ ○ ○
damage
check the chain
wheel bearing for ○ ○ ○ ○
looseness
Attachment check for good
s connection ○ ○ ○ ○

check the piston

rod, piston rod
thread for good
Test
connection, also
hammer ○ ○ ○ ○ ○
check for loose-
ness, deformation
and damages
lift cylinder Check for operat-
ion condition ○ ○ ○ ○ ○

check for leakage ○ ○ ○ ○ ○

check the pin and

cylinder bearing for ○ ○ ○ ○
wear and damages
 67
Maintenance Manual
Maintenance Interval Schedule

Hydraulic system

Three
Every Day Every Month Half Year Every Year
item description tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Check the hydraulic
pump for leakage ○ ○ ○ ○ ○
and noise
hydraulic
pump check the drive gear
of hydraulic pump ○ ○ ○ ○
for wear condition

check the oil level ○ ○ ○ ○ ○

replace oil ●
hydraulic oil clean the suction
tank filter element ○ ○ ○

Remove
contaminants ○ ○ ○

return oil change the return oil

filter filter ● ●

check for looseness ○ ○ ○ ○ ○

control
valve spool check the operation
condition ○ ○ ○ ○ ○

Check for leakage ○ ○ ○ ○ ○

Check the relief
valve and the tilt lock
valve for good ○ ○ ○ ○
Control
valve operation condition
Oil
measure the relief
valve pressure
pressur ○ ○
e gauge
Check for leakage,
looseness, cracks,
deformation and ○ ○ ○ ○ ○
pipe joints
damages
Replace the pipes ● 1-2year
68
Maintenance Manual
Maintenance Interval Schedule

Safety device and accessories

Three
Every Day Every Month Half Year Every Year
item description tools Months
(8hours) (200hours) (1200hours) (2400hours)
(600hours)
Check for good Test
Overhead installation hammer
guard and Check for
load- deformation,
backrest cracks and ○ ○ ○ ○ ○
damages

Check for good

Turn signal
lights
installation and ○ ○ ○ ○ ○
operation condition

Check for good

Horn installation and ○ ○ ○ ○ ○
operation condition

Check for good

Light and
bulbs
installation and ○ ○ ○ ○ ○
operation condition

Check for good

Backup
alarm
installation and ○ ○ ○ ○ ○
operation condition

Check for contam-

inants and check ○ ○ ○ ○ ○
Rearview for damages
mirrors
check for good
rearview ○ ○ ○ ○ ○

Check for good

Gauges
operation condition ○ ○ ○ ○ ○

Check for dama-

seat
ged or loose bolts ○ ○

Check the frame

and beam for
damages and ○
cracks
Check for loose Test
Body rivet and bolts hammer ○

Check the repaired

parts again if ○ ○ ○ ○ ○
necessary
All-around check ○
 69
Maintenance Manual
Maintenance Interval Schedule

Check the chassis

Grease
Refill lubrication after
gun ○ ○ ○ ○
grease or cleaned
replace oil Check oil in the
tank ○

Note: If replacing oils with that of other brands which is out of the specification of this machine,
the replacement interval should not be the same. Shorten the maintenance interval to 1/2 or 1/4.

It needs to replace the high viscosity oil as required even though that can be widely used in
different temperature, because the additives would deteriorate slowly to reduce the viscosity and
could damage the hydraulic system at high temperature.
70
Maintenance Manual
General Torque Specifications

General Torque Specifications

Tighten the bolts used in the machine according to the torque requirements shown in the following table
unless other specified:
Metric system

Standard Torque lb.ft (N.m)

Thread Size
8.8 Grade Strength 10.9Grade Strength
M6 7.7±1.1 (10.5±1.5)
M8 19± 2.9 (26±4)
M10 38 ±5 (52±7) 53 ±4 (72±6)
M12 66± 9 (90±12) 89±7 (120±10)
M14 107±15 (145±20) 144±11 (195±15)
M16 166±26 (225±35) 225±18 (305±25)
M18 229±33 (310±45) 306±26 (415±35)
M20 302± 37 (410±50) 443±37 (600±50)
M22 443± 59 (600±80) 590±52 (800±70)
M24 561±74 (760±100) 752±74 (1020±100)
M27 811±111 (1100±150) 1106±74 (1500±100)
M30 1106±148 (1500±200) 1364±111 (1850±150)
M33 1512±221 (2050±300) 2139±295 (2900±400)
M36 1955±258 (2650±350) 2286±184 (3100±250)

British system

Thread Size Standard Torque lb.ft (N•m)

1/4 9±3 (12±4)
5/16 18±5 (25±7)
3/8 33±5 (45±7)
7/16 52±11 (70±15)
1/2 74±11 (100±15)
9/16 110±15 (150±20)
5/8 148±18 (200±25)
3/4 266±37 (360±50)
7/8 420±59 (570±80)
1 645±74 (875±100)
 71
Maintenance Manual
General Torque Specifications

Oil Specifications

Oils that used in this machine should meet the following specifications when refill or replace to ensure
the normal use of the machine.
L-HV32 anti-wear hydraulic oil with ambient temperature between -20~-5°C;
L-HM32 anti-wear hydraulic oil with ambient temperature between -5~30°C;
L-HV68 anti-wear hydraulic oil with ambient temperature between 30~50°C

Oils used in plain areas

Type of oil Name of oil Position of use

in summer in winter
For roller bearing, sliding bearing, shaft of working
Grease ★ 2# MOS2 Molybdenum lithium based grease implement, steering cylinder, frame and support of
rear axle etc.
L-HV32 low
★ L-HM32 anti-wear For working implement hydraulic system, steering
Hydraulic oil temperature anti-
hydraulic oil hydraulic system, brake system
wear hydraulic oil
Gear oil ★ 85W/90# gear oil For drive axle bevel gear, gearbox
Brake oil DOT3 compound brake oil For brake system
Note: " ★ " used by the manufacturer after the machine is newly produced.

Oil used in plateau and severely cold areas

Type of oil Name of oil Position of use

in summer in winter
For roller bearing, sliding bearing, shaft of working
Grease 2# Moybdenum lithium based grease implement, steering cylinder, frame and support of rear
axle etc.
L-HV32 low temperature anti-wear For working implement hydraulic system, steering
Hydraulic oil
hydraulic oil hydraulic system, brake system
Gear oil SAE 80W-90/LS gear oil For gearbox
Brake oil DOT3,GB12981 HZY3 For brake system

CAUTION: Do not mix oils of different brands even if they have the same specifications.
Clean the system before refilling the different oil.

Replace the lubricant periodically even though the lubricant is very clean because the lubricant
might go bad after a long time use.

Choose the oil according to the lowest air temperature in the local area where the machine is
used.
72
Maintenance Manual
Lubricant Specifications

Lubricant 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. Prepare
to collect the fluid with suitable containers before removing any hydraulic oil line or
disassembling any component that contains fluids. Obey all local regulations for the disposal of
liquid.

Approximate
Applicable
Type Oil Brand Filling
Models
capacity (L)

40 CPD10/CPD15
L-HM32 anti-wear hydraulic oil// L-HV32 low temperature
Hydraulic oil
anti-wear hydraulic oil
CPD20/ CPD25/
50
CPD30

Gear oil 85W-90 gear oil 4.4 All

Brake oil DOT3 compound brake oil 0.5 All

Grease 2# or 3# general-purpose lithium base grease 0.5 All

 73
Maintenance Manual
Lubricant Specifications

Lubrication Chart

Sliding surface lubrication

Grease fitting lubrication
Gear oil injection
Gear oil releasing
Hydraulic oil injection

Brake oil injection

74
Maintenance Manual
Tire Information

Tire Information
AT LEAST 15m(50ft) AT LEAST 500m(1500ft)
Tire can be classified into pneumatic tire and
cushion tire according to different work principle.
Pneumatic tire is suitable for high-speed running
while cushion tire isn't because the cushion tire
has a big load carrying capacity.

To avoid damage caused by tire overheating,

do not drive those machines which are
installed with cushion tires on roads. Never The inflation pressure for nitrogen and air are the
drive the machine with overload at a high same when charging the tires. Consult your tire
speed; never drive the machine for a long dealer for operating pressures.
distance and a long time. As for the tire inflation pressure under normal
temperature, please refer to the tire pressure
decal on the machine.
Tire Inflation Information
The tire pressure is normal if the ambient
temperature is between 18 and 21°C. But the tire
Liugong recommends the use of dry nitrogen gas pressure will decrease significantly when you
for tire inflation and for tire pressure adjustments. drive the machine under a freezing temperature.
It includes all machines with rubber tires. An over low pressure will reduce the service life
Nitrogen is an inert gas that will not aid of the tires.
combustion inside the tire.
The use of nitrogen for tire inflation can not only Cushion Tire--Replace
reduce the risk of explosion, but also help to
prevent oxidation, aging of the rubber, and
corrosion of the wheel rim parts. This is Replace the cushion tire as follows with a new
especially important for tires that are expected to one if the tire is less than 3/4 thick.
have a long service life of at least four years. Maxim Tire overall
um dimension
Tire Wheel
load of
size rim Width O.D(
tire
(mm) mm)
(Kg)
Training in using the equipment is necessary
4.00E-
to avoid over inflation. A tire blowout or a rim Drive wheel 6.00-9 1675 160 540
9
failure can cause personal injury. 21 × 8- 6.00E-
Drive wheel 2040 200 540
9 9
Do not set the tire inflation equipment 23 × 9-
Drive wheel 6.50F 2810 225 595
regulator higher than 20 psi (140 kPa) over 10
the recommended tire pressure. Steering
5.00-8
3.50D-
970 175 470
wheel 8
Check and adjust the tire inflation pressure after Steering 18 × 7- 4.33R-
1220 135 470
them cooling enough. Ask all other persons to wheel 8 8
leave the dangerous areas (around the rim).
 75
Maintenance Manual
Working Implement System

The wheel rim of the cushion tire (GB10824) is
replaceable with the that of corresponding
pneumatic tire. But the installation and removal
of the cushion tire wheel rim should only be done
by using auxiliary instruments on a pressure
machine. Follow the below procedures when
installing the wheel rim to ensure safety and
accuracy:
1. Check compatibility of tire and wheel rim: that
is, whether the tire and rim model matches
with each other because two tires with same
specification may be installed with wheel rims
at different dimensions. Therefore, find out a
correct match before installing. Besides,
check the wheel rim for blur and defects.
Sanding the blur if there are any, otherwise,
that will damage the wheel hub.
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
reduce the friction possibility between wheel
hub and wheel rim.
Storage and Maintenance of
Cushion Tires
Do not store the cushion tires in bright, hot, oily
and chemical environment because the rubber
will deteriorate quickly in above-mentioned
environment. Do not expose the tires directly
under the above-mentioned environment when
storing. Lay the cushion tires flatly to avoid
personnel injuries.
Working Implement System
Mast--Lubricate
Lubricate according to lubrication diagram.
Clean the grease fitting thoroughly before
lubricating. Wipe the grease that overflows
outside after lubricating is finished.

CAUTION: DO not use any industrial CAUTION: when it needs to lubricate

grease or other commonly used lubricant as
it shall will swell the rubber and damage the
tire.
3. Place the tire correctly when installing it into
the wheel rim, otherwise, it will result difficulty
in installation and cause the machine shaking
when driving.
from a high position, please perform
lubrication by standing on a platform and
take proper measures to ensure safety,
otherwise, serious personnel injury could be
resulted!
Chain--Lubricate

CAUTION: The rim must be installed to Apply lubricant onto the chain.
the correct position and the bolt must be
tightened, otherwise the slide ring will be
loose and the tire will separate from the
wheel rim, which could cause danger to
personnel body.

CAUTION: Ensure that the tires and shaft

are located at the same center when
installing. Do not install tires with different
brands or conditions onto a same machine or
shaft. Do not mix cushion tire and pneumatic
tire when installing, otherwise, damage or
personnel injuries could be resulted.
76
Maintenance Manual
Working Implement System

Maintenance beside the Mast and 3. Lower the inner mast slowly till it is hung by
the chain.
Fork

CAUTION: Never repair or adjust in front

of the fork without the following safety
protective device when the mast and fork arm
carrier is being lifting. The following
measures are applicable only to common
check and lubrication to the forklift. As for
repairing the mast, changing cylinder or
chain and so on that needs further safety
measures, please contact the Liugong forklift
dealer.

Fix the Mast to Prevent Tipping Back Full Free Double Mast

To prevent mast from, tipping back of the place a
hard wooden block A (110mm×110mm× 800mm)
between the mast and the machine body.
Even operated in a very low space, this kind of
mast can still raise freely. The middle lift cylinder
raises the fork to a particular free height through
chain wheel, and then the second-grade rear lift
cylinder raises the inner mast and fork arm
carrier at the same time. The middle lift cylinder
is installed on the inner mast.

CAUTION: Choose suitable chain

according to different height of the mast and
do not exceed the maximum lift height.

1. Lift the mast.

2. Fasten upper beam A of the outer mast and
lower beam B of the inner mast with a chain.
3. Lower the inner mast slowly till it is hung by
the chain.
Common Double Mast 4. Lower the fork arm carrier completely.

When the inner mast rises, the chain wheel will

rotate, and the fork arm carrier will rise with the
inner mast at a speed ratio of 2:1.

WARNING: Choose suitable chain

according to different height of the masts.
Never exceed the maximum lift height.

1. Lift the mast.

2. Fasten upper beam A of the outer mast and
lower beam B of the inner mast with a chain.

Triple Mast
The middle lift cylinder firstly raises the fork to a
particular free height through chain wheel, with
the two second-grade rear lift cylinders raise the
inner mast followed. Under the effect of chain
wheel, the lifting speed of the inner mast is two
times quicker than that of the rear lift cylinders.
The middle lift oil cylinder is installed on the inner
mast.
CAUTION: Choose suitable chain
according to different height of the mast and
do not exceed the maximum lift height.
1. Lift the mast.
2. Fasten upper beam A of the outer mast and
lower beam B of the inner mast with a chain.
3. Lower the inner mast slowly till it is hung by
the chain.
4. Lower the fork arm carrier completely.
Maintenance of drive axle
Axle Oil Level--Check
CAUTION: Be careful of splashing hot oil
when refilling, draining, or loosening the
plug.
1. Park the machine on a level ground and
clean all of the oil filling positions. Slowly
drive the machine at low speed to keep oil
level plug on the axle at horizontal position.
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Maintenance Manual
Maintenance of drive axle
2. Turn the shift control lever to NEUTRAL, pull
up the parking brake lever to prevent
movement of the machine.
3. Remove the oil drain plug to check the oil
level. The oil level should reach the edge of
oil level plug. If not, replenish clean axle oil
and check again after 5 minutes.
4. Tighten the oil drain plug.
Drive Axle Oil--Replace
CAUTION: Care must be taken to ensure
that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before disassembling any
hydraulic line or component containing
fluids. And dispose all fluids according to the
local regulations.
1. Drain oil after the machine stops running for
a period time to let the impurities deposited in
the oil are suspended. Park the machine on a
flat ground, slowly drive the machine at low
speed to locate the oil drain plug on the axle
to the lowest position.
2. Stop the engine, turn the shift control lever to
NEUTRAL, and engage the parking brake
handle to prevent movement of the machine.
3. Loosen the oil drain plug on both wheel ends
and in the middle of the axle to drain oil, and
collect with a container.
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Maintenance Manual
Maintenance of Hydraulic System
CAUTION: Because the axle oil
temperature is still high when draining, wear
protective clothing and be careful to prevent
injury.
4. Tighten the oil drain plug in the bottom of the
axle.
5. Replenish clean axle oil from the oil drain
plug and oil filler plug on the axle till the oil
level reaches the edge of the plug. Observe
for about 5 minutes after replenishing, the oil
level should be kept stable.
6. Tighten the oil filling plug of the axle.
Maintenance of Hydraulic
System
Daily Maintenance for Hydraulic
System
● Try to unload the machine as possible and
lower the mast to a lowest position for
storage.
● During long time storage, lift, lower, tilt
forward, tilt backward the mast at least three
times for each month.
● Inspect the hydraulic oil viscosity once a
month for leakage, pollution etc.
Hydraulic Oil Level--Inspect
NOTICE: Park the machine on a flat
ground before inspecting the hydraulic oil.
Before inspecting the hydraulic oil, lift the battery
out of the machine to get access to the hydraulic
oil tank because nearly all of the hydraulic oil
tanks need to do this except for CPD30.
Open the hydraulic oil tank cap, clean the
surface oil with clean cloth, then take out the oil
dipstick to check the oil level. Tighten the cap
after check.
Hydraulic Oil-- Replace
Periodically
WARNING: 1. Be prepared to collect the
fluid with suitable containers before opening
any compartment or disassembling any
component containing fluids during the
operation of inspection, maintenance,
testing, adjusting and repair of the products.
And dispose of all fluids according to the
local regulations and mandates.
2. Pay close attention the cleanness during
oil replacement, do not let dirt enter the
hydraulic system.
3. If the hydraulic oil becomes deteriorated
due to the bad operating condition or severe
pollution, such as black color and bubbles on
the oil level, please change the hydraulic oil
in time.
1. Park the machine on flat, open ground. Turn
the reverse switch in NEUTRAL, engage the
parking brake lever to prevent the machine
from moving.
2. Start the machine and run at idle speed for
10 minutes. Repeat the operation of lifting
and lowering the fork, and forward and
backward tilting the mast so as to warm up
the hydraulic oil.
3. Lower the fork on the ground and apply a
slight downward force.
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Maintenance Manual
Maintenance of Hydraulic System

4. Turn off the power and remove the battery 6. Remove and clean the flange cover of the
box. hydraulic oil tank. Then remove the return oil
filter and take out the return oil filter element.
5. Clean the hydraulic oil tank outlet. Screw out
Replace the return oil filter element.
the oil drain plug to drain out hydraulic oil and
collect with a container. You can open the oil
filler cap over the tank to accelerate the oil
drain speed.

7. Remove the suction oil filter and take out the

suction oil filter element. Replace the suction
oil filter element
8. Wash the bottom and four walls of the
hydraulic oil tank with diesel oil, and dry with
clean cloth.
9. Secure the oil drain plug, return oil filter, the
flange cover, and the oil inlet pipe.
10. Replenish clean hydraulic oil from the oil filler
of the hydraulic oil tank until the oil level
reaches the graduation of 20L of the
hydraulic oil dipstick. Tighten the tank cover.
11. Operate the lift lever and tilt lever to raise and
lower the fork for 2~3 times. Tilt the mast
CAUTION: Wear protective clothing when
forwards and backwards and turn the mast
working with hydraulic oil. Hydraulic oil
from left to right to the maximum angle to fully
could be under high temperature and could
fill cylinders with hydraulic oil.
cause injury if contact with the skin.

Control Valve--Remove and

Disassemble

Remove the control valve from the machine and

clean its surface.
1. Unscrew the connecting bolt to disassemble
the control valve. Do not miss any check
valves and spring on joint surface
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Maintenance Manual
Maintenance of Hydraulic System
2. Remove the bolt from the head of slide valve
and the hexagon cap screw from the cover
side. Remove the slide valve which contains
leather cup, O-ring and seal plate from the
valve body.
3. Lay the slide valve onto the table vice and
remove the connecting bolt. Then remove the
spring and spring holder. Besides, remove
the spring and spool inside the self-lock valve
that attached to the slide valve.
Control Valve--Assemble and
Install
Clean all the removed components with mineral
oil. Check whether there is burr or notch, and
replace if necessary. Wrap the valve body and
slide valve, slide valve and spool up after
installation. Replace them if necessary.
1. Fix the slide valve tightly by a table vice, and
then insert spool and spring into the slide
valve, pay attention to the direction of the
spool.
2. Install the O-ring, leather cup, seal plate,
spring holder, spring and spring holder
orderly to the end of the slide valve. Install
the cover after installation and tighten the
connecting bolt on the cover to a torque of
25~32N·m.
3. Insert the assembled slide valve into the
valve body and install cover, then secure the
cover by tightening the connecting bolt to a
torque of 9~11N·m.
4. Fix the O-ring and leather cup to the head of
slide valve, and secure the seal plate by
tightening the bolt to a torque of 4.6~5.8N·m.
5. After the assembly, put the check valve,
spring and O-ring into each plate valve. Then
then secure them by tightening the bolt to
specified torque. (torque for on bolt:103 N·m,
for another: 66 N·m)
Main Safety Valve Pressure--
Adjust
The pressure of the main safety valve has
already adjusted before leaving the factory. The
users are prohibited to adjust the pressure. Take
forklift with a rated load of 1500 Kg for example
to explain the pressure adjustment methods:
1. Place a load of 125% times of the rated
capacity on the fork, that is, 1875 Kg.
2. Start the forklift and operate the lift lever. The
main safety valve pressure is normal if the
fork can lift to the height between 0-300mm.
if not, adjust the pressure according to step
(3).
3. Remove the control valve cover and loose
the locknut of the main safety valve if the fork
cannot lift (that is, the fork cannot lift off the
ground), then loosen the adjusting screw
clockwise to increase the pressure.
Loosening the adjusting screw
counterclockwise to reduce the pressure if
the lift height of the fork is over 300 mm off
ground.
4. Start the forklift and operate the lift lever to lift
the fork to a height between 0-300mm,
otherwise, repeat the adjustment according
to step (3) until the pressure meets the
requirement.
CAUTION: Pay attention to the
stationarity when placing load onto the fork.
After the pressure adjustment is finished, do
not allow any users to readjust the pressure.

Brake System Maintenance
Brake Oil--Check
The brake oil reservoir is located below the
steering wheel.
Replenish brake oil to 75% volume of the oil
holder. The brake oil symbol on the gauge will
flash to alert if the brake oil level is below the oil
level sensor. Replenish brake oil to appropriate
level.
Check and repair the brake system immediately
if the brake oil runs out quickly as an oil leakage
might result.
Parking Brake Force--Adjust
Disengage the parking brake to release brake
force.
Hang a spring scale to the middle of the parking
brake lever, then pull the spring scale backwards
to measure the brake force.
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Maintenance Manual
Brake System Maintenance
Turn the adjusting screw to adjust the brake
force. Turn the adjusting screw clockwise to
increase the brake force turn it counterclockwise
to decrease the force.
CAUTION: Parking brake performance
inspection is required after the brake force
adjustment ensure the effective brake ability.
Parking Brake Performance--
Inspect
CAUTION: Frequent check for parking
brake performance is required so as to
ensure safety when park or brake under
emergency.
1. Lift the fork to a height of 15cm to 20cm from
the ground, and make sure the brake
performance of the machine is in good
condition.
2. Start the machine and drive it onto a slope
with 15% (8.53°) grade. The slope surface
should be flat and dry.
3. Depress the service brake pedal, stop the
machine. Turn the reverse switch to neutral
position then turn off the power.
4. Turn the parking brake lever backwards and
release the service brake pedal slowly.
Check to see if the machine stays at the
original position.
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Maintenance Manual
Battery Maintenance
CAUTION: Body injury may result during
inspection if the machine moves.
Service Brake Performance--
Inspect
CAUTION: Ensure the parking brake
system is normal before inspect the service
brake performance so that the parking brake
lever can work properly if an emergency
happens.
Drive the machine on a flat and dry road at
maximum speed. Depress the service brake
pedal to stop the machine completely. After the
machine is stopped, turn the reverse switch to
NEUTRAL position and turn the parking brake
lever backwards, then release the service brake
pedal. Check for the brake distance of the
machine. The brake distance should be no more
than 6m.
CAUTION: Body injury may result during
inspection if the machine moves.
Battery Maintenance
Observe the operation instruction
carefully and stick this sign to an visible
position of the charge site.
Only allowed the trained personnel to work with
the battery.
Wear safety glasses and protective
clothing when working with battery.
Observe the regulations of DIN
EN50272-3 and DIN EN50110-1, etc
No smoking!
Open flame, glowing metal wire and
electric spark are not allowed to appear
around the battery. Do not install any equipment
that might create electric spark nearby,
otherwise, an explosion or fire could be resulted.
Danger of explosion or fire, avoid short
circuit!.
Recycle the discarded batteries. Follow
the related national environmental laws
and regulations on recycling the
discarded batteries.
Keep away from children. No child is
allowed to approach the fork lift
operation areas and the battery
charging areas.
The battery quality assurance becomes invalid
automatically if users don't follow the operation
instruction, fail to use the original equipment for
maintenance, or refill any solution in the
electrolyte without authorization. Any damage
caused by users will also result in a invalid
quality assurance.

Battery Inspection for New
Machine
Inspect whether the positive and negative
terminals are connected correctly;
Check the cables for good connection.
Inspect the voltage of the battery
Inspect the proportion of the electrolyte;
Inspect the liquid level of the electrolyte;
Clean the dirt and dust on the surface of the
battery.
Cautions for Battery
The following situations should be avoided
during battery usage: undercharge, a long-term
undercharge of battery would severely affect the
service life of battery.
CAUTION: It is recommended to operate
the forklift only after battery charging is
finished.
Testing Method for Electrolyte
Density
See the following illustration for the electrolyte
density testing method. Use battery liquid
densimeter 1 to extract the battery liquid. If the
liquid surface reaches the red section of the
densimeter, it indicates the battery power is
insufficient and needs to be recharged. If it
moves to the green section, it indicates the
battery has power and can still be used. If the
level moves to the yellow section, the battery
power is sufficient. When Battery power is
insufficient, it should be recharged before use.
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Maintenance Manual
Battery Maintenance
Over-discharge: After over-discharge, a
anglesite layer may produce at the positive
terminal and negative terminal on battery, which
makes the charging difficult. Sometimes, severe
over-discharge may cause polarity change.
Over-discharge can shorten the battery service
life and cause trouble to battery.
CAUTION: If the instrument shows that
the battery power is less than 20%, please
stop working and recharge the battery
instantly.
Over-charge: over-charge may cause a
excessive electrolyte electrolysis and high
temperature. The gas separates out of the
positive and negative terminal may loosen the
active substance structure of the terminals, and
reduce the service life of the battery.
CAUTION: When battery temperature
exceeds 50°C, stop charging temporarily until
the temperature falls below 40°C, or reduce
the charging current, drop down temperature
to ensure the normal temperature for the
battery.
Hydrogen will separate out when the battery is
working especially in and after charging.
Therefore, to ensure safety, keep the battery
charging room ventilated to exhaust the
excessive hydrogen.
CAUTION: Electrolyte densimeter is not
an accessory of battery. Please contact
Liugong's dealer for information.
84
Maintenance Manual
Battery Maintenance
CAUTION: keep ventilation and keep
away from fire when the machine is working
or the battery is charging.
CAUTION: Check the electrolyte
periodically for spillage. Collect the
electrolyte spillage with suitable container
and deposit it properly.
Daily Maintenance of Battery
Battery should be charged right after discharged.
CAUTION: Recharge the battery within 24
hours after the battery is used.
Check battery every week routinely. If the
surface of electrolyte falls when battery is in
regular use, only refill distilled water to the
battery which is full of eletricity.
1. Lowest level
2. Normal level
3. Highest level
CAUTION: Only refill distilled water or
pure water to the battery which is full of
electricity. Never fill vitriol, tap water and
other substance in it.
Check battery every week routinely. Use clean
and wet cloth to clean the surface of the battery
to keep the battery clean, which can prevents
dust or electrolyte on the cover of the battery
from inducing battery's self-discharge.
CAUTION: Please use wet cloth to clean
the surface of the battery; don't use whisk or
dry chemical-fiber material to clean it.
Check battery every week. Check tightness of
terminal bolts and bolts. Tighten or weld if it is
loose.
Driving electric machines in a low speed may
extend the battery's service life.
Make regular records on charge and discharge
of the battery to provide convenience for dealing
with the battery problems when necessary. Keep
record on the date when using, also record
battery charge, discharge and filling, and so on.
Battery--Charge
Charging Site
The charging site should be clean, ventilated and
free from inflammable and explosive goods.
Protective devices such as rubber glove,
protective glasses and apron and so on should
be prepared.
Multimeter, densimeter and thermometer and
other testing equipment should be prepared.
Set up water supply device and fire extinguisher.
Avoid exposed to sunshine and rain. Keep
temperature at room temperature.
If the battery electrolyte sprays or leaks in the job
site, it may damage the floor and other material
and cause pollution to air. Neutralize the
electrolyte with acid neutralization agent such as
soda, white lime or carbide and so on
immediately, and wash with water.
Use a safety device to replace the battery. Use
isolating rod if a crane is used to lift the battery.
Use chain wheel box if a jin chain hoist is used. If
a hand hoist is used, cover the uncowled battery
with isolating material to avoid short circuit
occurs to the chains and battery or to cable
terminals.

Charger
The charger is used for initial charging and
balance charging, with rated voltage of 48 V.The
maximum charging current (Unit in A) should not
be over the value determined by the following
formula: stated battery capacity (Unit in Ah)
divided by 5 = maximum charging capacity.
When the voltage of the battery reaches 63.5 V,
the battery is full-charged and the charger stops
charging automatically.
Normal Charge
The battery should be recharged after discharge.
The interval between discharge and recharge
can not exceed 24 hours. When charging, if the
temperature of electrolyte in the battery exceeds
50°C, please reduce the charging current or stop
charging temporally in order to prevent large
influence to the battery's function caused by the
rising of liquid temperature.
Recharge
If a charged battery is not used over 30 days, it
should be recharged each month by using 0.1C5
A current. Stop charging when the voltage and
proportion remain stable.
Battery--Recycle
It is prohibited to discard the lead-acid battery
without correct recycle measures; otherwise, it
may pollute the environment.
Obey the local environmental laws and
regulations on recycling the battery.
Lead, electrolyte and plastics inside the lead-
acid batteryare the recycling materials.
As for lead-acid battery recycling information,
please contact with the professional distributors.
85
Maintenance Manual
Electrical System
Electrical System
Electrical schematic
Please refer to the electrical schematic which is
listed in the PARTS MANUAL when maintain the
electrical system.
Maintenance of Motor
The left travel motor is located under the lower
left of the service pedal, the travel motor is
located between the battery and the
counterweight. In order to ensure the motor can
work regularly and extend the motor's service
life, check the battery every month routinely. Use
clean wet cloth to clean the dust accumulated on
the surface of the motor so as to cool the motor.
Check the tightness of bolts and cables on the
battery terminals. Tighten them if they are loose.
CAUTION: When motor is under repair
and maintenance, turn the start switch to
OFF, disconnect the battery connector to cut
off power. Use wet towel to clean the surface
of the motor, don't use whisk or dry chemical-
fiber material for cleaning so as to avoid
static to damage the encoder of the motor.
The motor will generate heat at work, its
temperature may exceed 100°C, so please
pay attention to protect your hands.
Maintenance of the motor before cooling is
not allowed.
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Maintenance Manual
Electrical System

Carbon Brush Maintenance 4. Take out the carbon brush. Be careful of the
sharp spring to avoid cutting your fingers and
the carbon brush during removing.
1. Unlock the buckle of the carbon brush and
remove the cover.

5. Check the carbon brush for good condition.

Replace if necessary.
2. Remove the cover to get access to the
carbon brush.

Carbon brush

6. Loosen the connected bolt before taking off

the brush.
3. Push the spring to take out the carbon brush.

Terminal

7. When install the carbon brush, push the
brush into the groove, then push the spring to
the middle so that the brush is forced evenly.
8. End by installing the brush cover.
Electronic Control Unit
Maintenance
Electronic control unit is installed inside the
counterweight. It is composed of travel motor
driver, oil pump motor driver and contactor.
Electronic control unit is fixed near the
counterweight. It may generate heat during
working which mainly cools through the
counterweight.
Check electronic control unit every month
routinely. Wipe out the dust accumulated on the
surface of the electronic control unit so as to let it
cool down easily. Check tightness of the terminal
fasteners, tighten the fasteners if they are loose
and ensure the aluminum plate of the electronic
control unit contacts with the counterweight.
87
Maintenance Manual
Electrical System
Capacitor in the controller acts as an
accumulator. It is necessary to discharge the
capacitor before serving the controller, which can
protect the personnel from possible electric
shock caused by the discharge of the capacitor.
Discharging procedure: Take out the battery
socket to cut off power supply. Then connect the
positive and negative terminals with wires for an
instant to discharge the capacitor completely.
CAUTION: When electronic control unit is
under repair and maintenance, turn the start
switch to OFF, disconnect the battery
connector to cut off power. Use compressed
air to blow out the dust on the surface of the
electronic control unit. If there is no
compressed air, use wet towel to clean the
surface of the electronic control. Do not use
whisk or dry chemical fibers for cleaning so
as to avoid static to damage the electronic
units inside the electronic control unit.
CAUTION: The electronic control will
generate heat at working, its temperature
may exceed 50°C. So please pay attention to
protect your hands. Maintenance of the
electronic control unit before cooling is not
allowed.
CAUTION: If it needs to remove the
electronic control unit when repaired, clean
the surface of it before reinstalling. Apply
heat conducting silicone grease between the
interface of electronic control and
counterweight to ensure good cooling effect
for the electronic control unit.
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Maintenance Manual
Electrical System

Fuse--Check/Replace
Model Color
The fuse box is located at the right rear of the
BK/ATC-5A Orange(OR)
battery.
The fuse is used to protect the electrical system BK/ATC-7.5A Brown(BR)
and prevent damages caused by the overloading
of circuit. If lights do not illuminate or electrical BK/ATCC-10A Red(RD)
equipment doesn't work, these may be caused
BK/ATC-15A Blue(BU)
by the broken fuse. Check and replace the fuse.
If the newly-replaced fuse burns out again, check BK/ATC-20A Yellow(YL)
the circuit and repair it if needed.
BK/ATC-30A Green(GN)

Fuse Replacement of the Electronic Control

Unit

Check and replace the fuse as follows:

1. Turn the start switch to OFF and disconnect

battery connector. Replace the fuse as follows:

2. Remove the cover of the fuse box, and take 1. Turn the start switch to OFF and disconnect
the broken fuse out with clamp. the battery connector.

3. Replace it with a new fuse with same 2. Loosen the bolts on both end of the fuse, and
specification. take the fuse out.

4. Install the fuse cover. 3. Replace it with a same standard fuse.

See the following table for slice fuse color with
different specifications.
4. Tighten the bolts at both ends of the fuse.
CAUTION: Replacing the broken fuse
with a new one with same specification and
series from different manufactures is
allowed.

There may be a circuit failure if frequent fuse

replacement occurs. Please contact Liugong
dealer if necessary.
 89
Maintenance Manual
Other Maintenance

Lighting System Seat Belt--Inspect

This machine is equipped with front floodlight, Check the seat belt for good condition before
front position light, turn signal light, brake light, using it. If necessary, replace it in time.
backup light and warning light, etc.
Adjust the seat belt's length before using it so as
In order to make it convenient for the users to to ensure its protecting function and comfort
replace broken bulbs, the following table lists the ability. Move the position of retractor on seat belt
specification of the bulbs used in this machine. to adjust the length of the seat belt.
Bulb table: No matter how well the seat belt looks like,
replace it every three years.
Size
Size CPD10 Consult your Liugong dealer for the replacement
No. Item Q’y CPD20 CPD15 of the seat belt.
CPD25 CPD30
CPD30AS
Front
1 2 24V 70W 12V 70W
floodlight
Rotating
2 1 24V 10W 12V 10W
beacon
Turn signal
3 4 24V 21W 12V 21W
light
Front
4 2 24V 10W 12V 10W
position light
Width/brake
5 2 24V 5/21W 12V 5/21W
light
6 Backup light 2 24V 10W 12V 10W

Other Maintenance

Backup Alarm--Test

The backup alarm is installed on the back of the

counterweight, below the cover.
1. Turn the start switch to ON position to turn on
power of the machine.
2. Turn the reverse switch backwards, the
backup alarm should sound immediately.
3. Turn the reverse switch to NEUTRAL
position or forwards, the backup alarm
should stop hooting.
90
Maintenance Manual
Other Maintenance
Troubleshooting
Machine Troubleshooting
Features
Forklift is unable to start
Forklift runs slowly
Forklift abnormal noise
Gearbox Troubleshooting
Noise Analysis
Features
High-pitch noise, noise
volume changes machine
runs
High-pitch, accumulated
noise
Low, grinding noise
Check or replace the planetary gear
Leak position
Exhaust valve of gearbox
gearbox cover
Brake lever
Grease fitting and drain
nipple
Possible reasons
Battery exhausted.
Loose connection.
Fuse belowing out.
Emergency button engaged
Shift switch not in neutral
Motor overheat, and speed limited
by controller.
Controller overheats protection.
Motor damaged
Motor coder damaged
Transmission system failure
Hydraulic system failure
Possible reasons
Part of tooth surface is damaged
during bevel gear installation
Failure in connection of motor and
gearbox
Motor Inner bearing failure
Axle bearing damaged
Preload error in axle bearing
Planetary gear damaged
Possible reasons
Gear oil level is too high
8 bolts are failed to meet required
Seal ring damaged
Failed to be tightened as required
Error in seal ring installation or seal
Solutions
Check, charge or replace the battery.
Tighten the battery terminal and smear a layer of
non-acidic grease.
Replace the fuse
Disengage the Emergency button.
Turn the shift switch to neutral
Too high motor current; check if the brake is blocked
or if the parking brake is engaged. Make sure the
brake should be released.
Stop operation until the controller temperature drops
Replace the bearing or motor
Replace.
See Gearbox Troubleshooting
See Hydraulic System Troubleshooting
Solutions
Check the tooth surface and replace the damaged
gear timely to avoid further damage to other gear
Check if motor connection is loose; tighten the
connection of driving wheel on motor shaft.
Check or replace the motor
Check or replace the axle bearing
Check and correct the preload in axle bearing
Check or replace the planetary gear
Solutions
Check and adjust the gear oil level
Check the bolt torque and tighten
Check and replace the seal ring
Check the torque of the oil plug and tighten it
Replace the seal ring

Connection between Motor O-ring damage
Gearbox axle Axle seal ring damaged
Drive Axle Troubleshooting
Features
Abnormal noise inside the
drive axle
Steering System Troubleshooting
Features
Heavy steering
Steering failure
Oil leakage in metering pump
Steering wheel clamping in
quick turning
Low oil pressure
Oil pressure higher than
setting valve pressure
Noise in relief valve
Too high oil temperature
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Maintenance Manual
Other Maintenance
Replace the O-ring
Check and replace the seal ring
Possible reasons Solutions
Replace the gear or adjust
The bevel gear wears out the too big meshing clearance
the meshing clearance
The planetary gear shaft of the differential wears
excessively
Replace
Tapered roller bearing wears excessively or loose Replace or adjust
Insufficient lubricant Refill
Possible reasons Solutions
Check valve failure inside valve body, the metering Clean or replace the
pump is blocked with dirt metering pump
Replace the piston sealing
Interior leakage of steering cylinder
ring
Replace the shaft of steering
Shaft failure of steering column
column
Metering pump failure Replace the metering pump
Replace the steering
Steering cylinder damage
cylinder
Steering hose broken Replace the hose
Wear in junction surfaces of valve, oil distribution plate,
Replace the metering pump
stator and back cover
Insufficient fixing torque of bolts for metering pump Tighten the bolts
Sealing ring aging and damaged Replace the seal ring
Flow control valve stem blocked Repair or replace
Flow control valve stem worn Replace the whole unit
Relief valve normal open (unable to close) Replace the whole unit
Relief valve normal close (unable to open) Replace the whole unit
Relief valve vibrates Replace the whole unit
Relief valve normal close (unable to open) Replace the whole unit
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Maintenance Manual
Other Maintenance

Relief valve vibrates Replace the whole unit

Changeable steering force Flow control valve stem blocked Remove for repair or replace

Flow control valve stem worn Replace the whole unit

Relief valve normal open (unable to close) Replace the whole unit

Difficult steering Flow control valve stem blocked Remove for repair or replace

Flow control valve stem worn Replace the whole unit

Metering Pump Troubleshooting

Failure Features Possible reasons Solutions

Oil leakage from valve body, plates,
Oil leakage stator and the joint surface of rear
cover
Steering wheel moves slightly
when turn slowly; and it moves
heavily when turn quickly
Bulbs exist in oil
Heavy
steering Producing irregular rattles
The oil cylinder sometimes moves
but sometimes not when turning
steering wheel
The steering wheel moves heavily
when turn slowly or quickly; and no
pressure for steering
Steering wheel moves lightly at
light load, heavily at heavy load
Dirt on the joint surface. Clean the surface.
Seal ring damaged at shaft diameter Replace the seal ring
Uneven washer surface at the stop Smoothing or replace the
bolt. washer.
Select proper oil pump or
Poor oil supply from oil pump. check if the dividing valve of
oil pump works normally
Air exists in steering system.
Too high oil viscosity.
Check valve failure inside valve
Exhaust air from the system
body.
and check the inlet lines
Pressure at the dividing valve is
lower than work pressure or the
dividing valve is blocked by dirt.
Insufficient oil level tank Fill oil up to required level
Use oil of recommended
Too high oil viscosity
viscosity
Input a φ8 steel ball if the ball
The check valve failure inside valve
is lost; or clean the ball if
body
blocked with dirt
Pressure at the dividing valve is
Adjust dividing valve
lower than working pressure or the
pressure or clean the valve.
dividing valve is blocked by dirt
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Steering wheel unable to reset

automatically; pressure drop
increases at central position
Noticeable increase in pressure
oscillation, or unable to turn
Steering
failure Confused oil distribution; steering
wheel rotates by itself or swings left
and right
Cylinders don't move (or move
slowly) when turning the steering
wheel.
Steering
wheel The metering pump doesn't
unable to discharge (the forklift deviated from
return its route) when the steering wheel
automaticall stops turning.
y to central
No unclear feeling when piston
No manual
reaches extreme end; cylinder
steering
doesn’t move when steering.
Spring piece broken Replace the spring piece
Pin broken or distorted Replace the pin
Universal driving shaft opening is Replace the universal driving
broken or distorted shaft
Error positioning of rotor and Reinstall according to
universal driving shaft Installation Guide (e)
Two-way overload valve failure
Clean the two-way overload
(steel ball blocked by dirt or spring
valve
failure)
(1)Steering column is different from
spool
(2)Valve blockage due to axial
Remove trouble according to
movement of steering column.
causes
(3)Too much turning resistance of
steering column
(4)Spring piece broken
Too much axial and radial clearance
Replace stator and rotor
between stator and rotor.

Brake System Troubleshooting

Feature Possible reasons Solutions

Brake oil leakage in brake system Repair
Improper clearance between shoe linings Adjust
Insufficient
Impurity adherence to shoe linings surface Repair or replace
brake force
Impurity mixed in brake oil Replace brake oil
Improper adjustment of brake pedal Adjust
Impurity adheres to shoe linings surface Repair or replace
Loose bolt connection or distortion in bottom plate Repair or replace
Noisy when
Shoe lining distortion after install or wrong install Repair or replace
engage brake
Wear of shoe lining Replace
Defective gearbox bearing Replace
Impurity adheres to shoe linings surface Repair or replace
Uneven brake
Improper clearance between shoe linings Adjust
Brake oil leakage in brake system Repair
Weak and Improper clearance between shoe linings Adjust and repair
forceless
brake pedal Air mixed in brake system Exhaust air
Improper adjustment of the brake pedal Readjust
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Lift System Troubleshooting

Feature Possible reasons Solutions

Too much axial and radial clearance in oil pump Repair or replace the oil pump
Use required oil and pay attention to weather
Too high viscosity or temperature of hydraulic oil
Weak lifting, impact on oil temperature
low lifting Clean contamination and replace the oil
Oil filter or suction pipe blocked
speed regularly; check or replace suction pipe
Wrong turning direction of motor, oil pump failure Change the turning direction of motor
Control valve inside leakage Replace the control valve
Insufficient oil in oil tank Fill oil as required
Big noise Filter blocked Clean or replace the filter
Tooth wear of oil pump Replace the oil pump
Too much Too much leakage, especially in the control valve Check the system and replace the control valve
slide in lift Seals failure of lift cylinder Replace the seals
Seal failure of tilt cylinder Replace
Mast tilt by
Stem spring failure of tilt valve Replace
itself
Control valve inside leakage Replace
Loose pipe joint Tighten the pipe joint with required torque
Seal ring failure Replace the seal ring
Oil leakage
Scratched piston rod surface Replace the piston rod
Oil hose aging Replace the oil hose

Electronic Control System Troubleshooting (SME)

Fault codes usually appear on the display if any fault occurs. The table of fault codes is shown as follows
as a reference for troubleshooting by users.

Code Possible reasons

1 Overvoltage of battery
2 Undervoltage of battery
3 Output voltage of accelerator exceeds the setting voltage, or the accelerator pedal is normal open
5 EPROM memory
6 Prevent low voltage alert of the charger
24 Overcurrent alert of the pump motor driver
25 Overcurrent alert of the left travel motor driver
9 Inverter capacitor charges fast
10 Inverter of pump motor overheats
11 Capacitor over discharges when starting
12 Battery low voltage alert
13 Right travel motor overheats
14 Pump motor has too high temperature
15 Right travel motor current compensational alert
16 Left travel motor current compensational alert
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17 Main relay failure

18 Burglar alarm circuit failure
20 Right travel motor driver has too high temperature
22 Left travel motor driver has too high temperature
21 Serial communication alert
37 5V voltage alert of coder
38 12Vvoltage output alert
50 Activate pump motor when starting
63 DIsconnect the seat switch when starting
64 Start sequence is in disorder
74 Right travel motor driver coder signal alarm
75 Left travel motor driver coder signal alarm
77 Right travel motor temperature sensor alarm
78 Left travel motor temperature sensor alarm
79 Pump motor temperature sensor alarm
81 Right travel motor power module alarm
81 Right travel motor power module alarm
82 Pump motor power module alarm
91 Angular sensor alarm

Electronic Control System Troubleshooting (CURTIS)

PROGRAMM
LED CODE ER LCD EXPLANATION POSSIBLE CAUSE
DISPLAY
No power or defective
LED OFF
controller
controller fault (E.g MCU
Solid ON
failure, etc)
Controller operational, no
0,1 ■¤
faults
1.EEPROM data lost or damaged
2.EEPROM data verification error
1,1 ¤¤ EEPROM fault
Use programmer 1311 to change any of the
data of the controller.
1.MOSFET short-circuited
1,2 ¤ ¤¤ Hardware failsafe fault
2.Motor open-circuited
1,3 ¤ ¤¤¤ Motor fault Motor fault
Battery voltage < close value of
2,1 ¤¤ ¤ Undervoltage
undervoltage.
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1. Actuate the lifting lock function of the

2,2 ¤¤ ¤¤ SRO fault controller
2. Wrong setting of SS lifting.
1.Improper sequences of accelerator/SS
input, KSI or interlock input
2,3 ¤¤ ¤¤¤ Startup lockout
2. Wrong startup lockout type selected
3.Wrong setting of accelerator
1. Accelerator wiring fault(open-circuited or
short-circuited).
2,4 ¤¤ ¤¤¤¤ Accelerator fault
2.Poor quality of accelerator.
3.Wrong accelerator type selected.
3,1 ¤¤¤ ¤ CONT DRVR OC Coil of the contactor short-circuited
1. Main contactor stuck.
3,2 ¤¤¤ ¤¤ Main contact welded 2.Wrong "CONTACT CNTRL" setting.
3.Main contactor shorted.
1.Precharge circuit errors
3,3 ¤¤¤ ¤¤¤ Precharge fault 2.External short or leakage path toB- on
external B+ connection.
1.Any contactor coil open or not connected.
Missing contactor or main
3,4 ¤¤¤ ¤¤¤¤ 2.Main contactor faults.
contacator did not close(DNC)
3. Wrong setting of CONTACT CNTRL
1. Battery voltage is lower than LOVOLT
CUTBACK setting value
4,1 ¤¤¤¤ ¤ Low battery voltage
2. Corroded battery terminal.
3.Loose battery or controller terminal.
1.Battery voltage > overvoltage shutdown
4,2 ¤¤¤¤ ¤¤ Overvoltage limit
2.Controller of charger is not disconnected.
1.Temperature > 85°C or < -25°C.
2 Excessive load on vehicle.
4,3 ¤¤¤¤ ¤¤¤ Over-/under-temp, cutback 3. Improper mounting of controller
4.Operation in extreme environments.
5.Temperature sensor fault
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H2B Chopper Troubleshooting

The diagnostic message can be indicated by a certain number of blinks of the LED, fault code
shown on the instrument or control unit.

BLINKS OF LED MDI SHOWN CONTROL UNIT SHOWN POSSIBLE REASONS

1 time AL10 EEPROM DATA KO (17)
1 time AL11 EEPROM PAR. KO (15)
1 time AL12 EEPROM CONF. KO (16)
1 time AL14 EEPROM OFFLINE (18)
1 time AL07 CHOPPER NO CONF (19)
1 time AL08 WATCH-DOG (20)
2 times AL79 INCORRECT START (10)
3 times AL30 VMN LOW (5)
3 times AL33 NOFULL CONDUCTION (7)
4 times AL78 VACC NOT OK (12)
5 times AL53 I HIGH AT ATAND (13)
5 times AL49 I=O EVER (14)
6 times AL76 SHORTED COIL (21)
6 times AL74 DRIVER SHORTED (22)
7 times AL62 THRMAL PROTHCTION (8)
8 times AL31 VMN HIGH (6)
8 times AL40 BREAK CONT OPEN (3)
8 times AL42 DIR CONT OPEN (2)
9 times AL39 BREAK CON CLOSED (1)
9 times AL41 DIR CON CLOSED (4)
32 times AL66 BATTERY LOW (9)
Doesn’t go out AL80 FORW+BACK (11)
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Fault Inspection Sequence

1. Turn on the start switch and depress the accelerator pedal, if the machine doesn’t move in both
forward and reverse direction, it is recommended to inspect as following sequence. Turn on the start
switch again and see if the LED links once during this period?
Is there any Yes Troubles with logic
LED
voltage in D1
doesn’t
end of See if fuse is burn out, start switch is damaged, wire connected between
blink. No
chopper? start switch to D1 is normal.
No Troubles with logic
Is there any Check other output of chopper if it is
Yes
Is there any voltage in normal.
voltage output accelerator plug Check connection from controller D2 to
No
in D2 end of D2? accelerator plug.
Yes
LED blinks chopper? Is there any high Check other output of chopper if it is
Yes
once. potential in normal.
chopper control
No Check seat switch, handle for damage?
end E4?
Check other output of chopper if it is
Check and see if any voltage transfers from Yes
normal.
No.15 wire to forward/reverse contactor.
No See if No.15 wire is broken.

2. Turn on the start switch and depress the accelerator pedal, if the machine doesn’t move in both
forward and reverse direction, but LED links, observe the numbers of blinks of LED and solve as
following methods.

Diagnose Fault By Control Unit

1. BRAKE CON CLOSED (only regenerative version): LED blinks 9 times and fault code AL39 is
shown on MDI instrument.

Test is carried out in the passage from running to initial regenerative braking. If, on running contactor
closure, the VMN is >2/3 VBATT, an alarm is issued. Possible causes:
1. The normally open contact of the braking contactor is stuck. Unlock the contact and clean it; if it is too
much damaged replace the contactor.
2. The braking contactor remains excited for a defect in the logic board or because the NTFR wire is in
short towards the negative.
For understanding if the defect is produced by one of these causes, select the running and press the
pedal without giving the seat or tiller request, if the activation only of the braking contactor is in
synchrony with the pedal (or selector) command verify what follows: disconnect the wire from the
NTFR connector and do again the test above, if the contactor remains disactivated replace the logic,
otherwise if the contactor moves check that there is not a wire in short with a metallic part.

2. DIR CONT OPEN: LED blinks 8 times and fault code AL42 is shown on MDI instrument.

Test is carried out at running request: running contactor closure is verified by checking that the VMN
signal is consistent. Possible causes:
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For finding out the causes follows the diagnosis procedure herefollowing:
FAULT
FEATURE TEST RESULT TEST RESULT
DESCRIPTION
Yes A1
You see forward When requesting
Only at forward contactor (TA) forward running Yes B1
running request closing for 0.3s. you find any
No
Then opening? voltage at coil
contacts for No C1
0.3s?
Yes A2
You see When requesting
Only at backward backward Yes B2
backward contactor (TI) running you find
running request closing for 0.3s. No?
any voltage at
Then opening? coil contacts for No C2
0.3s?
Yes A3
When requesting
You see forward forward running
you find any Yes B3
or backward
At both running voltage at TA
contactor (TA or
request No coil’s contacts
TI) closing 0.3s.
Then opening? (or at backward
contactor coil’s No C3
contacts (TI) for
0.3s?

A1: There is not a good contact either on TA (forward contactor) NA (normally open) or on TI (backward
contactor) NC (normally closed), due to dust, dirt or any particles which prevent a valid contact. Clean
contacts by means of compressed air; if necessary remove dirt applying a soft abrasive movement.
A2: There is not a good contact either on TI NA or on TA NC, due to dust, dirt or any particles which
prevent a valid contact. Clean contacts by means of compressed air; if necessary remove dirt applying a
soft abrasive movement.
A3: The most probably reason is that the normally closed contact of the braking contactor doesn't make
a good contact towards the battery negative for dust, dirt or because the contact doesn't learn
completely for a mechanical defect of the contactor. It could be necessary to replace the contactor.
It may be due to 1 of following causes of motor connecting interruption:
(a) Brushes lift up from collector (Fig.1).
(b) Brushes' cable burn up (Fig.2)
(c) Missing the barking contactor negative cable (Fig.3).
(d) Interruption either on motor winding or on motor itself cabling.
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B1: Forward contactor (TA) is supplied with a correct voltage but it doesn't close. Possible causes:
(a) Contactor coil is interrupted, verity its resistance using an ohmmeter.
(b) Contact can't move due to mechanical block.
(c) Nominal working coil voltage is greater than battery one.
B2: Backward contactor (TI) is supplied with a correct voltage but it doesn't close. Possible causes:
(a) Contactor coil is interrupted, verity its resistance using an ohmmeter.
(b) Contact can't move due to mechanical block.
(c) Nominal working coil voltage is greater than battery one.
B3: Backward and forward contactors are supplied with a correct voltage but they don't close; everything
said at point B1 and TA is valid here.
C1: Supply don't come up to TA, please check cabling and connections from TA coil to connector PT and
NTA.
C2: Supply don't come up to TI, please check cabling and connections from TI coil to connectors PT and
NTI.
C3: Supply don't come up to TA and TI, please check cabling and connections from the coils to
connectors PT, NTA and NTI.

3. BRAKE CONT. OPEN: LED blinks 8 times and fault code AL40 is shown on the MDI
instrument.

Test is carried out during the passage to running. After closure of the running contact, the braking
contactor closes, verifying that the VMN goes form 1/3 to 2/3. If this does not occur, an alarm is shown.
For finding out the causes follows the diagnosis procedures herefollowing:
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POSSIBLE
TEST RESULT TEST RESULT TEST RESULT
REASONS
A4
Yes
A5
At running request Yes C4
the TFR closes for When there’s the
0.3s? running request, is Check with an Yes B4
No there a voltage at ohmmeter of the
pin BTFR for a No B5
TFR coil is No
time of 0.3s? interrupted? B6

A4: There is not a good contact on the NA of TFR, clean the contact, if it is too much damaged replace
the contactor.
A5: Missing the positive cable on the braking contactor.
B4: Replace the contactor coil or the complete contactor.
B5: Contactor mechanically lock, unlock it and replace it.
B6: Contactor with working nominal voltage bigger than the feeding one.
C4: Supply doesn't come up to the contactor coil, please check the cabling and the connections from the
coil to the connector C1 (PTFR) and C5 (NTFR).

4. DIR. CON. CLOSED: LED blinks 9 times and fault code AL41 is shown on MDI instrument.

Test carried out during the passage to standby or braking. Checks that the running contactor opens by
comparing the consistent status of the VMN potential. Possible causes:
A: Running contactor stuck or slow to open.
B: Logic failure.

5. VMN LOW: LED blinks 3 times and fault code AL30 is shown on MDI instrument.

The test is carried out at standby and in running up to 90% of PWM. If the VMN voltage is lower than 1/3
of the battery voltage, an alarm is shown. For finding out the causes follows the diagnosis procedure
herefollowing:
CONDITIONS POSSIBL
UNDER WHICH RESUL RESUL RESUL E
TEST TEST TEST
FAULT IS T T T REASON
DETECTED S

Disconnect the Yes C5

motor cable The stuck
A running Yes B7
Turn on the start connected to the Yes contactor coil is
switch battery and then contactor is No B8
No supplied?
verify if the alarm locked in working
position D1, D2,
still present? No
D3
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With running
contactors on C5
running positions
As soon as the
accelerator Yes E1
Is it present the
pedal is
bypass or the
completely
weakening
released for
contactor? No C5
doing a release
braking

B7: If the running contactor remains stuck, you can verify:

(a) If the wire going from NTA to NTI is casually in short with a metallic part connected to the battery
negative;
(b) Disconnecting the contactor wire always excited from board connector if the contactor is no
longer excited, replace the logic board.
B8: A running contactor is stuck on working position, unlock the contact, it could be possible to replace
the contactor.

D1: Wrong connections of the motor cables. The stator and armature are crossed.
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D2: Short circuit between stator and rotator windings.

D3: Check that there are not metallic parts inside the contactor board that cause a short towards the
negative in the points connected to SH- and SH+.
C5: The most probably reason is that the failure is inside the controller, replace it.
E1: If there is the bypass contactor check that it is not stuck or it is too much slow in opening. For
verifying this possibility, disconnect the bypass and check if the failure disappears: if this happens,
replace the logic.

6. VMN HIGH: LED blinks 8 times and fault code AL31 is shown on MDI instrument.

Test carried out in standby. If the VMN voltage is greater than 2/3 VBATT, an alarm is shown. Possible
reasons:
A: Contactor stuck (only standard traction).

B: Short circuit between +BATT and VMN, please check if there are any metallic parts causing short
circuit in the contactor board.
C: Logic failure, probably the braking diode are broken, replace the power unit.
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7. NO FULL COND: LED blinks 3 times and fault code AL33 is shown on MDI instrument.

The test is carried out in full conduction. If in this condition, the VMN is found to be greater than 1/3
VBATT, the diagnostic circuit is faulty, causing a safety risk, and thus machine operation is inhibited. If
the defect persists, replace the logic.

8. THERMAL PROTECTION: LED blinks 7 times and fault code AL62 is shown on MDI
instrument.

An indication that the chopper temperature has exceeded 80°C.

The maximum current is gradually reduced, reaching 0 at a temperature of 85°C. If the alarm occurs
while cold:
A: If the alarm occurs while cold, the most probably reason is the failure of the thermal diagnosis circuit
on the power or on the logic board, replace on of the two parts or replace the complete controller.
B: If the alarm often occurs after short time the machine is working, probably it is due to inadequate heat
sink, check the fixing nuts tightening and the correct installation.

9. BAATTERY: LED blinks 32 times and fault code AL66 is shown on MDI instrument.

The battery charge is low. The alarm is signaled only if the BATTERY CHECK option has been selected.
When such fault occurs, the maximum currency will drop to 50%.

10. INCORRECT START: LED blinks twice and fault code AL79 is shown on MDI instrument.

An incorrect starting sequence. The machine only starts if the sequence is followed: start switch - handle
(or seat) - running. Possible reasons:
A: Running microswitch or handle microswitch stuck.
B: Error in sequence made by the operator, pedal pressed at the key on.
C: Incorrect wiring if there is not any defects externally is necessary to replace the logic.

11. FORW—BACK: LED blinks continuously and fault code AL80 is shown on MDI instrument.

The test is carried out continuously. An alarm is signalled when two requests for running are made
simultaneously. Possible causes:
A: Defective wiring.
B: Running microswitch stuck.
C: Incorrect manoeuvre.
D: If there is not external defects, replace the logic.

12. VACC NOT.OK: LED blinks 4 times and fault code AL78 is shown on MDI instrument.

The test is made in standby. The alarm indicates that the accelerator voltage is greater than 2V with
respect to the minimum value stored. Possible causes:
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A: A potentiometer wire is interrupted or the potentiometer negative has not been connected to the PIN
C2 of the logic board. In this case it is generated an alarm because the logic don’t find the load on the pin
C2.
B: The potentiometer is not correctly calibrated.
C: The potentiometer is defective (interrupted).

13. I HIGH AT STAND: LED blinks 5 times and fault code AL53 is shown on MDI instrument.

Test is carried out in standby, check that the current is nil. If this is not verified, an alarm is signaled. This
alarm shuts down the machine. Possible causes:
Current sensor broken and logic failure. First replace the logic, and if the defect persists, replace the
power unit.

14. I=O EVER: LED blinks 5 times and fault code AL49 is shown on MDI instrument.

Test is carried out in running. Check that the current during running is greater than a minimum value. If
not, an alarm is signalled and the machine is shut down. Possible causes:
A: The current sensor is faulty. Replace the power unit.
B: Wrong connections of the motor cables to the power bars SH- and SH+.

CAUTION: This fault occurs because the water is mixed into the chopper. Be careful when
use.

15. EEPROM PAP. KO: LED blinks once and fault code AL11 is shown on MDI instrument.

Fault in the area of memory in which the adjustment parameters are stored. This alarm inhibits machine
operation. If the defect persists when the key is switched off and on again, replace the logic. If the alarm
disappears, remember that the parameters stored previously have been cancelled, and replaced by the
default values.

16. EEPROM CONF. KO: LED blinks once and fault code AL12 is shown on MDI instrument.

Fault in the area of memory in which the special chopper configuration data is stored. If the defect
persists when the key is switched off and on again, replace the logic. Otherwise, keep in mind that the
chopper configuration has been reset to the default values (regeneration voltage, etc.); thus it must be
reprogrammed. Consult the console manual.

17. EEPROM DATA KO: LED blinks once and fault code AL10 is shown on MDI instrument.

The data in the area of memory that handles the hour-meter is incorrect. This alarm does not shut down
the machine. If the alarm disappears when the machine is switched off and on again, keep in mind that
the hour-metre data has been reset to zero.
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18. EEPROM OFF LINE: LED blinks once and fault code AL14 is shown on MDI instrument.

Fault in the nonvolatile memory that contains data relative to the area for the hour-metre, the alarms
stored and the programming parameters. If the alarm persists when the key is switched off and on again,
replace the logic.

19. CHOP NO CONF: LED blinks once and fault code AL07 is shown on MDI instrument.

The test is carried out in running. Fault in the area of memory in which the special chopper configuration
data is stored. If the defect persists when the key is switched off and on again, replace the logic. If the
alarm disappears, remember that the data stored previously have been cancelled, and replaced by the
default data.

20. WATCH DOG: LED blinks once and fault code AL08 is shown on MDI instrument.

The test is made in both running and standby. It is a self-diagnosis test within the logic. If an alarm
should occur, replace the logic.

21. SHORTED COIL: LED blinks 6 times and fault code AL76 is shown on MDI instrument.

There is an overcharge or a short circuit towards the positive of the battery on the negative contactor
output. Possible causes:
A: The coils of the contactors are in short circuit or they absorb more than 6A continue current.
B: Short circuit with +BATT of the cabling which cores out from the contactor connector.The alarm shows
an occurred overcharge and not the fail of a chopper component. When the external cause is removed it
is possible to restart again.

22. DRIVER SHORTED: LED blinks 6 times and fault code AL74 is shown on MDI instrument.

The test is carried out in standby. It checks that the during voltage of the drivers commanding the
contactors is at a coherent value with the forecasted state. Possible cause:
A: Logic value
B: Drivers broken because of an overvoltage in the cabling of the negative contactors. Replace the logic
after having removed the cause.

23. Socket G function ends potential list:

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WIRE SOC WIRE START SWITCH ON START SWITCH ON

FUNCTION
COLOR KET NO ONACCELERATOR UP ACCELERATOR DOWN

White- Positive of braking

G4 38 Low potential High potential
green contactor PTFE

Red-
G1 15 Contactor positive PT High potential High potential
black

High potential (low potential

Grey- Negative field weakening
G3 41 High potential when depressing
white contactor coil NTIND
accelerator pedal)

Blue- Negative backward

G2 23 High potential Low potential (bwd)
black contactor coil NTI

Red- Negative braking

G6 3l Low potential Low potential
green contactor coil NTFR

Y e l l ow - Negative forward contac-

G5 27 High potential Low potential (fwd)
green tor coil NTA

Negative of auxiliary con-

Black G7 60 High potential Low potential
tactor AUX G7
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Electrical System Troubleshooting

Features Possible reasons Solutions

1.Battery connector.
2.Fuse of control circuit is
No Instrument power burnt.
after the start switch 3.Emergency button is
is turned on. Forklift not turned on.
can’t work 4.Emergency button is
damaged.
Start switch is damaged.
1.Fuse is burnt.
2.Floodlight relay is
The floodlights do
burnt.
not work
3.Combination switch is
damaged.
Position lights don’t Combination switch is
work damaged.
1.Fuse of turn signal light
broken.
Turn signal lights
2.Flasher is damaged.
don’t work
3.Combination switch is
damaged.
1.Combination switch is 1.Check the combination switch, replace with a new switch if it is
Only one turn signal
damaged. damaged.
light turns on
2.Turn signal light is burnt 2.Check the turn signal light, replace with a new light bulb.
1.Fuse of the brake lights
is burnt
Brake lights don’t 2.Brake relay is damaged
work 3.Brake light switch is
damaged
4.Brake light bulb is burnt
1.Fuse of the backup light
is burnt.
2.Backup light relay is
Backup light doesn’t damaged.
work 3.Reverse switch is
damaged.
4.Backup light filament is
burnt.
1.Check the battery connector, connect it correctly.
2.Check the fuse, replace if necessary.
3.Check the emergency button for power. Turn it on if it does not
power on.
4.Check the battery button. Replace with a new emergency button if
it is damaged.
5.Check the start switch for normal condition, replace with a new one
if it is damaged.
1.Check the fuse of the floodlights. Replace with a new fuse if it is
burnt.
2.Check the relay of the floodlight, replace with a nw replay if it is
damaged.
3.Check the combination switch, replace with a new switch if it is
damaged.
Check the combination switch, replace with a new switch if it is
damaged.
1.Check fuse of the turn signal light, replace with a new fuse if it is
broken.
2.Check the flasher, replace with a new one if it is damaged.
3.Check the combination switch, replace with a new switch if it is
damaged.
1.Check fuse, replace if necessary.
2.Check the brake light relay, replace if necessary.
3.Check the brake light switch, replace if it is damaged.
4.Check the brake light bulb, replace if necessary.
1.Check the fuse, replace if necessary.
2.Check the backup light relay, replace it if necessary.
3.Check the reverse switch, replace it if necessary.
4.Check the backup light bulb, replace if it is burnt.
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Electrical Motor Troubleshooting

Features Possible reasons Solutions

1.Check the fixed screw and
connection for loosen, or replace the
1.The controller can not check the coder.
The motor vibrates coder.
2.The coder damaged.
when working. 2.Replace the coder
3.The cable loosen.
3.Check the cable and tighten the
bolt of connection pole.
The motor be locked
The bearing damaged. Replace
can not move.

Battery Troubleshooting

Features Possible reasons Solutions

1.Improper electrolyte proportion
2.Improper use of the battery. Battery terminal plate is
1.The electrolyte proportion should
salified by sulfuric acid and an internal short circuit
be: 1:280±0.005(20°C)
Battery exhausts 3.Operate the machine lifting and traveling at the same
2. Use or charge correctly.
quickly or can not time, causing battery discharging and result a terminal
3. Don’t operate the machine lift and
charge fully plate damage.
travel at the same time.
4.Don’t charge battery in time, which causing the battery
4. Charge the battery in time.
discharging at low voltage and result in a terminal plate
damage.
1.Active material expands or flakes off, baffle is 1. Change the terminal plate
damaged. 2. Flat the terminal plate, replace the
Battery short circuits 2.Terminal plate bends, baffle is damaged. baffle.
3. Too much sediments 3. Remove.
4. Conduction matter falls into the battery 4. Remove.
1.Recharge the battery to full state
1.Battery is under charge or paused during the first to let the active material recover.
charging process 2.Pour the electrolyte out, recharge
2. Discharged or discharging battery is stored too long. the battery.
3. Battery is under charge or over charge for long-term 3. Replace the terminal plate.
4. Electrolyte density is out of range or sulfuric acid is 4. Replace the terminal plate and
Terminal plate
refilled randomly. electrolyte.
sulfuration
5. Too low electrolyte level causing sulfuration to the 5. Replace the terminal plate.
terminal plate. 6.Replace the terminal plate and
6. Battery can not be charged in time. charge in time.
7. Battery is short-circuited. 7.Replace the terminal plate.
8. Impure electrolyte. 8.Replace the terminal plate and
electrolyte
1.Active material of the terminal plate flakes off. 1. Replace the electrolyte.
2. Impure electrolyte. 2. Replace the electrolyte.
Electrolyte is turbid
3. Too big charging current. 3. Charge the battery as required.
4. Too high charging temperature 4. Control the charging temperature.
1. Battery is used in too hot or too cold environment. 1.Melt the cracks and mend with the
Sealing compound
2. Improper transportation and storage, battery is placed melt of waste battery sealing
cracks
in reverse or struck compound.
110
Maintenance Manual
Maintenance Record

Maintenance Record

INDEX
A D
Application and Specification ..........................31
Applications .....................................................31
Attachment Cautions .......................................17
Attachment--Remove and Lift .........................57
Aux Lever (Optional) .......................................40
Axle Oil Level-Check .......................................77
B
Backup Alarm--Test ........................................89
Battery .............................................................44
Battery Connector ...........................................35
Battery Inspection for New Machine ...............83
Battery Maintenance .......................................82
Battery Troubleshooting ................................109
Battery--Charge ..............................................84
Before Operation .............................................34
Before Reuse ..................................................52
Before Storage ................................................51
Brake Oil--Check .............................................81
Brake Operation ..............................................48
Brake Pedal ....................................................39
Brake System Maintenance ............................81
Brake System Troubleshooting .......................93
Burn Prevention ..............................................14
C Fuel ................................................................. 17
Carbon Brush Maintenance ............................86
Cautions about Machine Maintenance ............26
Cautions about Machine Operation ................18
Cautions for Battery ........................................83
Chain--Lubricate .............................................75
Cold Weather Operation .................................50
Control Valve-Assemble and Install ................80
Control Valve--Remove and Disassemble ......79
Crushing and Cutting Prevention ....................14
Cushion Tire--Replace ....................................74
111
INDEX
Daily Maintenance for Hydraulic System ........ 78
Daily Maintenance of Battery .......................... 84
Downhill Operation ......................................... 48
Drive Axle Oil-Replace ................................... 77
Drive Axle Troubleshooting ............................ 91
E
Electrical Motor Troubleshooting .................. 109
Electrical schematic ........................................ 85
Electrical Storm Injury Prevention .................. 17
Electrical System ............................................ 85
Electronic Control System
Troubleshooting(CURTIS) .............................. 95
Electronic Control System Troubleshooting(SME)
......................................................................... 94
Electronic Control Unit Maintenance .............. 87
F
Fire &Explosion Prevention ............................ 15
Fire Extinguishers and First-aid Kit ................. 16
Fork ................................................................ 44
Fork Install ...................................................... 55
Fork Removal ................................................. 55
Forklift Storage ............................................... 51
Fuse--Check/Replace ..................................... 88
G
Gearbox Troubleshooting ............................... 90
General Hazard Information ........................... 11
General Torque Specifications ....................... 70
H
H2B Chopper Troubleshooting ....................... 97
Horn Button .................................................... 43
112
INDEX
Hot Weather Operation ...................................50
Hydraulic Oil Level--Inspect ............................78
Hydraulic Oil-- Replace Periodically ................78
I Operation Techniques .................................... 46
In Storage .......................................................51
INDEX ...........................................................111
Instrument Panel .............................................37
K
Key Spare Parts to be Periodically Changed ..30
L Preface ............................................................. 1
Leave the Machine ..........................................51
Lift Lever .........................................................39
Lift System Troubleshooting ...........................94
Lifting Operation ..............................................56
Lighting System ....................................... 43 , 89
Load Backrest .................................................42
Loading Operation ..........................................49
Lubricant Specifications ..................................72
M Use ................................................................. 45
Machine Starting .............................................46
Machine Troubleshooting ................................90
Main Parts of Forklift Body ..............................40
Main Safety Valve Pressure--Adjust ...............80
Main Specifications .........................................32
Maintenance beside the Mast and Fork ..........76
Maintenance Interval Schedule .......................58
Maintenance Manual .......................................58
Maintenance of drive axle ...............................77
Maintenance of Hydraulic System ..................78
Maintenance of Motor .....................................85
Maintenance Record .....................................110
Mast--Lubricate ...............................................75
Metering Pump Troubleshooting .....................92
Move Oversize Goods ....................................49
O
Oil Specifications ............................................ 71
Operation Manual ........................................... 34
Operator Controls and Instrument Panels ...... 34
Other Maintenance ......................................... 89
Overhead Guard ............................................. 42
P
Parking ........................................................... 50
Parking Brake Force--Adjust .......................... 81
Parking Brake Lever ....................................... 35
Parking Brake Performance--Inspect ............. 81
R
Rear Hood ...................................................... 44
S
Safety Decals and Decal Locations .................. 4
Safety in Attachment Installation, Adjustment and
Safety Information ............................................ 4
Safety Signs ..................................................... 4
Safety Symbol .................................................. 4
Seat ................................................................ 40
Seat Belt (Optional) ........................................ 41
Seat Belt--Inspect ........................................... 89
Serial Number of the Machine and Parts .......... 3
Service Brake Performance--Inspect .............. 82
Shift Control Lever .......................................... 36
Shut down the Machine .................................. 51
Side Shroud of the Hood ................................ 43
Sideshift Lever (Optional) ............................... 40
Stability and Barycenter .................................. 28
Start Switch .................................................... 34
Steering Operation ......................................... 47
Steering System Troubleshooting .................. 91
Steering Wheel .........................................36 , 42
Steering Wheel--Check .................................. 43
Stop the Machine ............................................ 50
Storage and Maintenance of Cushion Tires ... 75
 113
INDEX

Testing Method for Electrolyte Density ...........83

Tightening Torque of the Bolts ........................30
Tilt Lever .........................................................39
Tire Explosion Prevention ...............................17
Tire Inflation Information .................................74
Tire Information ...............................................74
Tires--Replace ................................................53
Towing Information .........................................56
Traction Pin .....................................................45
Transportation .................................................52
Transportation Information ..............................52
Traveling Operation ........................................46
Troubleshooting ..............................................90

Unloading Operation .......................................49

Working Implement System ............................75