202011005

CLG2020H/C-CLG2035H/C
CLG2020G-CLG2035G
FORKLIFT TRUCK

SERVICE MANUAL

Applicable type and model: CLG2020H/C, CLG2025H/C, CLG2030H/C, CLG2035H/C,

CLG2020G, CLG2025G, CLG2030G, CLG2035G
November 2, 2020 Content
CLG2020H/C-2035H/C,CLG2020G-2035G

Content
General Information ........................................................................................................1-1
Power System ..................................................................................................................2-1
Power Train System ........................................................................................................3-1
Hydraulic System ............................................................................................................4-1
Brake System...................................................................................................................5-1
Electrical System.............................................................................................................6-1
Frame System ..................................................................................................................7-1
Mast System.....................................................................................................................8-1
Covering Part System .....................................................................................................9-1
Appendix ........................................................................................................................10-1
Content November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 1-1
November 2, 2020 General Information
CLG2020H/C-2035H/C,CLG2020G-2035G

General Information
Preface..............................................................................................................................1-3
How to Read the Manual .................................................................................................1-5
Complete Machine Identification and Parameter Identification ..................................1-6
Engine Identification .......................................................................................................1-7
Standard Torque Table ...................................................................................................1-9
Torque Specifications – Metric Hardware ..........................................................................................1-9

Unit Conversion Table ..................................................................................................1-12

Cable Code Identification .............................................................................................1-13
Coating Materials...........................................................................................................1-15
Weight Table ..................................................................................................................1-16
Oil Specifications ..........................................................................................................1-17
Main Components of the Machine ...............................................................................1-18
Application and Specification ......................................................................................1-19
Applications..........................................................................................................................................1-19

Main Specifications .......................................................................................................1-20

1-2
General Information November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 1-3
November 2, 2020 Preface
CLG2020H/C-2035H/C,CLG2020G-2035G

Preface Accurately record the machine’s product

model number, product serial number, engine
serial number, and the numbers of the
This manual contains important instructions for primary components. If the machine is stolen,
operating, maintaining, inspecting, and you will need to provide these numbers to the
adjustment of this machine. The manual is a local authorities for reporting and tracking.
permanent and important part of the machine. You will also need to give these numbers to
This manual should be stored in a safe and your dealer to order parts or learn more about
clean place so that operators can read it easily. the condition of the machine. If this manual is
Make sure that the manual remains intact and in stored inside the machine, please ensure that
good condition. It should not be removed if the the numbers are also recorded in a safe place
machine is resold or leased. outside of the machine.

Please read this manual carefully to operate and Safety

maintain the machine properly and avoid
possible personal injury or machine damage. All Basic safety precautions are listed in “Safety
operators should be able to use the machine Information”. The text for warning symbols and
proficiently, properly, and safely. signs are also indicated, along with their
locations.
Some photographs and illustrations in this
manual show details of attachments those may Please read and understand the basic
be different from your machine. Guards and precautions listed in “Safety Information” before
covers may have been removed for the purpose operating the machine or performing lubrication,
of illustration. maintenance, or repairs on it.

Do not use the machine for any purposes other Operation

than those described in this manual. If you have
special requirements and would like to modify This section includes information on
the machine or add other specialized equipment instrumentation, control equipment, control
to it, please contact your dealer for confirmation. levers, as well as transport and towing. This
Otherwise, all consequences of unauthorized section is suitable for new drivers to study and
modification are your sole responsibility. for experienced drivers to review. Please refer
back to it often.
LiuGong provides a full warranty for users who
operate and maintain the machine in accordance Graphics indicate the correct operational steps
with the instructions in this manual. If the for inspecting, starting, operating, and stopping
machine is used improperly or is used to perform the machine.
operations other than those specified by the The techniques in this manual are basic. As
manufacturer, the warranty will become invalid operators’ knowledge of the machine and its
and requests for field maintenance may be performance grows, their operational proficiency
rejected. Only personnel with training or will likewise increase.
operational experience are allowed to operate
the machine, and only professionals are allowed Maintenance
to inspect or maintain the machine.
The “Maintenance” section provides guidance on
how to maintain the machine. Step-by-step
illustrations are categorized by maintenance
periods. Maintenance tasks without a specific
period are listed in “Other”. For items in “Periodic
Maintenance”, please refer to the details
provided below.
1-4
Preface November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

When maintenance or servicing of the engine Certified Engine Maintenance

requires replacing components that are critical
for environmental protection, use parts from the Correct maintenance and repair methods are
original manufacturer of the same model and essential to keeping the engine and machine
specifications. Otherwise, LiuGong will not bear systems operating properly. As the owner, you
any legal responsibility for the consequences. are responsible for performing the required
maintenance listed in the Maintenance Manual
Maintenance Periods for this machine. It is prohibited for persons
engaged in the business of repairing, servicing,
For convenience, you can use calendar time selling, leasing or trading engines or machines to
(days, weeks, months) to determine the remove, alter or render inoperative any
maintenance period rather than working time as emissions-related device or design element
shown on the hour meter, but only if the two are installed on or in an engine or machine that is in
nearly the same. We recommend that you compliance with the regulations. Certain
perform a given maintenance task as soon as elements of the machine, such as the exhaust
the maintenance period is reached in either of system, fuel system, electrical system, air intake
the two time calculations mentioned above. system and cooling system may be emissions-
In extremely harsh, dusty, or humid working related and should not be altered unless
environments, more frequent maintenance and approved by LiuGong.
lubrication than that described in ”Periodic
Declaration
Maintenance” is required. The maintenance
tasks listed in the original requirements should The forklifts CLG2020H/C, CLG2025H/C,
be repeated during maintenance. For example, CLG2030H/C, CLG2035H/C, CLG2020G,
when performing the maintenance tasks listed CLG2025G, CLG2030G and CLG2035G
for 500 work hours, you should also perform the manufactured by LiuGong are special industrial
maintenance tasks for 200 work hours, 50 work machines, which can be operated only in special
hours, and 8 hours/daily. areas that is stipulated in the Regulation on
All materials, illustrations, and specifications Safety Supervision for Special Equipment, such
in this manual are the latest product as factories, scenic spots and amusement sites.
information available at the time of
publication. LiuGong reserves the right to
make changes without notice.
 1-5
November 2, 2020 How to Read the Manual
CLG2020H/C-2035H/C,CLG2020G-2035G

How to Read the Manual ● The materials and technical specifications in

the Manual are changed with variation of
products, and all information, diagrams and
Composition of service manual specifications in the Manual are the latest
product information obtained at the time of
The Manual is used by green hands or technical publication. The company reserves the right
service personnel with rich experience for to make modification without any notice. If it
reference. This manual includes all technical needs to obtain the latest technical
information required for workshop maintenance. information, please consult the dealer of
In view of easy understanding and convenient LiuGong in local area or Service Department
reading, it is divided into General Information of LiuGong Forklift Marketing Co., Ltd.
section and Component Maintenance section.
Component Maintenance section covers: Marking of Revised Version
1. Power System
The meaning of version number for service
2. Power Train System manual of LiuGong is as follows:
3. Hydraulic System
4. Brake system
5. Electrical system 2nd Version

6. Frame system
Publication month
7. Mast System
8. Covering part system
Publication year
Other reference manuals
P22M00001
For basic information of structure, operation and
When the version is revised, the year and month
maintenance of the machine, refer to the
reflects revision date of the version, and the last
following two manuals, which are distributed to
numbers reflects revision times of the Manual.
the users in the form of vehicle accessory.
For example, 001 represents the first revision,
● Part drawing 002 represents the second revision, and so on.
Operation and maintenance manual

User's Guidance

● Because the influences to the machine from

area or processing are different, it shall con-
firm which machine is applicable, and what
work implements it has.
● Some accessories and optional parts in the
Manual may not be transported to relevant
areas, and consult your local LiuGong dealer
if required.
1-6
Complete Machine Identification and Parameter Identification November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Complete Machine
Identification and Parameter
Identification

IMPORTANT: Use only supporting manuals

designed for your specific machine. If incorrect
manual is chosen, improper service may occur.
Verify product identification number (PIN) and
engine model number when choosing the correct
manual.

Identify the product series number

The product PIN code is located on the right of

the vehicle front crossbeam plate and above the
tilt cylinder port.
PIN plate location

P22M00003
 1-7
November 2, 2020 Engine Identification
CLG2020H/C-2035H/C,CLG2020G-2035G

Engine Identification

Cummins QSF2.8 engine series number plate is located at the upper part of engine cylinder cover. Each
engine nameplate has two numbers (engine model and series number).
Engine series number plate

P22M00004

YANMAR 4TNE98 engine series number plate is located at the lateral side of engine cylinder cover.
Each engine nameplate has two numbers (engine model and series number).
Engine series number plate location

P22M00005
1-8
Engine Identification November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Engine series number plate

P22M00006

Mitsubishi PSI-2.4L engine series number plate is located at the lateral side of engine cylinder cover.
Engine series number plate location

P22M00007
Engine series number plate

P22M00008
 1-9
November 2, 2020 Standard Torque Table
CLG2020H/C-2035H/C,CLG2020G-2035G

Standard Torque Table

Torque Specifications – Metric Hardware

Use the following torques when specifications are not given.

These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or
when lubricated with engine oil, These values do not apply if graphite or Moly disulfide grease or oil is
used.

Grade 8.8 Bolts , Nuts , and Studs

Size N.m \ lbf·ft
M6 7.7±1.1N.m \ 5.7±0.8lbf·ft
M8 19±2.9N.m \ 14±2.1lbf·ft
M10 38±5N.m \ 28±4lbf·ft
M12 66±9N.m \ 48±7lbf·ft
M14 107±15N.m \ 79±11lbf·ft
M16 166±26N.m \ 122±19lbf·ft
M18 229±33N.m \ 169±24lbf·ft
M20 302±37N.m \ 223±27lbf·ft
M22 443±59N.m \ 327±44lbf·ft
M24 561±74N.m \ 414±55lbf·ft
M27 811±111N.m \ 598±82lbf·ft
M30 1106±148N.m \ 816±109lbf·ft
M33 1512±221N.m \ 1115±163lbf·ft
M36 1955±258N.m \ 1442±190lbf·ft

Grade 10.9 /12.9 Bolts , Nuts , and Studs

Size N.m
M10 72±6N.m \ 53±4lbf·ft
M12 120±10N.m \ 89±7lbf·ft
M14 195±15N.m \ 144±11lbf·ft
M16 305±25N.m \ 225±18lbf·ft
M18 415±35N.m \ 306±26lbf·ft
M20 600±50N.m \ 443±37lbf·ft
M22 800±70N.m \ 590±52lbf·ft
M24 1020±100N.m \ 752±74lbf·ft
M27 1500±100N.m \ 1106±77lbf·ft
M30 1850±150N.m \ 1364±111lbf·ft
M33 2900±400N.m \ 2139±295lbf·ft
M36 3100±250N.m \ 2286±184lbf·ft
1-10
Standard Torque Table November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Tightening torque of 24° cone O-ring sealed hose connector

Hose inner Tightening torque

Series Thread size
diameter mm N.m kgf.m
M12×1.5 5 16±1 1.6±0.1
M14×1.5 6.3 16±1 1.6±0.1
M16×1.5 8 26±2 2.7±0.2
M18×1.5 10 37±2 3.8±0.2
M22×1.5 12.5 47±2 4.8±0.2
Light-type
M26×1.5 16 89±4 9.1 ±0.4
M30×2 19 116±5 11.8±0.5
M36×2 25 137±6 14.0±0.6
M45×2 31.5 226±11 23.1±1.1
M52×2 38 347±16 35.4±1.6
M14×1.5 5 26±2 2.7±0.2
M16×1.5 6.3 42±2 4.3±0.2
M18×1.5 6.3 53±2 5.4±0.2
M20×1.5 8 63±3 6.4±0.3
M22×1.5 10 79±4 8.1 ±0.4
Heavy type
M24×1.5 12.5 84±4 8.6±0.4
M30×2 16 126±6 12.9±0.6
M36×2 19 179±8 18.3±0.8
M42×2 25 263±12 26.8±1.2
M52×2 31.5 368±17 37.6±1.7

Tightening torque of flange-type sealed hose connector bolt

Bolt performance Tightening torque

Series Bolt
level N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
8.8
M12 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
Light-type
M8 33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
10.9
M12 136±6 12.8±0.6
M16 310±15 31.6±1.5
 1-11
November 2, 2020 Standard Torque Table
CLG2020H/C-2035H/C,CLG2020G-2035G

Bolt performance Tightening torque

Series Bolt
level N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
M12 8.8 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
M20 420±20 42.8±2.0
Heavy type
M8 33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
M12 10.9 136±6 12.8±0.6
M16 310±15 31.6±1.5
M20 577±27 58.9±2.8

Tightening torque of thread angle type sealed hose connector

Material of
Carbon steel, alloy steel Aluminum product
fastenings
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 3.0±0.2
G3/8 73.5±4.5 7.5±0,46 49±3 5.0±0.3
G1/2 110±10 11.2±1.0 55±5 5.6±0.5
G3/4 165±15 16.8±1.5 74±4 7.5±0.4
G1 225±25 23.0±2.55 / /
G1-1/4 275±25 28.0±2.55 / /
G1-1/2 285±15 29.1±1.5 / /

Connector tightening torque

Tightening torque
Thread size
N.m kgf.m
M12 24±2 2.4±0.2
M14 30±2 3.1±0.2
M16 30±2 3.1±0.2
M18 30±2 3.1±0.2
1-12
Unit Conversion Table November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Unit Conversion Table

The Manual uses ISO International System of Units, and ISO international units are converted into
British units as shown in following figure:

Parameters Metric unit British unit Multiple

mm In 0.03937
Length
mm ft 0.003281
L US gal 0.2642
Capacity L US qt 1.057
m³ Yd3 1.308
Weight kg lb 2.205
N kgf 0.10197
Intensity
N lbf 0.2248
Nm kgf·m 0.10197
Torque
Nm lbf·ft 0.7375
MPa 3 10.197
kgf/cm
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C ×1.8+32
km/h mph 0.6214
Speed
min-1 rpm 1.0
L/min US gpm 0.2642
Flow
mL/rev cc/rev 1.0
 1-13
November 2, 2020 Cable Code Identification
CLG2020H/C-2035H/C,CLG2020G-2035G

Cable Code Identification

The wire in circuit diagram is marked in combination with wire No., color abbreviation codes and wire
gauge for maintenance. For example:

Indicates red, with the number of 108 and a diameter of 50.0mm2.

Wire gauge (note: unless marked, or else wire gauges are all 0.85mm2.

Color abbreviation codes

Wire number P22M00002

Wire No.

Wire No. is digital code for marking wire with three Arabic numbers in accordance with certain rules.

Color abbreviation codes

Color English Abbreviation Color English Abbreviation

Black BLACK BK Blue BLUE BU
Grey GREY GY Green GREEN GN
Red RED RD Yellow YELLOW YL
Brown BROWN BR Pink PINK PK
Violet VIOLET VT Orange ORANGE OR
White WHITE WH Light blue LIGHT BLUE LTBU
Red/green RED/GREEN RD/GN Yellow/blue YELLOW/BLUE YL/BU
Remarks: The code composed of 2 colors indicates double-color wire
For example: "RD/GN" shows red-green wire.
1-14
Cable Code Identification November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Wire specifications

Allowable current and voltage drop of AV wire, and approximate performances of AVS, AVSS, and QVR
shall be executed uniformly according to the following table.

Ambient temperature 30°C(86°F) 40°C(104°F) 50°C(122°F) 60°C(140°F) 70°C(158°F)

Allowable current/
A mV/m A mV/m A mV/m A mV/m A mV/m
voltage drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
8 74 213 66 190 57 164 47 135 33 95
Nominal 15 103 176 92 157 30 137 65 111 46 79
sectional
area(mm2) 20 135 148 121 133 105 116 85 94 60 66
30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 60 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37

Circuit type and color abbreviation code

For general corresponding rules between circuit type and wire color, see the following table.

Circuit type Color abbreviation codes

Power line OR, RD
Signal line WH
Earthing BK, GY
Communication line RD/GN, YU/BU
 1-15
November 2, 2020 Coating Materials
CLG2020H/C-2035H/C,CLG2020G-2035G

Coating Materials

Name Specification Main features and purposes

Features: rust protection for a long time
Long-term anti-rust agent LONG#2 light yellow Purposes: used for mounting face of pump, sensor, hydraulic
fitting, etc
Efficient cleaning agent Features: strong ability of cleaning
1755
1755 Purposes: used for pump and motor
Cleaning agent for
electromechanical HD-10 Used for cleaning oil pipe connectors, etc.
equipment
Diesel engine sealant 1515 Used for mounting face of diesel engine flange

Paint standard:

There are two main kinds of colors that applied to this machine:
Yellow: matte (60%-80%) RAL1006 yellow
Grey: matte (40%) RAL7021 grey
The standard of paint quality is as follows (for more information, see QJ/LG 08.44-2013):

S/N Items Indicator Testing method Remarks

Refer to the
Paint film shall be uniform
requirements at all
Paint film color, and no blistering, crack,
1 Visual check levels of surface for
appearance wrinkle, under screen, rust,
details of allowable
damage, dirt and so on
defects
For details, see the
requirements at all
Meet the minimum
Paint film levels of surface. For
2 requirements of paint film Visual/gloss meter
gloss matte paint, refer to
gloss at all levels of surface
the special
requirements
Meet the minimum
For details, please see
Paint film requirements of paint film
3 Thickness gauge of paint film the requirements at all
thickness thickness at all levels of
levels of surface
surface
Use single cutting edge or scriber to
perform the cross cut on the paint film Approval standard: No
with five horizontal and vertical lines. the whole piece of grid
Adhesion of Good adhesion and no peeling The distance between the scribing lines film drops. (Little film
4
paint film in detection of paint film is 1 mm~1.5 mm and the depth can drop around the
reach the steel plate substrate. Then scribing lines can be
stick the transparent adhesive tape and allowable.)
compact, then tear off the tape
Meet color difference For details, please see
Color
5 requirements at all levels of Visual check/Color difference meter the requirements at all
difference
surface levels of surface
1-16
Weight Table November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

S/N Items Indicator Testing method Remarks

There is no paint
6 Shield contamination, mechanical Visual check
impurity, rust and dirts
The decal should be correct,
7 Decal complete, decorous, firm, Visual check
smooth and no popping

Weight Table

The following table indicates the reference value of the weight of each component. When using the lifting
equipment , please refer to the following table to select the sling.

Component Weight kg (lb)

Engine 280(617.40)
Radiator 50(110.25)
Front axle assembly 150(330.75)
Rear axle assembly 70(154.35)
Front tire rim 100/(220.5)(3-3.5t), 55/(121.28)(2-2.5t)
Rear tire rim 45/(99.23)(3-3.5t), 35/(77.18)(2-2.5t)
Gearbox 150(330.75)
Overhead guard 80(176.40)
Seat 20(44.10)
Engine hood 25(55.13)
Control valve (four spools) 25(55.13)
Gear pump 10(22.05)
Load-backrest 30(66.15)
Fork arm carrier 150(330.75)
Fork (standard length: 1070) 65(143.33)
Inner mast 190(418.95)
Middle mast 150(330.75)
Outer mast 280(617.40)
Tilt cylinder 20(44.10)
Frame 400(882)
1500/(3307)(2t), 1600/(3528)(2.5t), 1750/(3858)(3t),
Counterweight
1900/(4189)(3.5t)
Battery 20(44.10)
 1-17
November 2, 2020 Oil Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G

Oil Specifications

Oil change interval and refill capacities:

Oil change
Type of oil intervals Capacity Oil type and classification
(hours)
Hydraulic HU-30 (GB2537-88 in summer)
1000 8 L/2.1136gal
transmission oil 6# hydraulic transmission oil (GB2512-81 in winter)
7L/1.85gal
(CUMMINS QSF2.8)
7.2 L/1.902gal CF class and
(YANMAR 4TNE98) above -10~30°C: SAE viscosity level 20
Diesel engine oil 500 -10~35°C: SAE viscosity level 30
10L/2.642gal -5 ~40°C: SAE viscosity level 40
(MITSUBISHI S4S) -40~10°C: SAE viscosity level 5W
10L/2.642gal CJ4 class and -30~15°C: SAE viscosity level 10W
(MITSUBISHI D04EG) above -40~10°C: SAE viscosity level 5W/20
5.7L/1.506gal -40~35°C: SAE viscosity level 5W/30
(PSI 4G64) -30~35°C: SAE viscosity level 10W/30
-20~40°C: SAE viscosity level 15W/40
9.5L -15~40°C: SAE viscosity level 20W/40
Gasoline engine 250 hour/ SM class and
(Kubota WG2503-GL- -10~35°C: SAE viscosity level 20/20W
oil 120day above
E3/WG2503-L-E3)
3.8L/1.00396gal
(NISSAN K25)
Above 8°C: 5#
Refill according to Above 4°C: 0#
usage requirements (it Above -5°C: -10#
Diesel oil
is recommended no to -5 ~ -14°C: -20#
exceed 50L) -14 ~ -29°C: -35#
-29 ~ -44°C: -50#
Gasoline 60L/15.85gal 93#
Gear oil of drive
1000 8 L/2.1136gal 85W/90(all-year), 80W/90(winter)
axle
Refill according to the
oil dispstick (refer to
the hydraulic oil L-HM32# anti-wear hydraulic oil (summer),
Hydraulic oil 2000
replacement L-HV32# low temperature anti-wear hydraulic oil (winter)
instructions for filling
methods)
Brake oil 4000 0.4 L/0.106gal DOT 3 Mobil synthetic brake oil
Grease 0.5 Kg/1.1lb 3# common lithium base grease (-20°C~+120°C)
Antifreeze + water 2000 8 L/2.1136gal Mobil (concentrated) / Shell(100%)antifreeze
1-18
Main Components of the Machine November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Do not mix oils of different brands even if they have the same specifications. Clean the system
before adding 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.
Except for the oil specifications in above table, when using the oil purchased in the market,
please contact with dealers of LiuGong.

Main Components of the Machine

1 12 16
2

14

15

13
4

11
10
9
8
7
6
5 P12M00141

1. Overhead guard 9. Frame

2. Mast 10. Engine hood
3. Load-backrest 11. Steering axle
4. Fork 12. Steering wheel
5. Front wheel 13. Rear wheel
6. Drive axle 14. Seat
7. Titling cylinder 15. Counterweight
8. Lifting cylinder 16. High exhaust pipe (optional)
 1-19
November 2, 2020 Application and Specification
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Application and Specification

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. Altitude: ≤3048m
2. Environmental temperature: -15°C~40°C
(The cold starting Aid device is not available)
3. Air relative humidity: ≤90%(When the
environmental temperature is 25°C)
4. Wind speed: ≤5m/s

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.

In windy condition, do not lift the mast too

high in order to prevent the falling of goods
and cause accidental body injury.
1-20
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

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

P12M00140
 1-21
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2020H/C)1-1

CLG2020H/C CLG2020H/C
1 Model (Cummins (Cummins
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 2000 2000
4 Load Center mm 500 500
5 Service Weight unloaded kg 3857 3857
Weights 6 loaded/unloaded, front kg 4342/1166 4342/1166
Axle Load
7 loaded/unloaded, rear kg 1515/2691 1515/2691
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 140 140
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 40 x 100 x 1070
23 Length to Fork Face with std 2-stage mast mm 2534 2534
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 470 470
add load length and
28 Right Angle Stack mm 4012 4012
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 18/18.5 18/18.5
32 Lift Speed loaded/unloaded m/s 0.7/0.73 0.7/0.73
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4 0.5/0.4
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 31 20 /31
1-22
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer Cummins Cummins
39 model QSF2.8T3NA49 QSF2.8T3NA60
Systems 40 emission compliance EU Stage IIIA EU Stage IIIA
41 Engine cylinders 4 4
42 displacement liter 2.8 2.8
43 rated power kw/rpm 36/2500 43/2500
44 max. torque N.m/rpm 186/1500 186/1500
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 89 89
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.053 0.053
48 Fuel Consumption diesel or LPG
L/h 3.741 3.741

Machine specifications (CLG2020H/C)1-2

CLG2020H/C CLG2020H/C
1 Model (Yanmar (Yanmar
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 2000 2000
4 Load Center mm 500 500
5 Service Weight unloaded kg 3857 3857
Weights 6 loaded/unloaded, front kg 4342/1166 4342/1166
Axle Load
7 loaded/unloaded, rear kg 1515/2691 1515/2691
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 140 140
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12° 6°/12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 40 x 100 x 1070
 1-23
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2534 2534

24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 470 470
add load length and
28 Right Angle Stack mm 4012 4012
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 18/18.5 18/18.5
32 Lift Speed loaded/unloaded m/s 0.64/0.73 0.64/0.73
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4 0.5/0.4
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20/31 20/31
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Yanmar Yanmar
39 model 4TNE98 4TNE92
Systems 40 emission compliance EU Stage IIIA EU Stage IIIA
41 Engine cylinders 4 4
42 displacement liter 3.319 2.659
43 rated power kw/rpm 43/2300 31.2/2450
44 max. torque N.m/rpm 187/1600 149/1700
45 external radiation noise dB 102 102
Noise
46 driver`s ear noise dB 86 86
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.056 0.053
48 Fuel Consumption diesel or LPG
L/h 3.953 3.741

Machine specifications (CLG2020H/C)1-3

CLG2020H/C CLG2020H/C
1 Model (Mitsubishi (Mitsubishi
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 2000 2000
4 Load Center mm 500 500
5 Service Weight unloaded kg 3857 3857
Weights 6 loaded/unloaded, front kg 4342/1166 4345/1185
Axle Load
7 loaded/unloaded, rear kg 1515/2691 1512/2672
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1677
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
1-24
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

15 Max. Fork Height with std 2-stage mast mm 3000 3000

16 Freelift with std 2-stage mast mm 140 140
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12° 6°/12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 40 x 100 x 1070
23 Length to Fork Face with std 2-stage mast mm 2534 2556
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2301
Chassis 27 Fork Overhang with std 2-stage mast mm 470 470
add load length and
28 Right Angle Stack mm 4012 4033
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 15.5/16 15.5/16
32 Lift Speed loaded/unloaded m/s 0.58/0.62 0.58/0.64
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.44 0.51/0.41
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20/30 20/30
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Mitsubishi Mitsubishi
39 model S4S D04EG
Systems 40 emission compliance EU Stage IIIA EPA 4F
41 Engine cylinders 4 4
42 displacement liter 3.331 3.331
43 rated power kw/rpm 35.3/2250 36/2250
44 max. torque N.m/rpm 177/1700 177/1800
45 external radiation noise dB 104 102
Noise
46 driver`s ear noise dB 87 86
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.058 0.050
48 Fuel Consumption diesel or LPG
L/h 4.094 3.529
 1-25
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2025H/C)2-1

CLG2025H/C CLG2025H/C
1 Model (Cummins (Cummins
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 2500 2500
4 Load Center mm 500 500
5 Service Weight unloaded kg 3988 3988
Weights 6 loaded/unloaded, front kg 5159/1182 5159/1182
Axle Load
7 loaded/unloaded, rear kg 1329/2807 1329/2807
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 45 x 100 x 1070
23 Length to Fork Face with std 2-stage mast mm 2539 2539
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 475 475
add load length and
28 Right Angle Stack mm 4017 4017
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 18/18.5 18/18.5
32 Lift Speed loaded/unloaded m/s 0.7/0.73 0.7/0.73
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4 0.5/0.4
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 31 20 /31
1-26
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer Cummins Cummins
39 model QSF2.8T3NA49 QSF2.8T3NA60
Systems 40 emission compliance EU Stage IIIA EU Stage IIIA
41 Engine cylinders 4 4
42 displacement liter 2.8 2.8
43 rated power kw/rpm 36/2500 43/2500
44 max. torque N.m/rpm 186/1500 186/1500
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 89 89
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.056 0.056
48 Fuel Consumption diesel or LPG
L/h 3.953 3.953

Machine specifications (CLG2025H/C)2-2

CLG2025H/C CLG2025H/C
1 Model (Yanmar (Yanmar
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 2500 2500
4 Load Center mm 500 500
5 Service Weight unloaded kg 3988 3988
Weights 6 loaded/unloaded, front kg 5159/1182 5159/1182
Axle Load
7 loaded/unloaded, rear kg 1329/2807 1329/2807
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12° 6°/12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 45 x 100 x 1070
 1-27
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2539 2539

24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 475 475
add load length and
28 Right Angle Stack mm 4017 4017
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 18/18.5 18/18.5
32 Lift Speed loaded/unloaded m/s 0.64/0.73 0.64/0.73
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4 0.5/0.4
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20/31 20/31
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Yanmar Yanmar
39 model 4TNE98 4TNE92
Systems 40 emission compliance EU Stage IIIA EU Stage IIIA
41 Engine cylinders 4 4
42 displacement liter 3.319 2.659
43 rated power kw/rpm 43/2300 31.2/2450
44 max. torque N.m/rpm 187/1600 149/1700
45 external radiation noise dB 102 102
Noise
46 driver`s ear noise dB 86 86
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.059 0.056
48 Fuel Consumption diesel or LPG
L/h 4.165 3.953

Machine specifications (CLG2025H/C)2-3

CLG2025H/C CLG2025H/C
1 Model (Mitsubishi (Mitsubishi
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 2500 2500
4 Load Center mm 500 500
5 Service Weight unloaded kg 3988 3988
Weights 6 loaded/unloaded, front kg 5159/1182 5161/1203
Axle Load
7 loaded/unloaded, rear kg 1329/2807 1327/2785
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1677
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
1-28
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

15 Max. Fork Height with std 2-stage mast mm 3000 3000

16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12° 6°/12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 45 x 100 x 1070
23 Length to Fork Face with std 2-stage mast mm 2539 2561
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2301
Chassis 27 Fork Overhang with std 2-stage mast mm 475 475
add load length and
28 Right Angle Stack mm 4017 4038
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 15.5/16 15.5/16
32 Lift Speed loaded/unloaded m/s 0.58/0.62 0.58/0.64
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.44 0.51/0.41
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20/30 20/30
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Mitsubishi Mitsubishi
39 model S4S D04EG
Systems 40 emission compliance EU Stage IIIA EPA 4F
41 Engine cylinders 4 4
42 displacement liter 3.331 3.331
43 rated power kw/rpm 35.3/2250 36/2250
44 max. torque N.m/rpm 177/1700 177/1800
45 external radiation noise dB 104 102
Noise
46 driver`s ear noise dB 87 86
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.061 0.053
48 Fuel Consumption diesel or LPG
L/h 4.306 3.741
 1-29
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2030H/C)3-1

CLG2030H/C CLG2030H/C
1 Model (Cummins (Cummins
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 3000 3000
4 Load Center mm 500 500
5 Service Weight unloaded kg 4489 4489
Weights 6 loaded/unloaded, front kg 6323/1561 6323/1561
Axle Load
7 loaded/unloaded, rear kg 1166/2927 1166/2927
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 45 x 122 x 1070
23 Length to Fork Face with std 2-stage mast mm 2693 2693
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2400 2400
Chassis 27 Fork Overhang with std 2-stage mast mm 498 498
add load length and
28 Right Angle Stack mm 4147 4147
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18.5/19 18.5/19
32 Lift Speed loaded/unloaded m/s 0.58/0.59 0.58/0.59
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4 0.5/0.4
34 Max. Drawbar Pull loaded kg 1900 1900
35 Max. Gradeability loaded / unloaded % 20 / 31 20 /31
1-30
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer Cummins Cummins
39 model QSF2.8T3NA49 QSF2.8T3NA60
Systems 40 emission compliance EU Stage IIIA EU Stage IIIA
41 Engine cylinders 4 4
42 displacement liter 2.8 2.8
43 rated power kw/rpm 36/2500 43/2500
44 max. torque N.m/rpm 186/1500 186/1500
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 89 89
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.059 0.059
48 Fuel Consumption diesel or LPG
L/h 4.165 4.165

Machine specifications (CLG2030H/C)3-2

CLG2030H/C
1 Model
(Yanmar engine)
General
2 Power Type Diesel
3 Base Capacity rated load center kg 3000
4 Load Center mm 500
5 Service Weight unloaded kg 4489
Weights 6 loaded/unloaded, front kg 6323/1561
Axle Load
7 loaded/unloaded, rear kg 1166/2927
8 Tire Type Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79
10 Wheels front / rear 2/2
Tires 11 Wheelbase mm 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000
16 Freelift with std 2-stage mast mm 145
17 Height, Upright Lowered with std 2-stage mast mm 2210
18 Height, Upright Extended with std 2-stage mast mm 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12°
20 Carriage width mm 1100
21 Fork Spread minimum/maximum mm 272/1072
22 Fork Dimension TxWxL mm 45 x 122x 1070
 1-31
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2693

24 Overall Width mm 1225
25 Overhead Guard Height mm 2200
26 Turning Radius minimum outside mm 2400
Chassis 27 Fork Overhang with std 2-stage mast mm 498
add load length and
28 Right Angle Stack mm 4147
clearance
29 minimum loaded mm 105
Gound Clearance
30 center of wheelbase mm 165
31 Travel Speed loaded/unloaded km/h 18.5/19
32 Lift Speed loaded/unloaded m/s 0.53/0.59
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4
34 Max. Drawbar Pull loaded kg 1900
35 Max. Gradeability loaded / unloaded % 20/31
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Yanmar
39 model 4TNE98
Systems 40 emission compliance EU Stage IIIA
41 Engine cylinders 4
42 displacement liter 3.319
43 rated power kw/rpm 43/2300
44 max. torque N.m/rpm 187/1600
45 external radiation noise dB 102
Noise
46 driver`s ear noise dB 86
Others 47 Tank Capacity fuel/hydraulic L 60/60
kg/cycle 0.062
48 Fuel Consumption diesel or LPG
L/h 4.376

Machine specifications (CLG2030H/C)3-3

CLG2030H/C CLG2030H/C
1 Model (Mitsubishi (Mitsubishi
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 3000 3000
4 Load Center mm 500 500
5 Service Weight unloaded kg 4489 4489
Weights 6 loaded/unloaded, front kg 6323/1561 6316/1577
Axle Load
7 loaded/unloaded, rear kg 1166/2927 1173/2912
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1722
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
1-32
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

15 Max. Fork Height with std 2-stage mast mm 3000 3000

16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12° 6°/12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 45 x 122 x 1070
23 Length to Fork Face with std 2-stage mast mm 2693 2715
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2400 2421
Chassis 27 Fork Overhang with std 2-stage mast mm 498 498
add load length and
28 Right Angle Stack mm 4147 4168
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 16.5/17 16.5/17
32 Lift Speed loaded/unloaded m/s 0.47/0.5 0.46/0.51
Performance 33 Lower Speed loaded/unloaded m/s 0.52/0.44 0.51/0.41
34 Max. Drawbar Pull loaded kg 1720 1750
35 Max. Gradeability loaded / unloaded % 15/20 15/20
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Mitsubishi Mitsubishi
39 model S4S D04EG
Systems 40 emission compliance EU Stage IIIA EPA 4F
41 Engine cylinders 4 4
42 displacement liter 3.331 3.331
43 rated power kw/rpm 35.3/2250 36/2250
44 max. torque N.m/rpm 177/1700 177/1800
45 external radiation noise dB 104 102
Noise
46 driver`s ear noise dB 87 86
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.064 0.056
48 Fuel Consumption diesel or LPG
L/h 4.518 3.953
 1-33
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2035H/C)4-1

CLG2035H/C CLG2035H/C
1 Model (Cummins (Cummins
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 3500 3500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4916 4916
Weights 6 loaded/unloaded, front kg 7054/1489 7054/1489
Axle Load
7 loaded/unloaded, rear kg 1362/3427 1362/3427
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 150 150
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 50 x 122 x 1070
23 Length to Fork Face with std 2-stage mast mm 2753 2753
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2435 2435
Chassis 27 Fork Overhang with std 2-stage mast mm 503 503
add load length and
28 Right Angle Stack mm 4192 4192
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18.5/19 18.5/19
32 Lift Speed loaded/unloaded m/s 0.58/0.59 0.58/0.59
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4 0.5/0.4
34 Max. Drawbar Pull loaded kg 1900 1900
35 Max. Gradeability loaded / unloaded % 20 / 31 20 /31
1-34
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer Cummins Cummins
39 model QSF2.8T3NA49 QSF2.8T3NA60
Systems 40 emission compliance EU Stage IIIA EU Stage IIIA
41 Engine cylinders 4 4
42 displacement liter 2.8 2.8
43 rated power kw/rpm 36/2500 43/2500
44 max. torque N.m/rpm 186/1500 186/1500
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 89 89
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.062 0.062
48 Fuel Consumption diesel or LPG
L/h 4.376 4.376

Machine specifications (CLG2035H/C)4-2

CLG2035H/C
1 Model
(Yanmar engine)
General
2 Power Type Diesel
3 Base Capacity rated load center kg 3500
4 Load Center mm 500
5 Service Weight unloaded kg 4916
Weights 6 loaded/unloaded, front kg 7054/1489
Axle Load
7 loaded/unloaded, rear kg 1362/3427
8 Tire Type Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79
10 Wheels front / rear 2/2
Tires 11 Wheelbase mm 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000
16 Freelift with std 2-stage mast mm 150
17 Height, Upright Lowered with std 2-stage mast mm 2210
18 Height, Upright Extended with std 2-stage mast mm 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12°
20 Carriage width mm 1100
21 Fork Spread minimum/maximum mm 272/1072
22 Fork Dimension TxWxL mm 50x 122x 1070
 1-35
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2753

24 Overall Width mm 1225
25 Overhead Guard Height mm 2200
26 Turning Radius minimum outside mm 2435
Chassis 27 Fork Overhang with std 2-stage mast mm 503
add load length and
28 Right Angle Stack mm 4192
clearance
29 minimum loaded mm 105
Gound Clearance
30 center of wheelbase mm 165
31 Travel Speed loaded/unloaded km/h 18.5/19
32 Lift Speed loaded/unloaded m/s 0.53/0.59
Performance 33 Lower Speed loaded/unloaded m/s 0.5/0.4
34 Max. Drawbar Pull loaded kg 1900
35 Max. Gradeability loaded / unloaded % 20/31
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Yanmar
39 model 4TNE98
Systems 40 emission compliance EU Stage IIIA
41 Engine cylinders 4
42 displacement liter 3.319
43 rated power kw/rpm 43/2300
44 max. torque N.m/rpm 187/1600
45 external radiation noise dB 102
Noise
46 driver`s ear noise dB 86
Others 47 Tank Capacity fuel/hydraulic L 60/60
kg/cycle 0.065
48 Fuel Consumption diesel or LPG
L/h 4.588

Machine specifications (CLG2035H/C)4-3

CLG2035H/C CLG2035H/C
1 Model (Mitsubishi (Mitsubishi
General engine) engine)
2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 3500 3500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4916 4916
Weights 6 loaded/unloaded, front kg 7054/1489 7044/1506
Axle Load
7 loaded/unloaded, rear kg 1362/3427 1371/3410
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1722
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
1-36
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

15 Max. Fork Height with std 2-stage mast mm 3000 3000

16 Freelift with std 2-stage mast mm 150 150
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6°/12° 6°/12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 50 x 122 x 1070
23 Length to Fork Face with std 2-stage mast mm 2753 2775
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2435 2456
Chassis 27 Fork Overhang with std 2-stage mast mm 503 503
add load length and
28 Right Angle Stack mm 4192 4213
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 16.5/17 16.5/17
32 Lift Speed loaded/unloaded m/s 0.37/0.51 0.37/0.51
Performance 33 Lower Speed loaded/unloaded m/s 0.52/0.44 0.51/0.41
34 Max. Drawbar Pull loaded kg 1720 1750
35 Max. Gradeability loaded / unloaded % 15/20 15/20
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Mitsubishi Mitsubishi
39 model S4S D04EG
Systems 40 emission compliance EU Stage IIIA EPA 4F
41 Engine cylinders 4 4
42 displacement liter 3.331 3.331
43 rated power kw/rpm 35.3/2250 36/2250
44 max. torque N.m/rpm 177/1700 177/1800
45 external radiation noise dB 104 102
Noise
46 driver`s ear noise dB 87 86
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.067 0.059
48 Fuel Consumption diesel or LPG
L/h 4.729 4.165
 1-37
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2020G)5-1

CLG2020G CLG2020G
1 Model
(PSI engine) (PSI engine)
General
2 Power Type Gasoline/LPG Gasoline/LPG
3 Base Capacity rated load center kg 2000 2000
4 Load Center mm 500 500
5 Service Weight unloaded kg 3888 3888
Weights 6 loaded/unloaded, front kg 4407/1231 4407/1231
Axle Load
7 loaded/unloaded, rear kg 1482/2657 1482/2657
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 140 140
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 40 x 100x 1070
23 Length to Fork Face with std 2-stage mast mm 2534 2534
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 470 470
add load length and
28 Right Angle Stack mm 4012 4012
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 17/18 17/18
32 Lift Speed loaded/unloaded m/s 0.75/0.8 0.75/0.8
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.4
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 32 20 /32
1-38
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer PSI PSI
4G64(dual fuel)
4G64(dual fuel)
39 model (NON-
(CERTIFIED)
CERTIFIED)
Systems 40 emission compliance EPA 4F N/A
41 Engine cylinders 4 4
42 displacement liter 2.351 2.351
46/2700(LPG) 46/2700(LPG)
43 rated power kw/rpm
48/2700(GAS) 48/2700(GAS)
168/1600(LPG) 168/1600(LPG)
44 max. torque N.m/rpm
170/2400(GAS) 170/2400(GAS)
45 external radiation noise dB 101 101
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.071 0.071
48 Fuel Consumption diesel or LPG
L/h 5.917 5.917

Machine specifications (CLG2020G)5-2

CLG2020G CLG2020G
1 Model (Nissan
(PSI engine)
General engine)
2 Power Type LPG Gasoline/LPG
3 Base Capacity rated load center kg 2000 2000
4 Load Center mm 500 500
5 Service Weight unloaded kg 3888 3888
Weights 6 loaded/unloaded, front kg 4407/1231 4407/1231
Axle Load
7 loaded/unloaded, rear kg 1482/2657 1482/2657
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 140 140
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 40 x 100x 1070
 1-39
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2534 2534

24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 470 470
add load length and
28 Right Angle Stack mm 4012 4012
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 17/18 16/17
32 Lift Speed loaded/unloaded m/s 0.75/0.8 0.52/0.65
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.43
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 32 20 /32
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer PSI Nissan
4G64
39 model (single fuel) K25
(CERTIFIED)
Systems
40 emission compliance EPA 4F N/A
Engine
41 cylinders 4 4
42 displacement liter 2.351 2.488
35.9/2300(LPG)
43 rated power kw/rpm 46/2700(LPG)
37.4/2300(GAS)
44 max. torque N.m/rpm 168/1600(LPG) 176.5/1600
45 external radiation noise dB 101 99
Noise
46 driver`s ear noise dB 85 83
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.071 0.064
48 Fuel Consumption diesel or LPG
L/h 5.917 5.333

Machine specifications (CLG2020G)5-3

CLG2020G CLG2020G
1 Model (Kubota (Kubota
General engine) engine)
2 Power Type Gasoline/LPG LPG
3 Base Capacity rated load center kg 2000 2000
4 Load Center mm 500 500
5 Service Weight unloaded kg 3888 3888
Weights 6 loaded/unloaded, front kg 4407/1231 4407/1231
Axle Load
7 loaded/unloaded, rear kg 1482/2657 1482/2657
1-40
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

8 Tire Type Pneumatic Pneumatic

9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 140 140
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 40 x 100x 1070
23 Length to Fork Face with std 2-stage mast mm 2534 2534
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 470 470
add load length and
28 Right Angle Stack mm 4012 4012
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 16/17 16/17
32 Lift Speed loaded/unloaded m/s 0.67/0.7 0.67/0.7
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.47 0.51/0.47
34 Max. Drawbar Pull loaded kg 1900 1900
35 Max. Gradeability loaded / unloaded % 20/30 20/30
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Kubota Kubota
39 model WG2503-GL-E3 WG2503-L-E3
EPA EPA
40 emission compliance
Systems EU Stage 5A EU Stage 5A
41 Engine cylinders 4 4
42 displacement liter 2.491 2.491
43 rated power kw/rpm 41.3/2600 41.3/2600(LPG)
175/1200(LPG)
44 max. torque N.m/rpm 167.6/ 175/1200(LPG)
1800(GAS)
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.049 0.049
48 Fuel Consumption diesel or LPG
L/h 4.083 4.083
 1-41
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

achine specifications (CLG2025G)6-1

CLG2025G CLG2025G
1 Model
(PSI engine) (PSI engine)
General
2 Power Type Gasoline/LPG Gasoline/LPG
3 Base Capacity rated load center kg 2500 2500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4020 4020
Weights 6 loaded/unloaded, front kg 5223/1246 5223/1246
Axle Load
7 loaded/unloaded, rear kg 1296/2773 1296/2773
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 45x 100x 1070
23 Length to Fork Face with std 2-stage mast mm 2539 2539
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 475 475
add load length and
28 Right Angle Stack mm 4017 4017
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 17/18 17/18
32 Lift Speed loaded/unloaded m/s 0.75/0.8 0.75/0.8
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.4
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 32 20 /32
1-42
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer PSI PSI
4G64(dual fuel)
4G64(dual fuel)
39 model (NON-
(CERTIFIED)
CERTIFIED)
Systems 40 emission compliance EPA 4F N/A
41 Engine cylinders 4 4
42 displacement liter 2.351 2.351
46/2700(LPG) 46/2700(LPG)
43 rated power kw/rpm
48/2700(GAS) 48/2700(GAS)
168/1600(LPG) 168/1600(LPG)
44 max. torque N.m/rpm
170/2400(GAS) 170/2400(GAS)
45 external radiation noise dB 101 101
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.074 0.074
48 Fuel Consumption diesel or LPG
L/h 6.167 6.167

Machine specifications (CLG2025G)6-2

CLG2025G CLG2025G
1 Model (Nissan
(PSI engine)
General engine)
2 Power Type LPG Gasoline/LPG
3 Base Capacity rated load center kg 2500 2500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4020 4020
Weights 6 loaded/unloaded, front kg 5223/1246 5223/1246
Axle Load
7 loaded/unloaded, rear kg 1296/2773 1296/2773
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 45x 100x 1070
 1-43
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2539 2539

24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 475 475
add load length and
28 Right Angle Stack mm 4017 4017
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 17/18 16/17
32 Lift Speed loaded/unloaded m/s 0.75/0.8 0.52/0.65
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.43
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 32 20 /25
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer PSI Nissan
4G64
39 model (single fuel) K25
(CERTIFIED)
Systems
40 emission compliance EPA 4F N/A
Engine
41 cylinders 4 4
42 displacement liter 2.351 2.488
35.9/2300(LPG)
43 rated power kw/rpm 46/2700(LPG)
37.4/2300(GAS)
44 max. torque N.m/rpm 168/1600(LPG) 176.5/1600
45 external radiation noise dB 101 99
Noise
46 driver`s ear noise dB 85 83
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.074 0.067
48 Fuel Consumption diesel or LPG
L/h 6.167 5.583

Machine specifications (CLG2025G)6-3

CLG2025G CLG2025G
1 Model (Kubota (Kubota
General engine) engine)
2 Power Type Gasoline/LPG LPG
3 Base Capacity rated load center kg 2500 2500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4020 4020
Weights 6 loaded/unloaded, front kg 5223/1246 5223/1246
Axle Load
7 loaded/unloaded, rear kg 1296/2773 1296/2773
1-44
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

8 Tire Type Pneumatic Pneumatic

9 Tire Pressure front / rear MPa 0.86/0.86 0.86/0.86
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1650 1650
12 front 7.0-12-12PR
Tire Size
13 rear 6.00-9-10PR
14 Tread Width front/rear mm 960/992 960/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2193 2193
18 Height, Upright Extended with std 2-stage mast mm 4076 4076
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1040 1040
21 Fork Spread minimum/maximum mm 230/1010 230/1010
22 Fork Dimension TxWxL mm 45x 100x 1070
23 Length to Fork Face with std 2-stage mast mm 2539 2539
24 Overall Width mm 1150 1150
25 Overhead Guard Height mm 2180 2180
26 Turning Radius minimum outside mm 2280 2280
Chassis 27 Fork Overhang with std 2-stage mast mm 475 475
add load length and
28 Right Angle Stack mm 4017 4017
clearance
29 minimum loaded mm 88 88
Gound Clearance
30 center of wheelbase mm 145 145
31 Travel Speed loaded/unloaded km/h 16/17 16/17
32 Lift Speed loaded/unloaded m/s 0.67/0.7 0.67/0.7
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.47 0.51/0.47
34 Max. Drawbar Pull loaded kg 1900 1900
35 Max. Gradeability loaded / unloaded % 20/30 20/30
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Kubota Kubota
39 model WG2503-GL-E3 WG2503-L-E3
EPA EPA
40 emission compliance
Systems EU Stage 5A EU Stage 5A
41 Engine cylinders 4 4
42 displacement liter 2.491 2.491
43 rated power kw/rpm 41.3/2600 41.3/2600(LPG)
175/1200(LPG)
44 max. torque N.m/rpm 167.6/ 175/1200(LPG)
1800(GAS)
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.052 0.052
48 Fuel Consumption diesel or LPG
L/h 4.333 4.333
 1-45
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2030G)7-1

CLG2030G CLG2030G
1 Model
(PSI engine) (PSI engine)
General
2 Power Type Gasoline/LPG Gasoline/LPG
3 Base Capacity rated load center kg 3000 3000
4 Load Center mm 500 500
5 Service Weight unloaded kg 4520 4520
Weights 6 loaded/unloaded, front kg 6386/1625 6386/1625
Axle Load
7 loaded/unloaded, rear kg 1134/2895 1134/2895
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 45x 122x 1070
23 Length to Fork Face with std 2-stage mast mm 2693 2693
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2400 2400
Chassis 27 Fork Overhang with std 2-stage mast mm 498 498
add load length and
28 Right Angle Stack mm 4147 4147
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18/19 18/19
32 Lift Speed loaded/unloaded m/s 0.6/0.64 0.6/0.64
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.4
34 Max. Drawbar Pull loaded kg 1700 1700
35 Max. Gradeability loaded / unloaded % 18/20 18/20
1-46
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer PSI PSI
4G64(dual fuel)
4G64(dual fuel)
39 model (NON-
(CERTIFIED)
CERTIFIED)
Systems 40 emission compliance EPA 4F N/A
41 Engine cylinders 4 4
42 displacement liter 2.351 2.351
46/2700(LPG) 46/2700(LPG)
43 rated power kw/rpm
48/2700(GAS) 48/2700(GAS)
168/1600(LPG) 168/1600(LPG)
44 max. torque N.m/rpm
170/2400(GAS) 170/2400(GAS)
45 external radiation noise dB 101 101
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.077 0.077
48 Fuel Consumption diesel or LPG
L/h 6.417 6.417

Machine specifications (CLG2030G)7-2

CLG2030G CLG2030G
1 Model (Nissan
(PSI engine)
General engine)
2 Power Type LPG Gasoline/LPG
3 Base Capacity rated load center kg 3000 3000
4 Load Center mm 500 500
5 Service Weight unloaded kg 4520 4520
Weights 6 loaded/unloaded, front kg 6386/1625 6386/1625
Axle Load
7 loaded/unloaded, rear kg 1134/2895 1134/2895
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 45x 122x 1070
 1-47
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2693 2693

24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2400 2400
Chassis 27 Fork Overhang with std 2-stage mast mm 498 498
add load length and
28 Right Angle Stack mm 4147 4147
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18/19 18/19.5
32 Lift Speed loaded/unloaded m/s 0.75/0.8 0.52/0.65
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.43
34 Max. Drawbar Pull loaded kg 1800 1800
35 Max. Gradeability loaded / unloaded % 20 / 32 20 /25
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer PSI Nissan
4G64
39 model (single fuel) K25
(CERTIFIED)
Systems
40 emission compliance EPA 4F N/A
Engine
41 cylinders 4 4
42 displacement liter 2.351 2.488
35.9/2300(LPG)
43 rated power kw/rpm 46/2700(LPG)
37.4/2300(GAS)
44 max. torque N.m/rpm 168/1600(LPG) 176.5/1600
45 external radiation noise dB 101 99
Noise
46 driver`s ear noise dB 85 83
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.077 0.07
48 Fuel Consumption diesel or LPG
L/h 6.417 5.833

Machine specifications (CLG2030G)7-3

CLG2030G CLG2030G
1 Model (Kubota (Kubota
General engine) engine)
2 Power Type Gasoline/LPG LPG
3 Base Capacity rated load center kg 3000 3000
4 Load Center mm 500 500
5 Service Weight unloaded kg 4520 4520
Weights 6 loaded/unloaded, front kg 6386/1625 6386/1625
Axle Load
7 loaded/unloaded, rear kg 1134/2895 1134/2895
1-48
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

8 Tire Type Pneumatic Pneumatic

9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 145 145
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 45x 122x 1070
23 Length to Fork Face with std 2-stage mast mm 2693 2693
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2400 2400
Chassis 27 Fork Overhang with std 2-stage mast mm 498 498
add load length and
28 Right Angle Stack mm 4147 4147
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18/19 18/19
32 Lift Speed loaded/unloaded m/s 0.53/0.56 0.53/0.56
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.47 0.51/0.47
34 Max. Drawbar Pull loaded kg 1750 1750
35 Max. Gradeability loaded / unloaded % 18/22 18/22
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Kubota Kubota
39 model WG2503-GL-E3 WG2503-L-E3
EPA EPA
40 emission compliance
Systems EU Stage 5A EU Stage 5A
41 Engine cylinders 4 4
42 displacement liter 2.491 2.491
43 rated power kw/rpm 41.3/2600 41.3/2600(LPG)
175/1200(LPG)
44 max. torque N.m/rpm 167.6/ 175/1200(LPG)
1800(GAS)
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.055 0.055
48 Fuel Consumption diesel or LPG
L/h 4.583 4.583
 1-49
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Machine specifications (CLG2035G)8-1

CLG2035G CLG2035G
1 Model
(PSI engine) (PSI engine)
General
2 Power Type Gasoline/LPG Gasoline/LPG
3 Base Capacity rated load center kg 3500 3500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4947 4947
Weights 6 loaded/unloaded, front kg 7118/1553 7118/1553
Axle Load
7 loaded/unloaded, rear kg 1329/3394 1329/3394
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 150 150
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 50x 122x 1070
23 Length to Fork Face with std 2-stage mast mm 2753 2753
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2435 2435
Chassis 27 Fork Overhang with std 2-stage mast mm 503 503
add load length and
28 Right Angle Stack mm 4192 4192
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18/19 18/19
32 Lift Speed loaded/unloaded m/s 0.6/0.64 0.6/0.64
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.4
34 Max. Drawbar Pull loaded kg 1700 1700
35 Max. Gradeability loaded / unloaded % 18/20 18/20
1-50
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

36 service Foot / Hyd

Brakes
37 parking Hand / Mech
38 manufacturer PSI PSI
4G64(dual fuel)
4G64(dual fuel)
39 model (NON-
(CERTIFIED)
CERTIFIED)
Systems 40 emission compliance EPA 4F N/A
41 Engine cylinders 4 4
42 displacement liter 2.351 2.351
46/2700(LPG) 46/2700(LPG)
43 rated power kw/rpm
48/2700(GAS) 48/2700(GAS)
168/1600(LPG) 168/1600(LPG)
44 max. torque N.m/rpm
170/2400(GAS) 170/2400(GAS)
45 external radiation noise dB 101 101
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.08 0.08
48 Fuel Consumption diesel or LPG
L/h 6.667 6.667

Machine specifications (CLG2035G)8-2

CLG2035G CLG2035G
1 Model (Nissan
(PSI engine)
General engine)
2 Power Type LPG Gasoline/LPG
3 Base Capacity rated load center kg 3500 3500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4947 4947
Weights 6 loaded/unloaded, front kg 7118/1553 7118/1553
Axle Load
7 loaded/unloaded, rear kg 1329/3394 1329/3394
8 Tire Type Pneumatic Pneumatic
9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 150 150
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 50x 122x 1070
 1-51
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

23 Length to Fork Face with std 2-stage mast mm 2753 2753

24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2435 2435
Chassis 27 Fork Overhang with std 2-stage mast mm 503 503
add load length and
28 Right Angle Stack mm 4192 4192
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18/19 18/19.5
32 Lift Speed loaded/unloaded m/s 0.6/0.64 0.43/0.54
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.4 0.51/0.43
34 Max. Drawbar Pull loaded kg 1700 1550
35 Max. Gradeability loaded / unloaded % 18/20 15/22
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer PSI Nissan
4G64
39 model (single fuel) K25
(CERTIFIED)
Systems
40 emission compliance EPA 4F N/A
Engine
41 cylinders 4 4
42 displacement liter 2.351 2.488
35.9/2300(LPG)
43 rated power kw/rpm 46/2700(LPG)
37.4/2300(GAS)
44 max. torque N.m/rpm 168/1600(LPG) 176.5/1600
45 external radiation noise dB 101 99
Noise
46 driver`s ear noise dB 85 83
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.008 0.073
48 Fuel Consumption diesel or LPG
L/h 6.667 6.083

Machine specifications (CLG2035G)8-3

CLG2035G CLG2035G
1 Model (Kubota (Kubota
General engine) engine)
2 Power Type Gasoline/LPG LPG
3 Base Capacity rated load center kg 3500 3500
4 Load Center mm 500 500
5 Service Weight unloaded kg 4947 4947
Weights 6 loaded/unloaded, front kg 7118/1553 7118/1553
Axle Load
7 loaded/unloaded, rear kg 1329/3394 1329/3394
1-52
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

8 Tire Type Pneumatic Pneumatic

9 Tire Pressure front / rear MPa 0.97/0.79 0.97/0.79
10 Wheels front / rear 2/2 2/2
Tires 11 Wheelbase mm 1700 1700
12 front 28x9-15-14PR
Tire Size
13 rear 6.5-10-10PR
14 Tread Width front/rear mm 1000/992 1000/992
15 Max. Fork Height with std 2-stage mast mm 3000 3000
16 Freelift with std 2-stage mast mm 150 150
17 Height, Upright Lowered with std 2-stage mast mm 2210 2210
18 Height, Upright Extended with std 2-stage mast mm 4046 4046
Mast
19 Mast Tilt, Fwd/Back with std 2-stage mast deg 6° / 12° 6° / 12°
20 Carriage width mm 1100 1100
21 Fork Spread minimum/maximum mm 272/1072 272/1072
22 Fork Dimension TxWxL mm 50x 122x 1070
23 Length to Fork Face with std 2-stage mast mm 2753 2753
24 Overall Width mm 1225 1225
25 Overhead Guard Height mm 2200 2200
26 Turning Radius minimum outside mm 2435 2435
Chassis 27 Fork Overhang with std 2-stage mast mm 503 503
add load length and
28 Right Angle Stack mm 4192 4192
clearance
29 minimum loaded mm 105 105
Gound Clearance
30 center of wheelbase mm 165 165
31 Travel Speed loaded/unloaded km/h 18/19 18/19
32 Lift Speed loaded/unloaded m/s 0.53/0.56 0.53/0.56
Performance 33 Lower Speed loaded/unloaded m/s 0.51/0.47 0.51/0.47
34 Max. Drawbar Pull loaded kg 1750 1750
35 Max. Gradeability loaded / unloaded % 18/22 18/22
36 service Foot / Hyd
Brakes
37 parking Hand / Mech
38 manufacturer Kubota Kubota
39 model WG2503-GL-E3 WG2503-L-E3
EPA EPA
40 emission compliance
Systems EU Stage 5A EU Stage 5A
41 Engine cylinders 4 4
42 displacement liter 2.491 2.491
43 rated power kw/rpm 41.3/2600 41.3/2600(LPG)
175/1200(LPG)
44 max. torque N.m/rpm 167.6/ 175/1200(LPG)
1800(GAS)
45 external radiation noise dB 103 103
Noise
46 driver`s ear noise dB 85 85
Others 47 Tank Capacity fuel/hydraulic L 60/60 60/60
kg/cycle 0.058 0.058
48 Fuel Consumption diesel or LPG
L/h 4.833 4.833
 1-53
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Main parts specifications 1

Item Specifications
Manufacturer Cummins Cummins Yanmar Yanmar Nissan
QSF2.8T3NA4
Model QSF2.8T3NA60 4TEN92 4TEN98 k25
9
4-stroke, direct
4-stroke, direct Vertical type, in-
injection, 4-stroke, 4-stroke,
Type injection, line, 4-stroke,
overhead overhead valve overhead valve
overhead valve self-suction
valve
Type of cooling Water cooling Water cooling Water cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder bore.×
Φ94×100 Φ94×100 Φ98×110 Φ98×110 Φ89×100
stroke(mm)
Capacity(L) 2. 8 2.8 3.319 3.319 2.488
Compression ratio 18.6 :1 18.6 :1 20 :1 20 :1 8.7:1
Engine Rated power(kw/ 35.9/2300(LPG)
36/2500 43/2500 42.1/2300 32.8/2450
rpm) 37.4/2300(GAS)
Max. torque(N.m/
186 /1500 186 /1500 187 /1600 149/1700 176.5/1600
rpm)
Diesel engine net
234 234 225 225 150
weight(kg)
Max. speed
2675 2675 2625 2725 3100
(unload)(rpm)
875(LPG)
Idle speed(rpm) 700 700 850 850
975(GAS)
Start motor 12V-3kw 12V-3kw 12V-2.3kw 12V-2.3kw 12V-1.2kw
Generator 14V-70A 14V-70A 12V-40A 12V-40A 12V-50A
Emission
EU Stage IIIA EU Stage IIIA EU Stage IIIA EU Stage IIIA N/A
compliance
1-54
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

Item Specifications
Pump(mL/r) 32 32 32 32 28
System maximum
83.2 83.2 83.9 83.9 86.7
flow(L/min)
Main overflow
valve set 19.5
pressure(MPa)
Switch-over
overflow valve set 12
pressure(MPa)

Hydraulic Lifting cylinder

System quantity, bore × rod 2- Φ 50 ×Φ 40 × 1495 (2T, 2.5T standard configuration)
diameter × 2- Φ 56 ×Φ 45 × 1495 (3T, 3.5T standard configuration)
stroke(mm)
Lifting cylinder
when retracted
limited speed
Tilting cylinder
quantity, bore × rod
2- Φ 80 ×Φ 35 × 143mm (standard configuration)
diameter ×
stroke(mm)
Tilting cylinder
when stretched out
front titling selflock
Manufacturer Jindao
Model YD30L
Type solenoid valve shift hydraulic transmission
Gear ratio(forward) F1：1.244
Gear ratio(reverse) R1：1.244
Gear ratio of PTO
Transmi- 1
port
ssion
Torque converter YJH265
Main oil
0.9~1.1
pressure(MPa)
Torque converter
inlet 0.3~0.7
pressure(MPa)
Net weight(kg) 108
Manufacturer Jindao
Model CQ30L
Drive Final drive ratio 14.224
axle Maximum static
7160
load(kg)
Brake drum brake/Φ 314
Model BA31750T
Battery Voltage/Capacity 12V/93AH
Full current CCA 750A
 1-55
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Main parts specifications 2

Item Specifications
Manufacturer Mitsubishi Mitsubishi PSI PSI PSI
4G64
4G64 4G64
(dual fuel)
Model S4S D04EG (dual fuel) (single fuel)
(NON-
(CERTIFIED) (CERTIFIED)
CERTIFIED)
4-stroke,
overhead
4-stroke, 4-stroke, 4-stroke,
4-stroke, in- valve,in-
electrical electrical electrical
Type line, overhead line,direct
injection, injection, injection,
cylinder injection,
overhead valve overhead valve overhead valve
electrical
injection
Type of cooling Water cooling Water cooling Water cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder bore.×
Φ94×120 Φ94×120 Φ86.5×100 Φ86.5×100 Φ86.5×100
stroke(mm)
Engine
Capacity(L) 3.331 3.331 2.351 2.351 2.351
Compression ratio 22:1 17.5 :1 9.5 :1 9.5 :1 9.5 :1
Rated power(kw/ 46/2700(LPG) 46/2700(LPG)
35.3/2250 36/2250 46/2700(LPG)
rpm) 48/2700(GAS) 48/2700(GAS)
Max. torque(N.m/ 168/1600(LPG) 168/1600(LPG)
177 /1700 177 /1800 168/1600(LPG)
rpm) 170/2400(GAS) 170/2400(GAS)
Diesel engine net
245 260 220 220 220
weight(kg)
Max. speed
2480 2475 2700 2700 2700
(unload)(rpm)
Idle speed(rpm) 770 770 750 750 750
Start motor 12V-2.2kw 12V-2.2kw 12V-1.2kw 12V-1.2kw 12V-1.2kw
Generator 12V-50A 12V-50A 14V-70A 14V-70A 14V-70A
Emission
EU Stage IIIA EPA 4F EPA 4F N/A EPA 4F
compliance
1-56
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

Item Specifications
Pump(mL/r) 32 32 32 32 28
System maximum
79.2 79.2 86.4 86.4 86.4
flow(L/min)
Main overflow
valve set 19.5
pressure(MPa)
Switch-over
overflow valve set 12
pressure(MPa)

Hydraulic Lifting cylinder

System quantity, bore × rod 2- Φ 50 ×Φ 40 × 1495 (2T, 2.5T standard configuration)
diameter × 2- Φ 56 ×Φ 45 × 1495 (3T, 3.5T standard configuration)
stroke(mm)
Lifting cylinder
when retracted
limited speed
Tilting cylinder
quantity, bore × rod
2- Φ 80 ×Φ 35 × 143mm (standard configuration)
diameter ×
stroke(mm)
Tilting cylinder
when stretched out
front titling selflock
Manufacturer Jindao
Model YD30L
Type solenoid valve shift hydraulic transmission
Gear ratio(forward) F1：1.244
Gear ratio(reverse) R1：1.244
Gear ratio of PTO
Transmi- 1
port
ssion
Torque converter YJH265
Main oil
0.9~1.1
pressure(MPa)
Torque converter
inlet 0.3~0.7
pressure(MPa)
Net weight(kg) 108
Manufacturer Jindao
Model CQ30L
Drive Final drive ratio 14.224
axle Maximum static
7160
load(kg)
Brake drum brake/Φ 314
Model BA31750T
Battery Voltage/Capacity 12V/93AH
Full current CCA 750A
 1-57
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Main parts specifications 3

Item Specifications
Manufacturer Kubota Kubota
Model WG2503-GL-E3-LGF-1(dual fuel) WG2503-L-E3-LGF-1(single fuel)
Type 4-stroke, direct injection 4-stroke, direct injection
Type of cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-3-4-2
Cylinder bore.×
Φ88×102.4 Φ88×102.4
stroke(mm)
Capacity(L) 2.491 2.491
Compression ratio 9.2:1 9.2:1
Rated power(kw/
41.3/2600 41.3/2600(LPG)
Engine rpm)
Max. torque(N.m/ 175/1200(LPG)
175/1200(LPG)
rpm) 167.6/1800(GAS
Diesel engine net
212 211
weight(kg)
Max. speed
2700 2700
(unload)(rpm)
Idle speed(rpm) 800 800
Start motor 12V-2.0kW 12V-2.0kW
Generator 12V-60A 12V-60A
Emission EPA/CARB Tier3 EPA/CARB Tier3
compliance EU StageV EU StageV
Pump(mL/r) 32 32
System maximum
86.4 86.4
flow(L/min)
Main overflow
valve set 19.5
pressure(MPa)
Switch-over
overflow valve set 12
pressure(MPa)

Hydraulic Lifting cylinder

System quantity, bore × rod 2- Φ 50 ×Φ 40 × 1495 (2T, 2.5T standard configuration)
diameter × 2- Φ 56 ×Φ 45 × 1495 (3T, 3.5T standard configuration)
stroke(mm)
Lifting cylinder
when retracted
limited speed
Tilting cylinder
quantity, bore × rod
2- Φ 80 ×Φ 35 × 143mm (standard configuration)
diameter ×
stroke(mm)
Tilting cylinder
when stretched out
front titling selflock
1-58
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

Item Specifications
Manufacturer Jindao
Model YD30L
Type solenoid valve shift hydraulic transmission
Gear ratio(forward) F1：1.244
Gear ratio(reverse) R1：1.244
Gear ratio of PTO
Transmi- 1
port
ssion
Torque converter YJH265
Main oil
0.9~1.1
pressure(MPa)
Torque converter
inlet 0.3~0.7
pressure(MPa)
Net weight(kg) 108
Manufacturer Jindao
Model CQ30L
Drive Final drive ratio 14.224
axle Maximum static
7160
load(kg)
Brake drum brake/Φ 314
Model BA31750T
Battery Voltage/Capacity 12V/93AH
Full current CCA 750A
 1-59
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

Work Scope

Operate the machine according to the rated load capacity in the load curve chart.

(The load chart used for CLG2020HC / CLG2020G forklift without sideshifter.)
1-60
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

(The load chart used for CLG2020HC / CLG2020G forklift with sideshifter.)
 1-61
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

(The load chart used for CLG2025HC / CLG2025G forklift without sideshifter.)
1-62
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

(The load chart used for CLG2025HC / CLG2025G forklift with sideshifter.)
 1-63
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

(The load chart used for CLG2030HC / CLG2030G forklift without sideshifter.)
1-64
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

(The load chart used for CLG2030HC / CLG2030G forklift with sideshifter.)
 1-65
November 2, 2020 Main Specifications
CLG2020H/C-2035H/C,CLG2020G-2035G Applications

(The load chart used for CLG2035HC / CLG2035G forklift without sideshifter.)
1-66
Main Specifications November 2, 2020
Applications CLG2020H/C-2035H/C,CLG2020G-2035G

(The load chart used for CLG2035HC / CLG2035G forklift with sideshifter.)
 2-1
November 2, 2020 Power System
CLG2020H/C-2035H/C,CLG2020G-2035G

Power System
Basic Information ............................................................................................................2-3
Safety .....................................................................................................................................................2-3

System Overview.............................................................................................................2-4
Structure and Function ...................................................................................................2-5
Engine System .......................................................................................................................................2-5
Brief Introduction of Function .............................................................................................................2-5
Main Technical Parameters of Engine .............................................................................................2-6
Air Intake System ...................................................................................................................................2-9
Brief Introduction of Function .............................................................................................................2-9
Schematic ..........................................................................................................................................2-9
Brief Introduction of Exhaust System Function ....................................................................................2-10
Cooling System ....................................................................................................................................2-10
Brief Introduction of Function ...........................................................................................................2-10
Schematic ........................................................................................................................................2-11
Brief Introduction of Fuel System Function ..........................................................................................2-11

Recommended Oil and Oil Change Cycle ...................................................................2-12

Removal and Installation ..............................................................................................2-13
Special Tools and Tooling Catalog ......................................................................................................2-13
Removal and Installation......................................................................................................................2-13
Engine ..............................................................................................................................................2-13
Air filter .............................................................................................................................................2-16
Muffler Assembly..............................................................................................................................2-19
Radiator Assembly ...........................................................................................................................2-22
Fuel Tank Cover Plate .....................................................................................................................2-25

Faults and Countermeasures .......................................................................................2-27

2-2
Power System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 2-3
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Safety

Basic Information Preventing Burns

After running for some time, parts of the machine

Safety will be hot,such as, engine, DPF (Diesel
Particulate Filter) and inter-cooler steel pipe,
those parts which are cooled down later shall be
Compressed Air inspected or repaired.
Compressed air may cause personal injury.
When using the compressed air for cleaning,
wear the mask, protection suits and shoes. The
maximum pressure of the compressed air for
cleaning should be lower than 0.2MPa.

Safe Disposal of Waste Fluids

P11000148
Improper treatment of waste engine oil, waste
diesel and waste DEF is harmful to environment
and ecosystem. Treatment shall conform with the Coolant
local laws and regulations.
At working temperature, the coolant of the
It is mandatory and necessary to collect the engine is at high temperature and has pressure,
liquid with containers spattered during the the radiator and all the pipes connected to the
inspection, maintenance, test, adjustment and radiator contain hot water or vapor, if you touch
repair of machine. Proper container shall be them, serious burn would occur.
prepared well before opening any fluid cavity or
disassembling the parts containing liquid. Use When checking the coolant level, the engine
proper container when draining liquid. shall be shut off and the filler cap shall be cooled
to the extent that it can be opened by bare
Do not use the food or drink containers because hands. Slowly loosen the filler cap of cooling
the fluid in it may be drunk by others by mistake. system to release the pressure.
Coolant contains alkali which may causing injury
and do not let it contact your skin, eyes and
mouth.

P19M00059

P11000147
2-4
System Overview November 2, 2020
Safety CLG2020H/C-2035H/C,CLG2020G-2035G

Fire & Explosion Prevention System Overview

All fuels, most lubricants and some coolants are
flammables. The function of the power system is: supplying
the machine with the mechanical energy
Fuel leaking onto the hot surface or electrical
converted from the chemical energy of fuel.
elements may cause fire.
Power system consists of engine system, air
Do not smoke when refilling or within refiling intake system, exhaust system, cooling system
area, and in the place storing flammables. and fuel system.
Power system composition diagram (take
Cummins as an example)

3
P11000157

Store the fuel, lubricant into containers with

relevant marks to avoid use by non-working
personnel.
Put the cleaning cloth soaked with oil or other
combustible materials into protective container,
and set it at a safe place. 2
4
Do not perform welding or flame cutting onto the
pipe containing flammable liquid. Before welding
or cutting, flammable liquid shall be cleaned up.
Accumulated flammable materials such as fuel,
lubricant or other scattered materials on the
machine shall be cleaned up.

Diethyl Ether

5
Do not use diethyl ether to start the engine.
1
Any approach which attempts to start the engine P22P00001
by use of diethyl ether may cause serious
damage to engine or casualties. 1. Engine system
2. Air intake system
3. Exhaust system
4. Cooling system
5. Fuel System

P11000158
 2-5
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Engine System

Structure and Function

Engine System

Brief Introduction of Function

Engine system mainly comprises engine, engine cradle, shock cushion, support and fan, etc. Engine is
the core of the power system, and provides driving power for the machine. In the engine system, the
engine is fixed on complete machine by the engine mounting which is composed of mounting bracket
and shock absorber; with shock isolating action of the shock absorber, the engine can work under
excellent environment, meanwhile, vibration of engine transferred to complete machine is reduced so as
to improve the riding comfort. The fan, driven directly by engine, provides enough wind for cooling
system for the purpose of cooling.
Engine system composition diagram (take Cummins as an example)

4
2
3
P22P00002

1. Engine 4. Support
2. Engine cradle 5. Fan
3. Shock cushion
2-6
Structure and Function November 2, 2020
Engine System CLG2020H/C-2035H/C,CLG2020G-2035G

Main Technical Parameters of Engine

Compon
Items Technical specifications
ents
QSF2.8T3NA4
Model QSF2.8T3NA60 4TEN92 4TEN98 k25
9
4-stroke, direct
4-stroke, direct Vertical type, in-
injection, 4-stroke, 4-stroke,
Type injection, line, 4-stroke,
overhead overhead valve overhead valve
overhead valve self-suction
valve
Type of cooling Water cooling Water cooling Water cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder bore.×
Φ94×100 Φ94×100 Φ98×110 Φ98×110 Φ89×100
stroke(mm)
Capacity(L) 2. 8 2.8 3.319 3.319 2.488
Compression ratio 18.6 :1 18.6 :1 20 :1 20 :1 8.7:1
Rated power(kw/ 35.9/2300(LPG)
Engine 36/2500 43/2500 42.1/2300 32.8/2450
rpm) 37.4/2300(GAS)
Max. torque(N.m/
186 /1500 186 /1500 187 /1600 149/1700 176.5/1600
rpm)
Engine net
234 234 225 225 150
weight(kg)
Max. speed
2675 2675 2625 2725 3100
(unload)(rpm)
875(LPG)
Idle speed(rpm) 700 700 850 850
975(GAS)
Start motor 12V-3kw 12V-3kw 12V-2.3kw 12V-2.3kw 12V-1.2kw
Generator 14V-70A 14V-70A 12V-40A 12V-40A 12V-50A
Emission
EU Stage IIIA EU Stage IIIA EU Stage IIIA EU Stage IIIA N/A
compliance
 2-7
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Engine System

Compon
ents
Items Specifications

4G64
4G64 4G64
(dual fuel)
Model S4S D04EG (dual fuel) (single fuel)
(NON-
(CERTIFIED) (CERTIFIED)
CERTIFIED)
4-stroke,
overhead
4-stroke, 4-stroke, 4-stroke,
4-stroke, in- valve,in-
electrical electrical electrical
Type line, overhead line,direct
injection, injection, injection,
cylinder injection,
overhead valve overhead valve overhead valve
electrical
injection
Type of cooling Water cooling Water cooling Water cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder bore.×
Φ94×120 Φ94×120 Φ86.5×100 Φ86.5×100 Φ86.5×100
stroke(mm)
Engine Capacity(L) 3.331 3.331 2.351 2.351 2.351
Compression ratio 22:1 17.5 :1 9.5 :1 9.5 :1 9.5 :1
Rated power(kw/ 46/2700(LPG) 46/2700(LPG)
35.3/2250 36/2250 46/2700(LPG)
rpm) 48/2700(GAS) 48/2700(GAS)
Max. torque(N.m/ 168/1600(LPG) 168/1600(LPG)
177 /1700 177 /1800 168/1600(LPG)
rpm) 170/2400(GAS) 170/2400(GAS)
Engine net
245 260 220 220 220
weight(kg)
Max. speed
2480 2475 2700 2700 2700
(unload)(rpm)
Idle speed(rpm) 770 770 750 750 750
Start motor 12V-2.2kw 12V-2.2kw 12V-1.2kw 12V-1.2kw 12V-1.2kw
Generator 12V-50A 12V-50A 14V-70A 14V-70A 14V-70A
Emission
EU Stage IIIA EPA 4F EPA 4F N/A EPA 4F
compliance
2-8
Structure and Function November 2, 2020
Engine System CLG2020H/C-2035H/C,CLG2020G-2035G

Item Specifications
Engine Model WG2503-GL-E3-LGF-1(dual fuel) WG2503-L-E3-LGF-1(single fuel)
Type 4-stroke, direct injection 4-stroke, direct injection
Type of cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-3-4-2
Cylinder bore.×
Φ88×102.4 Φ88×102.4
stroke(mm)
Capacity(L) 2.491 2.491
Compression ratio 9.2:1 9.2:1
Rated power(kw/
41.3/2600 41.3/2600(LPG)
rpm)
Max. torque(N.m/ 175/1200(LPG)
175/1200(LPG)
rpm) 167.6/1800(GAS
Engine net
212 211
weight(kg)
Max. speed
2700 2700
(unload)(rpm)
Idle speed(rpm) 800 800
Start motor 12V-2.0kW 12V-2.0kW
Generator 12V-60A 12V-60A
Emission EPA/CARB Tier3 EPA/CARB Tier3
compliance EU StageV EU StageV
 2-9
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Air Intake System

Air Intake System Schematic

Brief Introduction of Function

Air intake system mainly comprises air filter,

intake air filter alerter, alerter connector, clamp,
bracket and intake line, etc. It supplies clean and
dry air with proper temperature for engine to
combust so as to minimize engine wear and
optimize engine performance.
Exhaust system composition diagram (take
5
Cummins as an example)

1 2
3 4
5 P22P00004

1. Overhead guard
2. Intake line
3. Air filter
4. Engine

4
Working principle of air intake system: air from
the overhead guard inlet goes through intake line
to air filter and is clean and dry the dust and
2 3 water are excluded by filter element, and then it
1
P22P00003 goes into engine block through intake line for
combustion.
1. Air filter
2. Clamp
3. Bracket
4. Intake line
5. Electronic service indicator
2-10
Structure and Function November 2, 2020
Brief Introduction of Exhaust System Function CLG2020H/C-2035H/C,CLG2020G-2035G

Brief Introduction of Exhaust Cooling System

System Function
Brief Introduction of Function
Exhaust system mainly consists of muffler and
exhaust pipe, etc. It keeps all exhaust gases Air intake system mainly comprises air filter,
safely away from engine and discharged into the intake air filter alerter, alerter connector, clamp,
atmosphere quietly while maintaining the best bracket and intake line, etc. It supplies clean and
performance of engine. dry air with proper temperature for engine to
combust so as to minimize engine wear and
Exhaust system composition diagram (take
optimize engine performance.
Cummins as an example)
Cooling system composition diagram (take
Cummins as an example)

5
4
6
3

3
7

4
2
1 1
P22P00006

1. Lower hose
2. Upper hose
3. Radiator assembly
4. Baffle
5. Water hose
P22P00005
6. Auxiliary tank
7. Water hose
1. Exhaust pipe
2. Exhaust pipe
3. Exhaust pipe
4. Muffler
 2-11
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Brief Introduction of Fuel System Function

Schematic Brief Introduction of Fuel System

Function
4 Fuel system mainly comprises oil filter, fuel tank
cover, fuel filter and fuel line, etc. The fuel
system provides engine with clean and sufficient
5 fuel, which thus ensures proper operation of
engine.
Fuel system composition diagram (take
Cummins as an example)
3

2
6
5
1
1
P22P00007

1. Engine
2. Upper hose
3. Fan
4. Radiator assembly
5. Lower hose 2
4
The cooling system uses the engine for driving 3 P22P00008
the fan and adopts air blow for cooling. Water
outlet on the lower part of the radiator is 1. Engine fuel inlet line
connected with water inlet of the engine by lower 2. Engine fuel return line
3. Oil filter
hose and the water outlet of the engine is 4. Fuel tank cover
connected with the radiator through upper hose. 5. Bracket
When the coolant temperature is below 82°C 6. Fuel water separator
(180°F), coolant will do small circulation within
engine to warm up the engine. When coolant
temperature reaches 82°C (180°F), the
thermostat begins to open and some coolant
flows to upper water outlet and goes into the
radiator so that the fan begins to cool. When
coolant temperature reaches 95°C (203°F) or
higher, the thermostat is fully open, the bypass
hole is closed, and all coolant goes into the
radiator for cooling to form a large circulation.
2-12
Recommended Oil and Oil Change Cycle November 2, 2020
Brief Introduction of Fuel System Function CLG2020H/C-2035H/C,CLG2020G-2035G

Recommended Oil and Oil Change Cycle

Recommended oil

Oil Oil quantity Oil quality

7L (1.85US gal) (Cummins)
QSF2.8)
7.2 L (1.90US gal) (Yanmar Grade CF and
4TNE98) above -10 ~ 30°C (-50~86°F): SAE viscosity grade 20
Diesel engine
-10 ~ 35°C (-50~95°F): SAE viscosity grade 30
oil 10L (2.64US gal) (Mitsubishi -5 ~ 40°C (-41~104°F): SAE viscosity grade 40
S4S) -40 ~ 10°C (-104~50°F): SAE viscosity grade 5W
10L (2.64US gal) (Mitsubishi Grade CJ4 -30 ~ 15°C (-86~59°F): SAE viscosity grade 10W
D04EG) and above -40 ~ 10°C (-104~50°F): SAE viscosity grade 5W/20
5.7L (1.51US gal) (PSI 4G64) -40 ~ 35°C (-104~95°F): SAE viscosity grade 5W/30
-30 ~ 35°C (-86~95°F): SAE viscosity grade 10W/30
-20 ~ 40°C (-68~104°F): SAE viscosity grade 15W/40
9.5L (2.09US gal) -15 ~ 40°C (-59~104°F): SAE viscosity grade 20W/40
Grade SM and
(Kubota WG2503-GL-E3/ -10 ~ 35°C (-50~95°F): SAE viscosity grade 20/20W
above
WG2503-L-E3)
Gasoline 3.8L (1.00US gal) (NISSAN
engine oil K25)
Above 8°C (46°F): 5#
Refill according to usage Above 4°C (39°F): 0#
requirements (it is Above -5°F (-41°F): -10#
Diesel fuel
recommended no to exceed -5 ~ -14 °C(-41~-57°F): -20#
50L) -14 ~ -29 °C(-57~-84°F): -35#
-29 ~ -44 °C(-84~-111°F): -50#
Gasoline 60L(15.85US gal) 93#

Oil change cycle

Category Oil change interval (Operating hour) Approximate filling volume

NISSAN 250 3.8L (1.00US gal)
Gasoline engine oil Kubota 250 9.5L(2.09US gal)
Mitsubishi 250 5.7L (1.51US gal)
Cummins 500 7L (1.85US gal)
Diesel engine oil YANMAR 500 7.2L (1.90US gal)
Mitsubishi 500 10L (2.64US gal)
 2-13
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Special Tools and Tooling Catalog

Removal and Installation

Special Tools and Tooling Catalog

S/N Tool name Tool drawing Tool No. Remarks

1
2

Removal and Installation

Engine

Removal of engine

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
10#, 13#,
1 Torque wrench 3 3 Lifting rope 1
30#
2 Wood block 1 4
2-14
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

1. Remove the driver seat, engine hood (3), water
2 tank cover plate (2), overhead guard (or cab)
(1).
See the Section "Covering parts" for the specific
1
methods.

P22P00009

2. Remove the pedal pad and foot pedal (4).

4 See the Section "Covering parts" for the specific

methods.

P22P00010
 2-15
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Figures Operation instructions

3. Remove the battery (5) and the engine
connecting wire harness.
See the Section "Electric system" for the specific
method.

P22P00011

4. Remove radiator and water hose (6), fuel water

separator (7), exhaust pipe (8) and fuel pipe.
6 See the Section "Radiator" for the specific method
of removing the radiator. See the Section "fuel
water separator" for the specific method of
removing fuel water separator.

7
8

P22P00012

5. Put a wood block under the transmission,

remove the binder bolts between the
9
transmission and the engine (9) and the binder
bolts between the torque converter and engine,
10 and remove the engine cradle captive bolt (10).
Lift the engine. When installing, the tightening
torque of the engine cradle captive bolt is 360-
460N.m.
Tightening torque of binder bolts between the
torque converter and the engine is 22-30N.m, and
tightening torque of binder bolts between
transmission and engine is 45-59N.m.
P22P00013

Installation of the engine

The installation of the engine is reverse to its removal process.

2-16
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Air filter

Removal of air filter

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
10#, 13#,
1 Straight plier 1 2 Wrench 3
16#

Figures Operation instructions

1. Open the engine hood and remove the intake
air filter alerter wire harness socket (1)

P22P00014
2. Unscrew the intake line clamp (3) shown in the
Figure and loosen the connection between the
2 upper intake line (2) and the air filter

P22P00015
 2-17
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Figures Operation instructions

3. Unscrew the intake line clamp (3) shown in the
Figure and loosen the connection between the
3 intake line and the air filter

P22P00016

4. Remove the air filter clamp binder bolt (4)

4

P22P00017

5. Take out the air filter

P22P00018
2-18
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

6. Remove the intake air filter alerter and its
5
connector (5)

P22P00019

Installation of air filter

The installation of the air filter is reverse to its removal process. Keep the dusting bag of air filter
vertically downward.
 2-19
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Muffler Assembly

Removal of muffler assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
13#, 15#,
1 Wrench 3 2
10#

Figures Operation instructions

1. Remove the water tank cover plate mounting
bolt (1), and take out the water tank cover plate
(2). Remove binder bolt (3) between high
exhaust pipe and overhead guard.
1 3

P22P00020
2-20
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

2. Remove binder bolt (3) between high exhaust
pipe and muffler, and take out high exhaust
pipe.

P22P00021

3. Remove binder bolt (3) between muffler and

exhaust pipe.

P22P00022

4. Remove binder bolt (3) between muffler and

frame.

P22P00023
 2-21
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Figures Operation instructions

5. Take the muffler (4) out of the balance weight
vent.

P22P00024

Installation of muffler assembly

The installation of the muffler assembly is reverse to its removal process.

Do not tighten the binder bolts between the muffler and the frame before installing the binder bolts
between the exhaust pipe and the muffler (step 3) until the exhaust pipe is installed well.
2-22
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Radiator Assembly

Removal of radiator assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 13# 1 2 Straight wrench 27# 1

Figures Operation instructions

1. Remove hood and seat (1), and water tank
1 cover plate (2).
2
See the Section "Covering parts" for the specific
method.

P22P00025

2. Remove the binder bolt (3) between the beam

of overhead guard and the overhead guard,
then remove the beam (4).
3

P22P00026
 2-23
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Figures Operation instructions

3. Shut down the engine, and then open the
5 6 radiator filler cap and drain valve (9) for
draining the coolant after the complete
8
machine is fully cooled. When coolant is
7
9
drained, loosen the connection between the
overflow pipe (5), exhaust pipe (6), upper hose
(8), lower hose (7), oil pipe (10) and the
radiator.

10

P22P00027

4. Remove the binder bolt (3) between radiator

and frame, take out the radiator.
3

P22P00028
2-24
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Installation of the radiator assembly

The installation of the radiator assembly is reverse to its removal process.

When installing radiator, adjust the radiator leftwards and rightwards to make sure that the clearance A
between shroud and fan is balancing.

P22P00029

See the Section "Test and Adjustment" for the method of checking and adding coolant.
 2-25
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Fuel Tank Cover Plate

Removal of fuel tank cover plate

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Straight plier 1 3 Wrench 8# 1
2 Cross plier 1 4

Figures Operation instructions

1. Open the engine hood, remove battery (2) and
fuse box (1), and fuse box bracket.
See the Section "Electric system" for the specific
method.

2
1

P22P00030

2. Loosen the fuel sensor wire (4) and the fuel

pipe clamp and take away the fuel pipe (3).

3
P22P00031
2-26
Removal and Installation November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Remove the mounting screw of the fuel sensor,
take out fuel sensor (5).

P22P00032

4. Remove the binder bolt (6) between fuel tank

cover plate and frame, take out fuel tank cover
plate.

P22P00033

Installation of fuel tank cover plate

The installation of the fuel tank cover plate is reverse to its removal process.

When installing the fuel tank cover plate, apply sealant on the connecting part between the cover
plate and the frame and apply thread sealant on the binder bolt.
 2-27
November 2, 2020 Faults and Countermeasures
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Faults and Countermeasures

S/N Fault features Main reasons Inspection and troubleshooting

Check whether engine oil and hydraulic
(1) Overfilling of engine oil, shortage of
transmission oil are in normal level, and
hydraulic transmission oil
adjust them to normal level.
Engine weakness Check whether the intake air filter alerter is
1 and generating (2) Air filter element is blocked alarming, if any, clean the filter element or
black smoke replace it with a new one.
(3) Fuel filter is blocked Replace it with a new fuel filter element
(4) The complete machine overload Check whether the load is beyond the
operation capacity of the complete machine.
Normal voltage of battery is 24V. If too low, it
cannot drive the starter to work. Turn the
multimeter to its voltage function to check it,
(1) Low battery voltage
or use the fault diagnosis instrument to read
its real value "Battery voltage". If too low,
replace it with new battery.
Check whether there are too much oxides
(2) Starter relay and wires are in poor on the surface of wiring terminal, whether
contact the bolt on the surface of wiring terminal is
The engine can not
2 loose or broken.
be started
Check whether starter relay works normally
(3) Starter has been burned out
using the multimeter
Turn the ignition key to ON position and
(4) Ignition switch and start switch are check if the instrument panel comes on;
broken Turn ignition key to Start position and check
whether the starter has action
(5) Little fuel in the tank Check the instrument, if any, refill the fuel.
(6) Air exists in oil line Exhaust the air.
2-28
Faults and Countermeasures November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

S/N Fault features Main reasons Inspection and troubleshooting

Fill anti-freezing solution as required to
(1) Water amount is insufficient or coolant is
ensure its high boiling point and reduce
inappropriate
incrustation in cooling system.
There is greasy filth between cooling fins,
(2) Water radiator is blocked which prevents heat dissipation. Wash it by
compressed air or water gun.
(3) Water temperature sensor is damaged;
Measure it with surface thermometer.
wire grounding or indicator fails
Fan belt is too loose and needs adjustment.
(4) Fan speed is too low and blade is
Check if included angle of the blade relative
deformed or installed reversely
rotation plane becomes small.
Water temperature Water pump impeller being damaged,
3
is too high incrustation in the pump excessive, or the
(5) Cooling water pump is faulty
passage narrowed, all these may reduce the
coolant flow. Replace the water pump.
(6) The thermostat fails Replace thermostat.
(7) The radiator filler cap is damaged Replace the radiator filler cap.
Drain the coolant and clean the cooling
(8) Too much sediments in coolant
system, and refill clean coolant.
(9) Radiator leaks water Replace with new radiator.
(10)Air in the coolant Drain coolant and refill with new coolant.
(11)Exhaust back pressure too high Check whether exhaust system is blocked.
(12)Engine is overloaded Stop overload operation.
The end cover on
The bolts of the end cover on the engine
the engine cylinder Check the tightness of bolts, and replace the
4 cylinder head are not tightened, the cylinder
head leaks engine gasket.
head gasket is aged and damaged.
oil.
Bellows leak air,
muffler cracks or
5 Faults after vibration. Replace it with a new one.
has abnormal
noise.
 3-1
November 2, 2020 Power Train System
CLG2020H/C-2035H/C,CLG2020G-2035G

Power Train System

Safety................................................................................................................................3-3
System Overview.............................................................................................................3-6
System Parameters .........................................................................................................3-7
Drive Axle - Transmission Assembly ............................................................................3-8
Drive Axle - Transmission Parameter ....................................................................................................3-8
Driving Working Principle .....................................................................................................................3-10
Oil Line Working Principle ....................................................................................................................3-12
Structure Introduction...........................................................................................................................3-14
Torque Converter .............................................................................................................................3-17
Oil Pump Assembly..........................................................................................................................3-18
Main Pressure Regulating Valve and Relief Valve Assembly ..........................................................3-19
Solenoid Steering Control Valve Assembly......................................................................................3-20
Clutch ...............................................................................................................................................3-21
Drive Axle Assembly ........................................................................................................................3-22

Front Wheel Assembly..................................................................................................3-23

Rear Wheel Assembly ...................................................................................................3-24
Steering Axle..................................................................................................................3-25
Test and Adjustment .....................................................................................................3-26
Transmission........................................................................................................................................3-26
Inspection of Transmission Oil Pressure..........................................................................................3-26
Inspection of Transmission Oil Level ...............................................................................................3-27
Replacement of Transmission Oil ....................................................................................................3-27
Drive Axle.............................................................................................................................................3-28
Inspection of Drive Axle Oil Level ....................................................................................................3-28
Replacement of Drive Axle Oil .........................................................................................................3-29

Removal and Installation, Disassembly and Assembly.............................................3-30

Special Tools and Tooling Catalog ......................................................................................................3-30
Removal and Installation......................................................................................................................3-30
Transmission....................................................................................................................................3-30
Drive Axle.........................................................................................................................................3-33
Steering Axle Assembly ...................................................................................................................3-37
3-2
Power Train System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly and Assembly .................................................................................................................3-38

Transmission Assembly ...................................................................................................................3-38
Drive Axle.........................................................................................................................................3-43
Steering Axle....................................................................................................................................3-47

Faults and Countermeasures .......................................................................................3-50

 3-3
November 2, 2020 Safety
CLG2020H/C-2035H/C,CLG2020G-2035G

Safety "Caution" is also used for reminding the relevant

safety attentions of unsafe operation possibly
causing personal injury. "Danger" represents the
Many accidents in operation, maintenance, worst dangerous conditions. Safety sign of
repair and other aspects are caused by failing to "danger" or "warning" is an attachment set at the
observe the basic safety rules and precautions. If specific dangerous location. General precautions
the case of potential risk is fully aware in are listed on the safety sign of "Caution".
advance, these accidents usually can be
avoided. The operators must pay attention to In addition, please carefully follow the "Cautions"
these potential risks, and be trained for relevant listed in this Manual, otherwise, it may result in
skills before properly and safely operating, great damage to the machine. We are unable to
maintaining and repairing the machine. enumerate all the possible risks (including
potential dangers), and the warnings in the
● Any improper operation, maintenance and Manual and product do not cover all the risks and
repair method may lead to hazardous dangers. If the tools, operation procedures,
conditions, and may cause personal injury methods or techniques are not specially
and even death. recommended by our company, it is necessary to
● Be sure to read and understand the relevant ensure the personal safety of every one, and
security measures and precautions before protect the machine against any damage.
operating, maintaining and repairing the The contents herein are provided based on the
machine. status of the machine at the time when the
● Please strictly obey the safety warning Manual was written, whereas, all products are
information listed in this Manual and on the updating, and this machine is no exception. Any
machine during operating, maintaining and modification will influence the operation,
repairing the machine, otherwise heavy maintenance and repair of the machine,
casualties will occur. therefore, please contact the LiuGong dealers for
latest and most comprehensive service
Safety warning information in the Manual is information before operating, maintaining and
indicated by the following symbols: repairing the machine.

This word means danger will occurred

immediately, and if no avoidance, it may
cause death or serious personal injury.

This word means existing potential danger,

and if no avoidance, it may cause death or
serious personal injury.

This word means existing potential danger,

and if no avoidance, it may cause slight or
medium personal injury.
3-4
Safety November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Compressed air Prevent burn

Compressed air may cause personal injury. After running for some time, parts of the machine
When using the compressed air for cleaning, will be hot, such as engine, DPF (Diesel Particle
wear the mask, protection suits and shoes. The Filter) and inter-cooler steel pipe, those parts
maximum pressure of the compressed air for which are cooled down later shall be inspected
cleaning should be lower than 0.2 MPa. or repaired.
Safe treatment of waste liquid
● Improper treatment of waste engine oil,
waste diesel and waste DEF is harmful to
environment and ecosystem. Treatment shall
conform with the local laws and regulations.
● It is necessary to contain and place the liquid
spattering during the inspection,
P11000148
maintenance, test, adjustment and repair of
machine with vessel. Proper container shall
be prepared well before opening any fluid Coolant
cavity or disassembling the parts containing
At working temperature, the coolant of the
liquid. Use proper containers when draining
engine is at high temperature and has pressure.
the liquid.
The radiator and all the pipes connected to the
● Do not use the food or drink containers radiator contain hot water or vapor, if you touch
because they may be drunk by others by them, serious burn would occur.
mistake.
● When checking the coolant level, the engine
shall be shut off and the filler cap shall be
cooled to the extent that it can be opened by
bare hands. Slowly loosen the filler cap of
cooling system to release the pressure.
● Coolant contains alkali which may causing
injury and do not let it contact your skin, eyes
and mouth.

P19M00059

P11000147
 3-5
November 2, 2020 Safety
CLG2020H/C-2035H/C,CLG2020G-2035G

Safeguard from fire and explosion

● All fuels, most lubricants and some coolants

are flammables.
● Fuel leaking onto the hot surface or electrical
elements may cause fire.
● Do not smoke when refilling or within refiling
area, and in the place storing flammables.

P11000157

● Store the fuel, lubricant into containers with

relevant marks to avoid use by non-working
personnel.
● Put the cleaning cloth or other combustible
materials with oil soaked into protective
container, and set it at a safe place.
● Do not perform welding or flame cutting onto
the pipe containing flammable liquid. Before
welding or cutting, it shall be cleaned
completely with flammable liquid.
● Accumulated flammable materials such as
fuel, lubricant or other scattered materials on
the machine shall be cleaned up.
● Diethyl ether (Warning: Do not use diethyl
ether to start the engine)
● Any approach which attempts to start the
engine by use of diethyl ether may cause
serious damage to engine or casualties.

P11000158
3-6
System Overview November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

System Overview

As shown in the power train system composition diagram, the engine is coupled with the transmission 3,
a part of engine power is used to drive the torque converter to work and another part is used to drive the
hydraulic pump so as to provide power for the hydraulic system. The engine output power is input into
the transmission 3 after being torqued by the torque converter. Under the control of its shift control
valve, the transmission can output power and speed at different positions with gear clutches. The power
output from the transmission is transmitted to the main drive of drive axle 1 via a drive shaft, and then
transmitted to front wheel assembly by by left and right half shaft via main drive differential, thus finally to
drive the loader to travel and work.
Power train system composition diagram

1 2

P22T00001

1. Drive axle 4. Rear wheel assembly

2. Front wheel assembly 5. Steering axle assembly
3. Transmission assembly
 3-7
November 2, 2020 System Parameters
CLG2020H/C-2035H/C,CLG2020G-2035G

System Parameters

Main technical parameters of power train system are listed in table below.

Main technical parameters of power train system

System components Items Parameters Remarks

Model Shao Xing Gearbox YD30
Transmission
Control mode Electronically-controlled shift
Torque converter Type YJH265
Drive mode Spiral bevel gear 1st reduction
Drive axle
Brake mode Drum brake
Tire structure Bias tire with an inner tube Solid tire available
Front tire Specifications 28×9-15-14PR
Level 14
Front rim Specifications 7.00T-15
Tire structure Bias tire with an inner tube Solid tire available
Rear tire Specifications 6.5-10-10PR
Level 10
Rear rim Specifications 5.0F-10
3-8
Drive Axle - Transmission Assembly November 2, 2020
Drive Axle - Transmission Parameter CLG2020H/C-2035H/C,CLG2020G-2035G

Drive Axle - Transmission Assembly

Drive Axle - Transmission Parameter

The technical parameters of the drive axle - transmission assembly in this machine are listed in the table
below.

Technical parameters table of the drive axle - transmission assembly

Items Main technical parameters

Rated power of the matched engine kW(ps) 33~45(45~61)
Rated speed of matched engine r/min 2300~2650
YD30 transmission CQ30 drive axle
Transmission
Forward gear 1.244
ratio 14.224
Reverse gear 1.244
Main oil pressure MPa (psi) 0.9~1.2(131~174)
Electric device 12V.DC/26W
Torque converter oil inlet pressure Mpa (psi) 0.3~0.7(44~102)
Model YJH265
Effective diameter mm(In) 265(10.43)
Torque ratio under stall condition 3.10±0.15
Torque Max. efficiency >0.79
converter
Nominal impeller torque under stall condition N.m
35.7±1.5(3.64±0.15)
(kgf·m)
Nominal impeller torque under maximum
33±1.5(3.37±0.15)
efficiency condition N.m (kgf·m)
Rotation direction (facing to input end) Clockwise
No.6, No. 8 hydraulic GL-5 85W-90 heavy-
Working oil
transmission oil duty vehicle gear oil
Capacity L (US gal) About 11 (2.9) About 8 (2.1)
Working oil temperature °C (°F) 70~95(158~203)
Max. working oil temperature °C (°F) 120 (248) (not more than 5min)
Overall dimensions (length × width × height) mm×mm×mm
889×1174×504(35×46×20)
(In×In×In)
Net weight kg (lb) 436(961)
 3-9
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Drive Axle - Transmission Parameter

BLANK PAGE
3-10
Drive Axle - Transmission Assembly November 2, 2020
Driving Working Principle CLG2020H/C-2035H/C,CLG2020G-2035G

Driving Working Principle

The hydraulic transmission axle box integrated transmission schematic diagram is as shown in the figure
below, composed of YD30 hydraulic transmission and CQ30 drive axle. Torque converter is driven by the
engine through flexible coupling plate 1 to rotate impeller 4, and the fluid goes into turbine 2 at high
speed along the blade direction to rotate the turbine. Stator 3 makes torque converter convert the torque
and the torque is transferred to hydraulic transmission input shaft assembly 10 through turbine shaft 5
(input shaft assembly 10). When putting into forward gears, reverse clutch runs idly. Transferring
sequence is 10→7→12→11→14→15→16→17→18→19 to drive differential 20 for output. When putting
into reverse gears, forward clutch runs idly. Transferring sequence is
10→13→7→12→11→14→15→16→17→18→19 to drive differential 20 for output. The forward and
reverse clutches are controlled by electromagnetic power shift control valve. Oil pump 6 is internal gear
pump, which is directly driven by the engine through impeller. Oil pump supplies pressure oil to the
system. After torque converter works, oil goes into the radiator and then into the transmission to lubricate
friction plate, bearing and gear.

CQ30reduction case drive

axle Outpu

Input

Output

Output YD30 hydraulic transmission

P22T00002
 3-11
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Driving Working Principle

1. Flexible coupling plate 14. Universal coupling

2. Turbine 15. Input flange
3. Stator 16. Drive gear
4. Impeller (gear) 17. Driven gear
5. Turbine shaft [input shaft assembly (forward gear 18. Drive spiral bevel gear
clutch)] 19. Driven spiral bevel gear
6. Oil pump 20. Differential
7. Forward gears 21. Half shaft gear
8. Friction plate 22. Planetary gear
9. Spacer 23. Impeller (gear)
10. Turbine shaft [input shaft assembly (forward gear 24. PTO output gear
clutch)] 25. Inner pump output gear
11. Output flange 26. Hydraulic transmission axle box integrated transmission
12. Output gear schematic diagram
13. 13- countershaft assembly (reverse gear clutch)
3-12
Drive Axle - Transmission Assembly November 2, 2020
Oil Line Working Principle CLG2020H/C-2035H/C,CLG2020G-2035G

Oil Line Working Principle

Hydraulic transmission oil line schematic diagram is as shown in figure below

YD30 hydraulic transmission oil line schematic diagram

Lubrication

Pressure

Inching valve rod

Inching valve displacement
characteristic curve P22T00003

1. Filter 9. Forward and reverse valve

2. Oil pump 10. Cushion valve
3. Main pressure control valve 11. Make up valve
4. Damper orifice 12. Secondary filter
5. Torque converter 13. Forward gear clutch
6. Cooler 14. Reverse gear clutch
7. Torque converter safety valve
8. Inching valve
 3-13
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Oil Line Working Principle

The engine absorbs the oil from oil tank via filter 1 through torque converter impeller drive oil pump 2 to
provide the whole transmission with pressure oil. The oil from oil pump 2 passes through the secondary
filter 12 and then enters into main pressure control valve 3, then divided into two parts, one of which
flows to torque converter relief valve 7, while another part of oil flows to inching valve 8.
The oil flowing to torque converter relief valve 7 passes through relief valve and then flows into torque
converter 5 to transmit torque, then passes through heat exchanger 6 to lubricate the parts in
transmission.
The oil flowing to inching valve 8 passes through damper orifice 4, whose flow volume to forward and
reverse valve 9 is controlled by degree of opening and closing inching valve 8. When the inching valve 8
fully opens, the oil directly passes through inching valve 11 and flows to the oil tank; and when the
inching valve 8 fully closes, the oil passes through inching valve 8 and flows to forward and reverse valve
9.
The forward and reverse valve 9, based on the electrical signal, controls the oil to flow to forward gear
clutch 13 or reverse gear clutch 14 to realize shift operation of transmission.
The cushion valve 10 and make up valve 11 play a role of cushion and compensation in the whole
process of shifting, so as to reduce the impact from shift of transmission.
3-14
Drive Axle - Transmission Assembly November 2, 2020
Structure Introduction CLG2020H/C-2035H/C,CLG2020G-2035G

Structure Introduction

YD30 hydraulic transmission is composed of hydraulic torque converter, transmission, universal

coupling, while CQ30 reduction case drive axle is composed of reduction case, differential, differential
seat (axle housing), hub, brake and etc. The engine power, torque converted by torque converter 14, is
input to input assembly 15 (reverse gear clutch) of transmission by torque converter turbine via splined
coupling; and transmission is composed of input shaft assembly (reverse gear clutch) 15, countershaft
assembly (forward gear clutch) 13, output gear 10, output flange 11, oil inlet shaft sleeve assembly 16,
drive gear 17, PTO gear 18, inner pump gear 19, electrohydraulic control valve assembly 21, oil supply
pump assembly 20 and etc. The reduction case drive axle is mainly composed of input flange 24, drive
gear 25, driven gear 26, spiral bevel gear set 29, differential 30, left and right bracket 31 (36), left and
right brake 32 (37), brake hub 33, half shaft 34 and etc. The transmission and reduction case is coupled
with universal coupling 22. The forward or reverse clutch is controlled via electrohydraulic control valve
assembly 21, and the power transmitted from transmission passes through the reduction case and
differential driving is produced by differential assembly 30 via the coupling 8 and then transmitted to the
wheels via half shaft gear and half shaft. Also, the transmission and reduction case drive axle housing
play a role of oil tank. The transmission and reduction case drive axle are fixed and coupled by bracket
(damping bracket) 2 and cushion 5.
Hydraulic transmission axle box integrated structure diagram

1 2 3 4 5 6

7 8 P22T00004
 3-15
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Structure Introduction

Hydraulic transmission

19 20 21

18
17

16

15

14
13

12

11
10
9 P22T00005
3-16
Drive Axle - Transmission Assembly November 2, 2020
Structure Introduction CLG2020H/C-2035H/C,CLG2020G-2035G

Reducer drive axle

35 36 37

34 33 32 31 30 29 28 27 26 25 24 23 22

P22T00006

1. Hydraulic transmission 21. Electrohydraulic control valve assembly

2. Bracket 22. Differential seat assembly
3. Binder bolt 23. Differential cover
4. Base plate 24. Input flange
5. Cushion 25. Drive gear
6. Reducer drive axle 26. Driven gear
7. Bolt 27. End cover
8. Universal coupling 28. Locknut
9. Housing group 29. Spiral bevel group
10. Output gear 30. Differential assembly
11. Output flange 31. Left (right) bracket
12. Torque converter housing group 32. Left (right) brake
13. Countershaft assembly (forward gear clutch) 33. Brake hub
14. Torque converter assembly 34. Half shaft
15. Input shaft assembly (reverse gear clutch) 35. Front cover plate
16. Oil inlet shaft sleeve assembly 36. Left (right) bracket
17. Drive gear 37. Left (right) brake
18. PTO gear
19. Inner pump gear
20. Pump assembly
 3-17
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Structure Introduction

Torque Converter

YJH265 hydraulic torque converter structure diagram is shown as figure below. It is mainly composed of
impeller 1, stator 2, turbine 3 and elastic connecting plate 4 and etc.
The impeller 1 is coupled with engine flywheel via elastic connecting plate 4, and the impeller converts
the mechanical energy of engine into kinetic energy of working oil, and allows the oil flow into turbine 3 at
a high speed along the vane to push the turbine to rotate, and outputs from the internal spline of the
turbine and transmit the torque and speed to transmission. The oil from the turbine enters into stator 2.
When the torque converter is under heavy load, and torque converting stage with low turbine speed, the
stator is stopped by one-way clutch and can not rotate, the torque the oil flow acting on stator react on
the turbine to make the torque of turbine equal to the sum of that of impeller and stator, and thus the
output torque is greater than input torque, and automatic torque converting is made, as the ratio between
turbine speed and stator speed is greater than a certain value, the stator disengages and rotates freely,
the torque converting stops, and now the state is the coupled state.
YJH265 torque converter is a welded hydraulic type, which can't be dismantled.
YJH265 torque converter structure diagram

4 3 2 1

P22T00007

1. Impeller 3. Turbine
2. Stator 4. Flexible coupling plate
3-18
Drive Axle - Transmission Assembly November 2, 2020
Structure Introduction CLG2020H/C-2035H/C,CLG2020G-2035G

Oil Pump Assembly

YD30-3000 oil pump assembly structure diagram is shown as figure below. Oil pump assembly mainly
consists of oil pump body 1, oil pump cover 2, oil pump input shaft 3, oil pump drive gear 4, oil pump
inner gear 5, steel ball 6, spring 7 and etc. Casting oil pump body 1 is cast with high-pressure cavity and
low-pressure cavity. Installed on transmission housing, the oil pump assembly transfers power to the
drive gear 4 of oil pump through acceleration (transmission ratio is 0.8857) of gear pair and inner pump
drive gear driven directly by upper impeller of torque converter, which makes internal gear 5 of oil pump
to rotate, and internal gear pump is formed to provide oil to the system; the pump has protector for
pressure and flow, and when pressure (or flow) increases to a certain value, part 6 opens automatically
to keep a certain pressure (or flow).
YD30-3000 oil pump assembly structure diagram
1
2
3
4
5

7 6

P22T00008

1. Oil pump body 5. Oil pump inner gear

2. Oil pump cover 6. Steel ball
3. Oil pump input shaft 7. Spring
4. Oil pump drive gear
 3-19
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Structure Introduction

Main Pressure Regulating Valve and Relief Valve Assembly

Main pressure regulating valve consists of valve body, spring, spool, cylindrical pin, and etc. Main
pressure regulating valve controls the clutch oil pressure within the range of 0.9Mpa-1.1Mpa. A part of oil
enters control valve through inching valve to realize shift; a part of oil enters relief valve;
The relief valve consists of relief valve body, overflow spring, spool, screw plug, and etc. Set the oil
pressure at range of 0.3Mpa~0.7Mpa (44psi~102psi), and it enters the torque converter to work.
YD30 main pressure regulating valve and relief valve structure diagram

Main pressure regulating valve Relief valve

4

5
3

6
2

7
1

P22T00009

1. Valve body 5. Valve body

2. Spool 6. Spool
3. Spring 7. Spring
4. Plug 8. Plug
3-20
Drive Axle - Transmission Assembly November 2, 2020
Structure Introduction CLG2020H/C-2035H/C,CLG2020G-2035G

Solenoid Steering Control Valve Assembly

D30-4000 solenoid steering control valve assembly consists of YQX30D-4200 solenoid steering valve
and YD30-4100 control valve assembly, and control valve assembly structure diagram is shown as figure
below. Control valve assembly mainly consists of valve body 1, accumulator valve 2, inching valve 3,
solenoid valve 4, and etc. The inching valve rod is connected to inching pedal link rod, when depress the
inching pedal, the inching valve rod compresses inwards. When the inching valve rod compresses
inwards for 5mm (0.20 In), clutch pressure starts to decrease, when it decreases to some pressure,
friction plate skids, and the vehicle moves slightly; when the inching valve rod compresses for 11mm
(0.43 In), clutch pressure is decreased to 0, inner and outer friction plates separate, and the vehicle
stops moving; when the inching valve rod compresses for 13mm (0.51 In), its stroke terminates.
Accumulator valve 2 is a cushion valve, which is used to reduce impact of clutch connection and
separation.
YD30-4000 control valve assembly structure diagram

P22T00010

1. Valve body 3. Inching valve

2. Accumulator valve 4. Solenoid valve (directional valve)
 3-21
November 2, 2020 Drive Axle - Transmission Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Structure Introduction

Clutch

YD30 hydraulic transmission has two clutches: reverse gear clutch (input shaft assembly) and forward
gear clutch (countershaft assembly). Structure of clutches is shown as figure below. Clutch assembly
consists of input shaft (or countershaft) assembly 1, clutch gear 2, inner friction plate 13, spacer (outer
friction plate) 14, piston ring 16, piston 17, and etc. The clutch is wet multi-disc hydraulic clutch. Reverse
gear (input shaft assembly) and forward gear (countershaft assembly) clutches have 6 inner friction
plates, 5 spacers and 1 dished plate respectively. Clutch housing is welded to input shaft (or
countershaft). Pressure oil control valve enters reverse gear (input shaft) or forward gear (countershaft)
clutches respectively to achieve forward and reverse gear shifting. The outer circle of the piston is
provided with piston ring 16. Input (or counter) shaft is provided with sealing ring 18 to ensure piston
sealing when the clutch is working. At neutral gear, no pressure oil enters clutch, and piston returns
under the action of spring force of return spring, which makes the spacer and friction plate to be in
disengaged state. When shifting gears, oil pressure applies the piston, which makes the spacer and
friction plate to be engaged against each other. Frictional force transfers the power from torque converter
to forward gear or reverse gear.

P22T00011
3-22
Drive Axle - Transmission Assembly November 2, 2020
Structure Introduction CLG2020H/C-2035H/C,CLG2020G-2035G

Drive Axle Assembly

CQ30 reduction case drive axle assembly structure diagram is shown as figure below. The reducer drive
axle assembly consists of a pair of cylindrical gears, 2-level reduction composed of a pair of spiral bevel
gears, differential, differential seat, left (right) bracket, brake hub, half shaft, and etc. The reducer drive
axle assembly contains input flange 1, drive gear 2, driven gear 3, drive spiral bevel gear 5, driven spiral
bevel gear 4, differential seat assembly 9, differential cover 8, two half shaft gears 16, four planetary
gears 18, cross axle 17, differential housing assembly 14, left and right brackets 10 (21), left and right
brakes 11 (22), hub assembly 12, half shaft 13, and etc. Thrust washer 19 and washer 15 are mounted
between differential housing and planetary gear, half shaft gear.
CQ30 drive axle assembly structure diagram

14 15 16 17 18 19 20 21 22

13 12 11 10 9 8 7 6 5 4 3 2 1 P22T00012

1. Input flange 12. Hub assembly

2. Drive gear 13. Half shaft
3. Driven gear 14. Differential housing assembly
4. Driven spiral bevel gear 15. Washer
5. Drive spiral bevel gear 16. Half shaft gear
6. Driven shaft cover 17. Spider
7. Shim 18. Planetary gear
8. Differential cover 19. Thrust washer
9. Differential seat assembly 20. Front cover plate
10. Left (right) bracket 21. Left (right) bracket
11. Left (right) brake 22. Left (right) brake
 3-23
November 2, 2020 Front Wheel Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Structure Introduction

Front Wheel Assembly

Technical parameters of front wheel assembly on the machine are shown in the table below:

System
Items Parameters Remarks
components
Tire structure Bias tire with an inner tube
Specifications 28×9-15-12PR
Tire
Level 12
Tire air pressure (kPa) 830
Rim Specifications 7.00T-15

1
2 P22T00013

1. Rim 2. Tire

Composed of tire and rim, the front wheel assembly is both components bearing weight of a complete
machine and direct components driving the complete machine to travel.
3-24
Rear Wheel Assembly November 2, 2020
Structure Introduction CLG2020H/C-2035H/C,CLG2020G-2035G

Rear Wheel Assembly

Technical parameters of rear wheel assembly on the machine are shown in the table below:

System
Items Parameters Remarks
components
Tire structure Bias tire with an inner tube
Specifications 6.5-10-10PR
Tire
Level 10
Tire air pressure (kPa) 790
Rim Specifications 5.00F-10

2
1

P22T00014

1. Tire 2. Outer rim 3. Inner rim

Composed of tire and rim, the rear wheel assembly is both components bearing weight of a complete
machine and direct components driving the complete machine to travel.
 3-25
November 2, 2020 Steering Axle
CLG2020H/C-2035H/C,CLG2020G-2035G Structure Introduction

Steering Axle

P22T00015

As a steering axle with transverse cylinder, it is applicable for 2-3.5T forklift, which forms a steering
system with steering mechanism of forklift, and the vehicle steering can be realized. The steering axle
mainly consists of steering axle body, steering cylinder, steering knuckle, steering hub, and etc. When it
is used, mount the steel rings on hubs at two ends, and fasten them with hub nuts. Then connect it to
forklift chassis through brackets at front and rear ends of axle, and fix it on the chassis with bolts through
holes on the supporting seats at two ends.
When forklift turns, moving of transverse cylinder drives steering knuckles at two ends to rotate around
pivot pin of the steering knuckle, which drives wheels to rotate, and the forklift will turn. As double acting
cylinder, steering cylinder is connected to cylinder interface through two hydraulic oil pipes. When
hydraulic system works, steering cylinder moves along axle and drives the steering knuckle rotate
through link. Cross section of the steering axle is I-shaped beam body, which is welded with low alloy
high-strength steel plates. Use taper roller bearing when steering knuckle rotates, which resolves the
shortcoming of high failure rate of needle bearing.
3-26
Test and Adjustment November 2, 2020
Transmission CLG2020H/C-2035H/C,CLG2020G-2035G

Test and Adjustment

Transmission

Inspection of Transmission Oil Pressure

P22T00016

Parameter list of the measuring point

S/N of the
measuring Name of the measuring point Theoretical values Port dimension
point
1 Clutch oil pressure test port 0.9~1.1MPa(131~160psi) M10×1
2 Torque converter input oil pressure test port 0.3~0.7MPa(44~102psi) RC1/8
 3-27
November 2, 2020 Test and Adjustment
CLG2020H/C-2035H/C,CLG2020G-2035G Transmission

Inspection of Transmission Oil Level 2. Start the engine and run it at idle speed.
When temperature of transmission oil
reaches the working temperature
(80°C~90°C) (176°F~194°F), the engine
shuts off.
3. Unscrew the drain plug at lower rear side of
transmission to drain oil, and collect it with
container.

1
Upper 2
limit
Lower
limit
P22T00017

Park the forklift on a flat ground, turn the shift

control lever to neutral gear and pull up the
parking brake handle, place fork on the ground,
runs the engine for 2 minutes before shutting it
off, and then check it.
Open the engine hood, pull out the oil scale, wipe
it clean with clean cloth, put it back into the hole, 3 P22T00018
and pull it out to check the oil level, which must
be between upper limit and lower limit. If oil is 1. Oil filler
2. Dipstick
insufficient, please add more. 3. Oil drain plug

Replacement of Transmission Oil

At the working date of the first 100 working Because the transmission oil temperature is
hours, replace the transmission oil and replace it still high at this time, so wear protective
every 1,000 working hours. Replace the articles, and carefully operate to avoid
transmission oil at least once every year. personal injury.

During the inspection, maintenance, test and When draining oil, oil in both transmission
adjustment of the machine, prepare proper and torque converter, radiator should be
containers to collect such liquid when drained off.
remove any hydraulic oil lines or dismantle
any parts that contain liquid. Dispose all 4. Replace transmission oil filter.
liquid properly as per local law and 5. Mount drain plug and corresponding sealing
regulation. elements.
1. Stop the forklift on a flat ground, turn the shift
control lever at neutral gear; pull up the
parking brake handle to prevent the forklift
from moving, and place fork on the ground.
3-28
Test and Adjustment November 2, 2020
Drive Axle CLG2020H/C-2035H/C,CLG2020G-2035G

6. Unscrew the oil filling plug at upper part of Drive Axle

transmission, take out the transmission oil
level gauge, fill clean transmission oil from
filler port till it reaches the upper limit area of Inspection of Drive Axle Oil Level
the gauge.
7. Start the engine, and run it at idle speed.
Check oil level repeatedly and refill
transmission oil till the oil level are higher When draining and refilling the drive axle, be
than the lower limit area of the gauge. In the careful to unscrew the plug to prevent hot oil
process, the transmission may make slight from spilling.
abnormal sound, and the reason is
insufficient transmission oil. The abnormal
sound will disappear after filling oil to 1. Park the machine at the flat ground. Wipe
specified oil level. any part required to be refilled clean prior to
inspection.
8. When temperature of transmission oil
reaches the working temperature
(80°C~90°C) (176°F~194°F), check the oil 1
level again, and it should be in upper limit
area of the gauge. If oil is insufficient, please
fill more; if oil is excessive, please drain
some.
2
9. Insert the oil level gauge, screw it clockwise, 3
and cover it with a filler plug. P22T00019

1. Oil filler
2. Oil level hole
3. Oil drain hole
2. Put the shift control lever at neutral position,
pull up the parking brake handle to prevent
the forklift from moving.
3. Remove the oil level hole plug, and check if
the oil level inside of drive axle is at lower
edge of oil level hole. If the oil level is below
the lower edge of oil level hole, refill clean
drive axle oil. After refilling, observe it for 5
min, and it is alright if the oil level keeps
stable.
4. Screw the oil level hole plug.
 3-29
November 2, 2020 Test and Adjustment
CLG2020H/C-2035H/C,CLG2020G-2035G Drive Axle

Replacement of Drive Axle Oil

During the inspection, maintenance, test and

adjustment of the machine, prepare proper
containers to collect such liquid when
remove any hydraulic oil lines or dismantle
any parts that contain liquid. Dispose all
liquid properly as per local law and
regulation.
The oil drain operation shall be carried out
after the vehicle has been driven for a period
of time. The impurity precipitated in the axle
housing shall be fully suspended.

1. After the forklift has traveling for some time,

the impurity precipitated in the axle housing
shall be fully suspended. Drive the forklift to a
flat ground.
2. The engine shuts off. Turn the shift control
lever to neutral position, pull up the parking
brake handle to prevent the forklift from
moving.
3. Loosen the drain plug at bottom of drive axle
joint, drain the oil out, and then collect the oil
with a container.

Because the drive axle oil may be at a higher

temperature at this time, so wear protective
articles, and carefully operate to avoid
personal injury.

4. Screw the drain plug at bottom of drive axle.

5. Loosen the filler plug on top of drive axle
joint, fill clean drive axle gear oil till the oil
level reaches lower edge of oil level hole.
After refilling, observe it for 5 min, and it is
alright if the oil level keeps stable.
6. Screw the filler plug on top of drive axle.
3-30
Removal and Installation, Disassembly and Assembly November 2, 2020
Special Tools and Tooling Catalog CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation, Disassembly and Assembly

Special Tools and Tooling Catalog

S/N Tool name Tool drawing Tool No. Remarks

1
2

Removal and Installation

Transmission

Removal of Transmission

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
27#, 13#,
1 Wrench 17#, 18#, 6 1 Socket 38# 1
10#, 24#
Lifting eye, wood
2 13# 1 2
block, lifting rope

Figures Operation instructions

1. Remove the driver seat, engine hood (3), water
1 tank cover plate (2), overhead guard (or cab)
(1), and high exhaust pipe.
2
See the introduction of covering parts system and
power system for specific methods.

P22T00020
 3-31
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Figures Operation instructions

2. Remove the pedal pad and foot pedal (4).
4
See the Section "Covering parts" for the specific
methods.

P22T00021

3. Remove oil inlet/return pipes of the

transmission radiator and the radiator
5
connecting joint (5). Lay the oil pipe properly or
add some plugs to avoid oil leakage. (Wrench:
27#)

P22T00022
4. Remove foot pedal bracket (6), inching flexible
6 shaft (7), hydraulic oil radiator pipe (8) and tilt
cylinder pipe (9). Lay the oil pipe properly or
add some plugs to avoid oil leakage. (Wrench:
13#, 17#, 18#)

8 9

P22T00023
3-32
Removal and Installation, Disassembly and Assembly November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

5. Put wood blocks under drive axle and
10 transmission, install lifting eye on the
transmission sling mounting hole (10), put a
lifting rope under the transmission bracket (11),
11 and hoist these three points with hook and
lifting rope till the lifting rope is strained. (Lifting
eye, wood block and lifting rope)

10

P22T00024

6. Remove the binder bolts between the

transmission and drive axle and the binder
bolts between the transmission and the engine.
Open the transmission observation hole (12)
12
and remove the binder bolts (13) between the
torque converter and the engine flywheel. Lift
13 the transmission out carefully.
When installing, tightening torque of binder bolts
between the transmission and drive axle is 190-
260N.m (19.4-26.5kgf·m).
14 7. Tightening torque of binder bolts (14) between
the torque converter and the engine is 22-
P22T00025 30N.m (2.2-3.1kgf·m), and tightening torque of
binder bolts between the transmission and the
engine is 45-59N.m (4.6-6kgf·m). (Wrench:
10#, 13#, 24#)

Installation of Transmission

The installation of the transmission is reverse to its removal process.

 3-33
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Drive Axle

Removal of Drive Axle

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
14#, 17#,
1 Wrench 3 3 Plier Wrench 13# 1
24#
2 Cross plier 1 4 Socket 38#, 36# 2

Figures Operation instructions

1. Remove mast, load-backrest and fork arm
carrier (1) assembly.
See Chapter "Mast system" for the specific
method.

1
P22T00026
2. Loosen the joint nut between the brake oil pipe
(2) and the drive axle. (14# Wrench)

P22T00027
3-34
Removal and Installation, Disassembly and Assembly November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Remove pedal and pedal pad (3).
See Chapter "Covering parts" for the specific
method.

P22T00028
4. Remove the web plate and access door (4)
(cross plier)

4
P22T00029
5. Remove the captive bolts on hand brake, take
the hand brake out of the access door, and
remove the brake cable (5). (Plier Wrench:
13#)

P22T00030
 3-35
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Figures Operation instructions

6. Fix the drive axle at HALF position with lifting
device and lifting ropes and lift it to suspend
the wheel and put a wood block under the drive
axle, transmission and frame. Remove the
binder bolts between the tilt cylinder
connecting oil pipe (6) and the axle box. (7)
When installing, tightening torque of axle box
binder bolts is 190-260N.m (19.4-26.5kgf·m).
(Wrench: 17#, 24#)

6
P22T00031
7. Remove tire mounting nut (9), and remove
front wheel assembly (8).
When installing, the tightening torque is 550-
650N.m (56.1-66.3kgf·m). (38# Socket)

P22T00032
3-36
Removal and Installation, Disassembly and Assembly November 2, 2020
Removal and Installation CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

8. Remove the binder bolts (10) between the
drive axle and the frame, and remove the drive
axle.
When installing, tightening torque of bolts is 965-
1165N.m (98.4-118.8kgf·m). (36# Socket)

10 P22T00033

Installation of Drive Axle

The installation of the drive axle is reverse to its removal process.

 3-37
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation

Steering Axle Assembly

Removal of Steering Axle Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 22#, 30# 2 3 Lifting device 1
2 Lifting rope 1 4

Figures Operation instructions

1. Make sure oil in steering hydraulic pipelines
has been sufficiently cooled, after prepare the
collection of hydraulic oil, disconnect the
connector on the side of steering axle for
steering oil pipelines 1. (Wrench: 22#)

P22T00034
2. Hoist the counterweight with lifting device, and
remove mounting bolts 2 of the steering axle.
Hoist the lifting device, and hang
counterweight and take out steering axle.
(Wrench: 30#, lifting rope, lifting device)

2
P22T00035

Installation of Steering Axle Assembly

The installation of the steering axle assembly is reverse to its removal process.
3-38
Removal and Installation, Disassembly and Assembly November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly and Assembly

Transmission Assembly

Disassembly of Transmission Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
12#, 6#,
Inner hexagon
1 10#, 13#, 6 4 Lifting device 10# 1
spanner
16#, 18#
2 Filter wrench 30#, 18# 2 5 Torque wrench 15# 1
3 Lifting rope 1 6

Figures Operation instructions

1. Unscrew drain plug 1 before disassembling the
transmission, and drain residual oil in the tank;
check O-ring 2, and if it is damaged, replace
with a new one, and then screw the plugs back
into the tank after draining oil. (Inner hexagon
spanner: 12#)

2 1

P22T00036
2. Remove torque converter assembly 3; it is
necessary to rotate and push it inside when
3 assembling the torque converter, and you
should feel that 3-gear spline meshes.

P22T00037
 3-39
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

Figures Operation instructions

3. Remove oil dipstick 4, air cap group 5 and
secondary filter 6; use filter wrench to avoid
4 fine filtration scratch when installing and
removing the fine filter; for tightening
secondary filter, it is better to screw another 3/
5
4-1 circle after rubber lip contacts with the
junction surface when assembling. (Filter
wrench, wrench: 18#)
7
6

P22T00038
4. Remove solenoid control valve assembly 12
and inching bracket 10. If paper gasket 13 is
8 damaged when removing, replace it with a new
9 one after cleaning residual paper gasket on
junction surface; clean the residual oil on
10 junction surface when assembling. (Wrench:
11 12#, 13#)
12

13

P22T00039
5. Remove the bracket 16 (wrench: 18#)

16

15

14

P22T00040
3-40
Removal and Installation, Disassembly and Assembly November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

6. Take down captive bolts, and remove oil supply
pump assembly. If the paper gasket paper is
damaged when removing, replace it with a new
17 18 19 20 21 one after cleaning residual paper gasket on
junction surface, and then take out coarse
filter; it is necessary to clean the residual oil on
junction surface when assembling, and install
oil supply pump assembly after installing
cleaned coarse filter (or new coarse filter).
(Wrench: 13#, Inner hexagon spanner: 6#)

P22T00041
7. Remove bolts connecting the two housings of
23 transmission and open the transmission; when
assembling, glue again after cleaning residual
22 flange sealant, and be careful not to let sealant
enter the tank when gluing, to prevent oil
passage from blocking. Tighten the bolts on
opposite angle. (Torque wrench: 15mm)

P22T00042
8. Remove oil baffle 30, and remove output gear
27
31 and output flange 27; back of output flange
should bear against the mounting gear and
bearing when assembling. (Wrench: 10mm
and 18mm)

32
31
30
29
24
28 26 25
P22T00043
 3-41
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

Figures Operation instructions

9. Remove two sets of clutch assembly; be
careful to protect the sealing ring from scratch
34 33 when installing clutch assembly.

P22T00044
10. After taking down captive bolts and removing
oil inlet shaft sleeve assembly, take out the
drive gear of oil pump; pay attention to not
leaving out the two O-rings on junction surface
39 38 37 36 35 when assembling. (Wrench: 16#)

P22T00045
11. Take down the drive gear 43 of inner pump and
drive gear 44 of outer pump (PTO port) after
44 removing oil drip pan 42. (Wrench: 13mm)
45
40 41 42 43

P22T00046
3-42
Removal and Installation, Disassembly and Assembly November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

12. Remove clutch gear 7, take down retaining ring
14 8, and take out inner and outer friction plates;
13
15 piston assembly 15 can be removed after
16 taking down retaining ring 13 and return spring
17 1 14; before assembling, check wear condition of
2 each friction plate. Replace them if it is
3 necessary, and replace sealing ring 17 (1
4 piece) and 19 (2 pieces) after disassembling.
5
19 18 8 6
12 9 7
11 10 P22T00047

Assembly of Transmission Assembly

The assembly of the transmission assembly is reverse to its disassembly process.

 3-43
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

Drive Axle

Disassembly of Drive Axle

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Inner hexagon 10#, 12#,
1 12#, 6# 2 3 Torque wrench 3
spanner 19#
12#, 17#,
2 Wrench 4 4
21#, 24#

Figures Operation instructions

1. Unscrew drain plug 1 before disassembling the
drive axle, and drain residual oil in the axle;
check O-ring 2, and if it is damaged, replace
with a new one, and then screw the plugs back
into the axle after draining oil. (Inner hexagon
spanner: 12#)

1
2
P22T00048
2. Take down captive bolts, and remove half shaft
4; when assembling, glue again and install
after cleaning residual sealant on junction
surface. The tightening torque of bolts is 110-
4 3 130 N.m (11.2-13.3 kgf·m). (Torque wrench:
19#)

P22T00049
3-44
Removal and Installation, Disassembly and Assembly November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Remove locknut 8 after taking down thrust
washer 7, and then take down hub assembly 9;
9 8 7 6 5 when assembling locknut, turn torque of the
hub should be 6-8N.m (0.6-0.8 kgf·m). (Torque
wrench: 10#)

P22T00050
4. Remove the captive bolt. Remove brake
assembly 12. (Wrench: 21#)

12 11 10

P22T00051
5. Take down captive bolt, and remove left/right
bracket 15. (Wrench: 24#)
16 15 14 13

P22T00052
 3-45
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

Figures Operation instructions

6. Take down captive bolts, and remove front
cover plate 19; when assembling, glue again
17 18 19 and install after cleaning residual sealant on
junction surface. (Wrench: 12#)

P22T00053
7. Remove bearing support 23, and take down
adjusting nut 21 and differential assembly 24.
21 Pay attention to marking left and right positions
24 of bearing support, and install the bearing
support back to housing after removing
23 differential assembly. (Wrench: 24#)
22
20

P22T00054
8. Take out drive spiral bevel gear 31 after
removing output shaft end cover 27 and
29 locknut 28; when assembling, screw the
27 locknut after bearing against the drive spiral
25
30 28 26 bevel gear with tooling, and tightening torque
of the locknut is 250±30N.m (25.5±3.1 kgf·m).
(Torque wrench: 12#)
31 32 33

P22T00055
3-46
Removal and Installation, Disassembly and Assembly November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

9. Take out drive gear 39, driven gear 38 and
output flange 34 after removing differential
39 38 37 36 35 34 cover 37. (Wrench: 12#)

P22T00056
10. Remove two bearings and oil seal from hub
assembly. Apply grease between bearing 3
and oil seal 4 when assembling.

2 3 4

P22T00057
11. Take down driven spiral bevel gear 3, open
2 differential, and take out internal planetary gear
1
6 10 and half shaft gear 8; pay attention to
5 checking the wear condition of washer 7 and 9
4
3 when assembling, replace them with new ones
if it is necessary. (Wrench: 17mm and 21mm)

11
10
9
8
7 P22T00058

Assembly of Drive Axle

The assembly of the drive axle is reverse to its disassembly process.

 3-47
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

Steering Axle

Disassembly of Steering Axle

P22T00059

S/N Code name Name Quantity

1 Z30_G Steering axle body assembly 1
2 Z30KD002 Link 2
3 Z30KD002C Steering oil cylinder assembly 1
4 Z30KD007C Right steering knuckle assembly 1
5 CB297-94 Tapered roller bearing 33206 4
3-48
Removal and Installation, Disassembly and Assembly November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

S/N Code name Name Quantity

6 JB/T7940.2-1995 Grease fitting 2
7 CB/T4H995 Nut M12 2
8 CB3452.1-88 O-ring 25X3.55 2
9 Z30KD003C King pin 2
10 Z30KD010C Locknut 2
11 Z30_8 Rubber oil seal 85x110x12 2
12 CB297-94 Tapered roller bearing 3027E 2
13 CB297-94 Tapered roller bearing 30207E 2
14 CB97.H5 Washer 30 2
15 Z30KD009 Nut 2
16 CB92-86 Pin 6.3x55 2
17 Z3HD010 Hub cap 2
18 Z30KD0U Hub 2
19 Z30KD012 Hub nut 16
20 Z3HD013 Hub bolt 16
21 CB92-86 Pin φ3.2x50 2
22 Z30KD008C Lock sleeve 2
23 Z30KD009C Composite dust ring 4
24 Z30KD005C Dust ring seat 2
25 Z30KD006C Dust ring 2
26 Z3HD018 Bearing seat 2
27 Z3HD019 Oil nylon liner 2
28 Z30KD020 Shim 4
29 CB5781-2000 Bolt M12X40 2
30 Z30KD011C Left steering knuckle assembly 1
31 CB7940. 1-1995 Straight-through type forced filling oil cup 4
32 CB5780-86 Bolt M8X18 4
33 CB93-1987 Standard spring washer 8 4
34 Z30KD022 Baffle 2
35 Z30KD023 Radial knuckle bearing G16ES 2
36 Z30KD024 Bushing 8
37 Z30KD025 Link pin 4
38 CB5782-2000 Bolt M14X45 4
39 CB93-1987 Standard spring washer 14 4
40 CB95-2002 Washer 14 4
41 CB119-86 Pin 10x20 2
 3-49
November 2, 2020 Removal and Installation, Disassembly and Assembly
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

Disassembly sequence: ● When assembling, fill #3 lithium lubricating

grease on hub bearing and steering knuckle
1. Remove hub: bearing, and the amount is 1/3~1/2 of the
Part 18, including part 12, 13 bearings inside, bearing clearance.
can be removed after removing part17, and ● When assembling part 15 slot nut as shown
part 16, part 15 and part 14 in order with flat in the diagram, firstly screw it and loosen 1/
hammer. 8~1/6 round, and insert cotter pin to lock it;
2. Remove link: ● Control the hub starting force within
40~90N.m (4.1~9.2kgf·m); the hub starting
Take out part 34 after removing part 32, 33,
force is initial rotation force of the hub.
then push part 37 out with a punch, and part
Generally, hang spring balance on hub bolt,
2 can be removed.
and a number can be got when the hub
3. Remove king pin: rotates;
After removing part 21, unscrew part 10, and Spring Scale
part 9 can be removed by grabbing and pull-
ing up part 31.
4. Remove steering knuckle:
After part 9 is removed, part 22 will fall out.
Then parts 22, 23, 24, 25 and 30 (including
part 5 bearing inside) can be removed in
order.
5. Remove cylinder:
Loosen parts 38, 39 and 40, and part 3 cylin-
der can be removed; P22T00060

● When installing part 10 slot nut, lock it with

Assembly of Steering Axle torque of 90N.m (9.2kgf·m), and loose it, lock
it again with torque of 34N.m (3.5 kgf·m), and
The assembly of the steering axle is reverse to
then lock the nut with cotter pin.
its disassembly process.
● Tightening torque of cylinder captive bolts is
Precautions when assembling steering axle: within 140~165N.m (14.3~16.8kgf·m), and
apply anaerobic thread locking glue.
● When install the steering axle, check if
grease in the lubricating part is full;
● When assembling dust ring, apply lubricating
grease on the lip part evenly;
● When assembling hub bolts and hub, use
press-fitting or tap with a copper hammer;
● Use cotter pins on steering knuckle and king
pin strictly as per the standard specification;
● When installing steering axle, add adjusting
shim between front/rear brackets and axle
body end shaft, and there must not be axial
clearance between bracket end and end
axle;
3-50
Faults and Countermeasures November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Faults and Countermeasures

S/N Fault features Main reasons Inspection and troubleshooting

(1) Oil level of torque converter Check whether the hydraulic transmission
hydraulic transmission is low. oil is in normal level, and adjust it to normal
level if necessary.
(2) Transmission oil filter is blocked. Check whether the oil filter is blocked, if any,
clean or replace it.
(3) Return spring of inching valve is
Check and replace the spring.
broken.
1 Insufficient power (4) Displacement of oil pump is Check whether oil pump is worn, if any,
insufficient. replace it.
(5) Torque converter oil pressure is too Check the oil pressure, and adjust it to
low. normal value.
(6) Clutch oil pressure is too low, and Check the oil pressure, and adjust it to
clutch skids. normal value.
(7) Clutch piston ring is worn. Check and replace it.
(8) Clutch friction plate is worn. Check and replace it.
(1) Input elastic plate is loose or out of Tighten the bolts or replace it with a new
shape. one.
(2) Spline wear Disassemble and replace it with a new one.
2 Abnormal noise (3) Gear damage Disassemble and replace it with a new one.
(4) Bearing wear or damage Disassemble and replace it with a new one.
(5) Air cavity caused from insufficient oil Check it and replenish.
(6) Hub bearing is worn or damaged. Disassemble and replace it with a new one.
(1) Oil seal wear or strain Disassemble and replace it with a new one.
(2) Rubber is hard or out of shape. Disassemble and replace it with a new one.
3 Oil leakage
(3) Loose bolts and oil leakage of
Screw it again.
junction surface
(1) Oil leakage at cylinder oil port Replace O-ring
Weak or no (2) Oil leakage at two ends of cylinder Replace the seal
4
steering (3) Piston sealing ring wear Clean and replace piston seal
(4) Piston rod surface is scratched Replace cylinder
(1) Insufficient lubricating grease for the
Fill grease
The piston linkage knuckle bearing at two ends of link
5
is blocked. (2) Polluted knuckle bearings at two
Replace knuckle bearing
ends of linkage
(1) Tighten torque of king pin lock
Adjust as per requirements
groove nuts is too large
The steering
(2) Insufficient lubricating grease for the
6 knuckle does not Fill grease
bearing
rotate freely
(3) Ineffective dust ring, and polluted
Replace dust ring
bearing
 3-51
November 2, 2020 Faults and Countermeasures
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly

S/N Fault features Main reasons Inspection and troubleshooting

(1) 1/8~1/6 round is not loosened after
Adjust as per requirements
Hub rotation is screwing lock groove nuts.
7
blocked. (2) Insufficient lubricating grease for the
Fill grease
bearing
The gasket of the
8 transmission oil The paper gasket has worn away. Replace it with a new one.
pump leaks oil.
The seals of (1) The seal has worn away. Replace it with a new one.
transmission torque
9 converter are
damaged and leak (2) The seal is hardened or deformed. Replace it with a new one.
oil.
(1) Use normally, the solenoid valve is Check the solenoid valve of gear box and
blocked. replace it if it is damaged.
10 Unable to reverse (2) The gap of transmission friction
Check the friction disc gap and replace the
discs is too small or the disc is
disc if necessary.
sintered.
(1) The plane bearing of steering axle
Replace the plane bearing.
has worn.
Abnormal noise
11 (2) The needle bearings of steering
when steering Check the knuckle assembly, replace needle
knuckle have worn, the king pin is
bearings and king pin.
blocked and worn.
3-52
Faults and Countermeasures November 2, 2020
Disassembly and Assembly CLG2020H/C-2035H/C,CLG2020G-2035G
 4-1
November 2, 2020 Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G

Hydraulic System
Basic Information ............................................................................................................4-3
Safety Precautions for Hydraulic System...............................................................................................4-3
Overview of Hydraulic System ...............................................................................................................4-6
Technical Parameters of Hydraulic System ...........................................................................................4-9
Schematic Diagram of Hydraulic System.............................................................................................4-11
Universal Tools and Tooling for Hydraulic Maintenance......................................................................4-14

Work Hydraulic System ................................................................................................4-15

Hydraulic Oil Tank................................................................................................................................4-18
Mounting Position and Functional Structure ....................................................................................4-18
Assembly and Disassembly of Hydraulic Oil Tank...........................................................................4-19
Banked Direction Control Valve Assembly...........................................................................................4-22
Assembly and Disassembly of Banked Direction Control Valve Assembly......................................4-22
Banked Direction Control Valve Assembly...........................................................................................4-25
Removal and Installation of Banked Direction Control Valve Assembly ..........................................4-26
Disassembly of Banked Direction Control Valve .............................................................................4-28
Oil Pump Assembly..............................................................................................................................4-32
Removal and Installation of Oil Pump Assembly .............................................................................4-32
Disassembly of Oil Pump .................................................................................................................4-36
Commissioning of Work Hydraulic System ..........................................................................................4-38
Main Technical Parameters .............................................................................................................4-38
Pressure Adjustment and Test.........................................................................................................4-39

Steering Hydraulic System ...........................................................................................4-40

Disassembly and Assembly for Steering Hydraulic System.................................................................4-41
Disassembly of Steering Wheel Assembly...........................................................................................4-44
Disassembly of Steering Gear .............................................................................................................4-46
Steering Pressure Test ........................................................................................................................4-49

Hydraulic Cooling System ............................................................................................4-50

Mast Hydraulic System .................................................................................................4-50
Removal and Installation of Mast Hydraulic System ............................................................................4-53
Disassembly of Oil Cylinder .................................................................................................................4-53
Disassembly of Two-Stage Standard Oil Cylinder ...........................................................................4-53
Disassembly of Two-Stage Full Free Cylinder .................................................................................4-55
4-2
Hydraulic System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly of Three-Stage Full Free Cylinder ..............................................................................4-61

Speed Limit Valve and Explosion-Proof Valve.....................................................................................4-62
Working Principle of Speed Limit Valve ...........................................................................................4-62
Working Principle of Explosion-Proof Valve.....................................................................................4-63

Tilt Cylinder Mounting System.....................................................................................4-64

Removal and Installation of Tilt Cylinder Mounting System .................................................................4-65
Disassembly of Tilt Cylinder.................................................................................................................4-67

Common Faults and Reasons Analysis ......................................................................4-69

 4-3
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Safety Precautions for Hydraulic System

Basic Information

Safety Precautions for Hydraulic

System

Compressed Air
P11000204
Compressed air may cause personal injury. Even if the pressured liquid is leaked as small as
When using the compressed air for cleaning, a pin hole, it may penetrate the muscles and lead
wear the mask, protection suits and shoes. Do to death. If shot by the spouted high-pressure oil,
not point the compressed air at yourself or please contact a doctor and take a medical
anyone. The compressed air may penetrate the treatment immediately.
skin and lead to severe injury or even death. The
maximum pressure of the compressed air for Safe Disposal of Waste Liquid
cleaning should be lower than 0.2 MPa (29Psi).
Inappropriate disposal of waste liquid will
High-pressure Solution endanger environment and ecology. Please
observe local laws and regulations when dispose
Prevent from being scalded by high-pressure oil. the waste liquid.
When overhauling or replacing the pipes of
hydraulic system, check whether the pressure of It is mandatory and necessary to collect the
system had been released. Hydraulic oil under liquid with containers spattered during the
pressure will damage your skin severely when it inspection, maintenance, test, adjustment and
spattered on you. repair of machine. Proper container shall be
prepared well before opening any fluid cavity or
Take care when remove the hydraulic pipelines disassembling the parts containing liquid. Use
or connectors. When the oil spouts, the released proper container when draining liquid.
high-pressure oil may lead to the continuous
movement of the hoses. Do not use the food or drink containers because
they may be drunk by others by mistake.
Please wear safety glasses and leather gloves
when checking for leakages. Do not use bare
hands to check the leakage but plate or paper
plate.

P11000134 P19M00059
4-4
Basic Information November 2, 2020
Safety Precautions for Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Precautions for Accumulator Application Preventing Extruding or Cut Off

The dangerous high-pressure nitrogen is Do not have your hands, arms or any other
contained in the accumulator, so read the bodies placed between moving parts. For
following requirements and properly use the example, between work implement and cylinder,
accumulator. between machine and working implement.
The accumulator shall be checked before charge When working under the work implement, you
of nitrogen. It is prohibited to charge the shall support the equipment properly. Do not
accumulator with gas if the accumulator does not support the work implement depending on
have a nameplate, or the words on the hydraulic cylinder. If control mechanism moves
nameplate are missed so that its type can not be or hydraulic oil line leaks, work implement will
identified, or if the steel seal marks are drop. If it is necessary to remove the shield, you
incomplete or cannot be read clearly, or if there is shall fix it well after the repair.
defect with the housing and therefore safe use
Unless otherwise stated, any adjustment is not
cannot be ensured.
permitted to be performed when machine or
The accumulator can only be filled with nitrogen engine is running. If the repair procedure must
other than oxygen, compressed air or other be performed when machine is running, do not
flammable air to avoid explosion. let the machine stay in an unattended status.
Arrange one operator seated in the seat and
Slowly charge the nitrogen into the accumulator
prepare to shut down the engine at any time.
so as to avoid the breakage of the rubber bag.
Do not use twisted or worn wire rope. Wear
gloves during operation and move.
When forcing to extrude the bayonet, you shall
make sure no one is standing around it. You shall
wear safety goggles in order to protect your
eyes.
When knocking object with hammer, please
make sure the flying debris will not hurt others.
P11000190

The air valve of the accumulator shall be Oil

installed upward vertically. The accumulator shall
Hot oil and parts will cause personnel injury, and
be stably fixed on the bracket without being
do not let the hot oil and parts contact your skin.
welded.
Do not drill any hole on the accumulator or carry
open fire or heat sources close to the
accumulator.
Do not conduct any welding operation on the
accumulator.
Since the accumulator is a high-pressure
container, it shall be replaced and repaired by P11000148
professional operators.
Release the air before discarding the waste
accumulator.
 4-5
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Safety Precautions for Hydraulic System

At working temperature, the hydraulic oil tank is Precautions for Accessories

hot and contains pressure. When opening oil
filler cap of hydraulic oil tank, shut off the engine It shall be installed and commissioned by
and cool the filler cap down until it can be qualified personnel; the operator shall be trained,
opened by bare hands. Remove the tank cover and his/her operation and maintenance shall be
slowly to release the pressure of hydraulic oil performed strictly according to the operation
tank so as to prevent from being scalded by hot instructions for accessories.
oil.
When installing and using the spare accessory,
Release pressure of the system before please read related instructions, manuals and
disassembling all pipes, connector, or relevant informations about the accessories.
parts.
Incorrect installation or purchase of accessories
will not only cause safety issues, but also have
Pipeline, Pipe and Hose
the negative effect on service life and operation
Do not warp or knock the high-pressure pipeline, of the machine.
and do not install the abnormally warped or Do not use the accessories unauthorized by
broken pipe or hose onto the machine. LiuGong. Using unauthorized accessories will
Repair the loose or damaged pipe and hose of cause safety issues, do harm on the normal
fuel and lubricant pipeline and hydraulic system operation of machine and influence its service
in time. Leakage will cause fire hazard, and if life.
repair or replacement is necessary, please It is forbidden to make any refit on the
contact the authorized dealer by LiuGong accessories without permissions; otherwise you
Machinery Co., Ltd. shall bear the responsibility.
If following problems occur, it shall be replaced. LiuGong Machinery Co., Ltd will not be
● Damage or leakage of connector. responsible for the injury, accident and damage
of machine due to using unauthorized
● The outer layer of hose is worn or cracked, accessories.
and reinforced steel wires are exposed.
● Partial bulge of hose.
● The hose is twisted or flattened.
● The hose reinforcement steel has embedded
to the outer layer.
● Misplacement of the end connectors.
Make sure all clamps, guard and heat shield are
installed correctly to prevent shaking or
overheating by friction with other parts.
Otherwise, it will generate toxic gases resulting
in poisoning.
4-6
Basic Information November 2, 2020
Overview of Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Overview of Hydraulic System Steering hydraulic system CLG2020-35H/C

1
The hydraulic system is the actuator of the forklift
and mainly composed of three functional
modules, i.e. a work hydraulic system, a steering
hydraulic system, and a hydraulic cooling
system. Where, the steering hydraulic system 2
supplies oil for the steering circuit preferentially
through the priority valve to ensure steering
function; the work hydraulic system controls the
3
coordinated actions of all oil cylinders through
the control valve so that the forklift can adapt to
the requirements of different working conditions;
the hydraulic cooling system cools the hydraulic
oil to ensure oil temperature within the
reasonable scope of work. Layout of hydraulic
system CLG20-35G/C is shown as follows: P22H00002

Work hydraulic system CLG2020-35H/C 1. Steering wheel

2. Steering gear
3. Steering cylinder
1 Cooling system CLG2020-35H/C
7
3

4
2 6

2
1
3
P22H00003

1. Radiator inlet line

5
2. Hydraulic radiator
P22H00001 3. Radiator outlet line

1. Banked direction control valve assembly

2. Control valve
3. Gear pump
4. Oil suction flange
5. Oil suction filter
6. Return oil filter
7. Oil return seat
 4-7
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Overview of Hydraulic System

Three-stage full free mast hydraulic system Two-stage mast hydraulic system CLG2020-
CLG2020-35H/C 35H/C

3
1
4

5
3

P22H00004
P22H00005
1. Triple valve line
2. Lift cylinder (side cylinder)
3. Lift cylinder (center cylinder) 1. Triple valve line
4. Quadruple valve line 2. Lift cylinder (side cylinder)
5. Speed limit valve 3. Quadruple valve line
4. Speed limit valve
4-8
Basic Information November 2, 2020
Overview of Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Two-stage full free mast hydraulic system Tilt cylinder mounting system diagram
CLG2020-35H/C

5
1

4
P22H00007

1. Pin shaft
2 2. Tilt cylinder

P22H00006

1. Triple valve line

2. Lift cylinder (right side cylinder)
3. Lift cylinder (center cylinder)
4. Lift cylinder (left side cylinder)
5. Quadruple valve line
6. Speed limit valve
 4-9
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Technical Parameters of Hydraulic System

Technical Parameters of Hydraulic System

Main technical parameters of hydraulic system CLG2020-25H/C

Item Unit(s) Theoretical values

Type Quantitative system
System working pressure (Max) Mpa(Psi) 19.5 (2828.2)
NISSAN ml/r 28.2
Displacement of working pump
other ml/r 32
Maximum speed of working pump r/min 2700
Manual duplex (triple, quadruple)
Control valve /
valve rod

Work Tilt cylinder (bore × rod diameter × stroke) mm Φ80×35× 94 (front 6º rear 6º)
hydraulic Lift cylinder (side cylinder) Φ50×40×1565
mm
system Three-stage full (bore × rod diameter × stroke) (4.7 m three-stage mast)
free mast Lift cylinder (center cylinder) Φ75×55×795
mm
(bore × rod diameter × stroke) (4.7 m three-stage mast)
Lift cylinder (plunger side cylinder) Φ45×35×1489
mm
Two-stage full (bore × rod diameter × stroke) (3 m two-stage mast)
free mast Lift cylinder (center cylinder) Φ75×55×765
mm
(bore × rod diameter × stroke) (3 m two-stage mast)
Two-stage Lift cylinder Φ50×40×1495
mm
standard mast (bore × rod diameter × stroke) (3 m two-stage mast)
Type Priority turn

Steering System working pressure Mpa(Psi) 12(1740)

hydraulic Steering gear ml/r 100
system Steering turns Turn(s) 4(Left to right)
Steering cylinder (bore × rod diameter × stroke) mm Φ70×50×208
Working Hydraulic oil type / HM32 (general configuration)
medium Cleanliness NAS 1638 ≤ Grade 9
4-10
Basic Information November 2, 2020
Technical Parameters of Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Main technical parameters of hydraulic system CLG2030-35H/C

Item Unit(s) Theoretical values

Type Quantitative system
System working pressure (Max) MPa(Psi) 19.5 (2828.2)
NISSAN ml/r 28.2
Displacement of working pump
other 32
Maximum speed of working pump r/min 2700
Manual duplex (triple, quadruple)
Control valve /
valve rod

Work Tilt cylinder (bore × rod diameter × stroke) mm Φ80×35× 94 (front 6º rear 6º)
hydraulic Lift cylinder (side cylinder) Φ56×45×1565
mm
system Three-stage full (bore × rod diameter × stroke) (4.7 m three-stage mast)
free mast Lift cylinder (center cylinder) Φ85×60×782
mm
(bore × rod diameter × stroke) (4.7 m three-stage mast)
Lift cylinder (plunger side cylinder) Φ50×40×1489
mm
Two-stage full (bore × rod diameter × stroke) (3 m two-stage mast)
free mast Lift cylinder (center cylinder) Φ85×60×752
mm
(bore × rod diameter × stroke) (3 m two-stage mast)
Two-stage Lift cylinder Φ56×45×1495
mm
standard mast (bore × rod diameter × stroke) (3 m two-stage mast)
Type Priority turn

Steering System working pressure MPa(Psi) 12(1740)

hydraulic Steering gear ml/r 100
system Steering turns Turn(s) 4(Left to right)
Steering cylinder (bore × rod diameter × stroke) mm Φ70×50×208
Working Hydraulic oil type / HM32 (general configuration)
medium Cleanliness NAS 1638 ≤ Grade 9
 4-11
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Schematic Diagram of Hydraulic System

Schematic Diagram of Hydraulic System

Hydraulic principle of CLG2020-35H/C equipped with duplex valve

Steering
cylinder

Tilt
cylinder

To mast hydraulic
system

Two-stage standard mast hydraulic

Two-stage or three-stage full

free mast hydraulic system

P22H00008
4-12
Basic Information November 2, 2020
Schematic Diagram of Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Hydraulic principle of CLG2020-35H/C equipped with triple valve

Steering
cylinder Attachment
cylinder

Tilt
cylinder

To mast hydraulic
system

Two-stage standard mast hydraulic

Two-stage or three-stage
mast hydraulic system

P22H00009
 4-13
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G Schematic Diagram of Hydraulic System

Hydraulic principle of CLG2020-35H/C equipped with quadruple valve

Attachment
cylinder

Attachmen
cylinder

Tilt
cylinder

To mast
hydraulic system

Two-stage standard mast hydraulic

Two-stage or three-stage full

free mast hydraulic system

P22H00010
4-14
Basic Information November 2, 2020
Universal Tools and Tooling for Hydraulic Maintenance CLG2020H/C-2035H/C,CLG2020G-2035G

Universal Tools and Tooling for Hydraulic Maintenance

Common tools table

Name Specifications (Qty.)

Open-end wrench 8#, 12#, 13#, 17#, 19#, 21#, 22#, 24#, 27#, 30#, 32#, 41#
Straight screwdriver
Cross screwdriver
Plier
Scissor
Torque wrench
Inner hexagon spanner One set in metric standard and one set in imperial standard

Notice: The removed standard parts should be placed with relevant material together to
avoid being mixed.
 4-15
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Universal Tools and Tooling for Hydraulic Maintenance

Work Hydraulic System 1. When work hydraulic system has no any

action, which means the control valve is in
the neutral position, oil output from gear
A: Overview - components and position pump returns to the oil tank through control
valve, and the work implement stays in the
The work hydraulic system is used to control the original position.
actions of forklift mast work implement. For
example, control the lifting, lowering and tilting of 2. Lift and lower the mast by operating the
forklift mast. The system is a quantitative system control valve lift plate. Tilt the mast forward or
(see the schematic diagram of hydraulic system). backward by operating the control valve tilt
The system consists of hydraulic oil tank (welded plate, and corresponding actions can also be
on the frame), gear pump, control valve, banked achieved by operating other plates.
direction control valve, cylinder of work 3. Oil suction flange (including oil suction filter)
implement, line and other accessories. Gear and oil return seat (including return oil filter)
pump absorbs and pumps out hydraulic oil for are mounted on the hydraulic oil tank of the
operation from the oil tank; it will control the frame.
coordinated actions of all oil cylinders through
control valve so that the forklift will adapt to B: Overview - analysis of technical
working requirements of different work parameters and working principle of the work
conditions. Layout of work hydraulic system system
CLG2020-35H/C is shown as follows:
1. Work parameters of work system
Work hydraulic system CLG2020-35H/C
Item Parameters
18.5±0.5Mpa
1 CLG2020-30H/C
System (2682.5±72.5Psi)
7 pressure 20.5±0.5MPa
CLG2035H/C
(2972.5±72.5Psi)
85L(22.475gal)/
System flow
min@2600r/min
4
2 6

5
P22H00001

1. Banked direction control valve assembly

2. Control valve
3. Gear pump
4. Oil suction flange
5. Oil suction filter
6. Return oil filter
7. Oil return seat
4-16
Work Hydraulic System November 2, 2020
Universal Tools and Tooling for Hydraulic Maintenance CLG2020H/C-2035H/C,CLG2020G-2035G

2. Working principle of work system

1) Introduction for control valve OPS principle
The control valve OPS function is: when driver isn't at the operation position, the control mast device
shall not have any action. OPS function is controlled by No.2 solenoid valve II and No.3 solenoid valve I.
When there is nobody in the seat, solenoid valve I and solenoid valve II are not energized. When
solenoid valve II is not energized, oil supplied by banked direction control valve pump flows back to the
oil tank as shown by the thick line in the following Figure, at this time, operate the valve rod for lifting and
other linkages, no action occurs. When solenoid valve I is not energized, lowering action cannot be
achieved by lowering the valve rod. Positions of corresponding objects to solenoid valve I and solenoid
valve II are as shown in the exploded view of banked direction control valve.
Work hydraulic system CLG2020-35H/C

3
2
P22H00011

1. Priority valve 2. Solenoid valve II 3. Solenoid valve I

 4-17
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Universal Tools and Tooling for Hydraulic Maintenance

2) Introduction for priority steering principle

When the complete machine isn't turning, pressure can't be detected by the priority valve LS port in the
control valve, at this time, the oil flowing direction is as shown by the thick line in CLG2020-35H/C
steering hydraulic system diagram, and just a small amount of oil about 2L (0.528gal)/min spills out from
LS port. When the complete machine is turning, pressure can be detected by the priority valve LS port in
control valve, at this time, the oil flowing direction is as shown by the thick line in CLG2020-35H/C
cooling system diagram. Oil will first flows to SF port and then to steering gear, while the left oil flows to
other working block of the banked direction control valve, and faster turning speed, more oil flow shunt.
When flow from the pump is smaller than the flow that turning needs, all oil will flow to SF port and to
steering gear.
Work hydraulic system CLG2020-35H/C

3
2

P22H00012

1. Priority valve 2. Solenoid valve II 3. Solenoid valve I

4-18
Work Hydraulic System November 2, 2020
Hydraulic Oil Tank CLG2020H/C-2035H/C,CLG2020G-2035G

Hydraulic Oil Tank

Mounting Position and Functional Structure

Including oil suction flange and oil return seat, the hydraulic oil tank is integrated with the frame, which
locates at right side of the complete machine. Its function is to store the hydraulic oil required for work of
the hydraulic system, precipitate the pollutant of oil in hydraulic tank, separate the air from oil and cool
the hydraulic oil. A return oil filter has been set in the oil tank to filter the pollutant in oil lines of the
hydraulic system so as to guarantee the cleanliness of hydraulic oil. Structural diagram of hydraulic oil
tank is as follows:
Structural diagram of hydraulic oil tank

2
3

4
1
P22H00013

1. Oil suction flange 2. Oil filler 3. Oil return seat 4. Oil drain hole

Oil suction flange equipped with oil suction pipe is oil suction passage. Meanwhile, oil suction flange is
equipped with oil suction filter to prevent big particulates in oil tank from entering the hydraulic system.
The oil filler is for filling hydraulic oil, filler cap of which is equipped with respirator and hydraulic oil
dipstick. The function of the breather is that it sucks air from atmosphere to fill the air space when the air
pressure in oil tank is negative and that exhaust extra air to realize the protection function when the air
pressure in oil tank is out of limit. Hydraulic oil dipstick is used to observe the oil level of oil tank. Oil
return seat is used for oil return of the system with return oil filter, the function of which is to filter the oil
returning to the hydraulic oil tank to prevent pollutant from entering into the system through the oil tank to
cause pollution again. Washing port is the position where oil suction flange and oil return seat are
removed, it is used to clean the dirt in the oil tank through the position. Oil drain hole is used to drain the
oil out of oil tank when replacing oil or cleaning oil tank.
 4-19
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Hydraulic Oil Tank

Assembly and Disassembly of Hydraulic Oil Tank

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 19#, 8# 2 2

Relevant preparation before starting:

First, park the complete machine.

Cleaning is the key point. Thoroughly clean the outer surface of the components before removal.
It will prevent foreign matters from entering the mechanism.
Stick label identification on all the pipings, hoses, circuits and steel tubes for easier installation.
Clog up all the pipelines, hoses and steel tubes to prevent contaminants from entering the
system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused. Method to release pressure: Put the mast system
straight first, and lower it to bottom until the cylinder does not bear force; then flame out and
power on the complete machine, and operate banked direction control valve rod back and forth
for several times to release the pressure.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter can not be removed until the engine stops
and the oil is cool enough for being touched by bare hand.
4-20
Work Hydraulic System November 2, 2020
Hydraulic Oil Tank CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

1. Find the drain plug at bottom of oil tank at right
frame, and then wipe the circumference of
drain plug;
2. Place a clean oil basin below the drain plug for
collecting the hydraulic oil; screw off the drain
plug;

P22H00014

3. Unscrew 6 bolts and remove the oil suction

flange;

P22H00015

4. Put the removed oil suction flange at a clean

1 position, and remove one O-ring and two oil
suction filters manually;
2

P22H00016
 4-21
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Hydraulic Oil Tank

Figures Operation instructions

5. Unscrew manually and directly the oil filler cap
counterclockwise;
6. Unscrew 6 bolts and remove the oil return seat;

P22H00017

7. Put the removed oil return seat at a clean

position, and remove one seal gasket and two
1 oil suction filters manually;

P22H00018

Assembly of hydraulic oil tank Assembling process: In the order from 7 to 1, keep
all components clean when assembling, and for
tightening torque, refer to the requirements on
torque in appendix.
4-22
Work Hydraulic System November 2, 2020
Banked Direction Control Valve Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Banked Direction Control Valve Assembly

Assembly and Disassembly of Banked Direction Control Valve Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 13#, 18# 2 2 Plier 1

Relevant preparation before starting:

Park the machine.

Cleaning is the key point. Thoroughly clean the outer surface of the components before removal.
It will prevent foreign matters from entering the mechanism.
Stick label identification on all the pipings, hoses, circuits and steel tubes for easier installation.
Clog up all the pipings, hoses and steel tubes. That will prevent fluid loss and prevent dirts from
entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused. Method to release pressure: Put the mast system
straight first, and lower it to bottom until the cylinder does not bear force; then flame out and
power on the complete machine, and operate banked direction control valve rod back and forth
for several times to release the pressure.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter can not be removed until the engine stops
and the oil is cool enough for being touched by bare hand.
 4-23
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Banked Direction Control Valve Assembly

Figures Operation instructions

After removing the instrument cover, go on the
following steps:
1. After screwing cotter pin 2 with plier till it is
straight, take out cotter pin, and take out pin 3;
2. Unscrew bolt 6 with a wrench, and then
remove 1, 2, 3, 4 and 5 and disassemble the
2 control lever 3;
3

P22H00019

3. After unscrewing bolt 6 with a wrench, 1, 2, 3, 4

5 and 5 can be removed, and the control lever 3
can be disassembled;

3
1

2 4
6

P22H00020
4-24
Work Hydraulic System November 2, 2020
Banked Direction Control Valve Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

4. Unscrew 2 with a wrench, revolve and unscrew
lever 1, remove cotter pin 5 with a plier, take
5 out pin 4, and remove 3 & 6;

1
4

P22H00021
Assembling of banked direction control valve Assembling process: Assemble in the reserse
assembly order, after which adjust height of the control lever
to a proper position.
Adjusting process: Loosen tightening nuts 2 in the
valve rod, and adjust the rod 1 to adjust handle of
the control assembly to a proper position.
 Notice: During adjusting, keep opening
direction of the valve rod vertical to front
crossbeam plate, as shown in left Figure.

P22H00022
 4-25
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Banked Direction Control Valve Assembly

Banked Direction Control Valve Assembly

After removal and installation of the banked direction control valve assembly or disassembly and
assembly of the banked direction control valve, following tests need to be carried out:
1. Operate the banked direction control valve for 10-20 minutes, including lifting and lowering,
tilting forward and backward, actions of attachments (if there are attachments) and keeping
down the pressure of each block, to check if there is oil leakage, if any, stop the operation
immediately for maintenance;
2. The forklift forks heavy objects with rated load weight, and the mast gets straight for lifting to
height of 1-2m (39.37-78.74in); the complete machine stalls, after standing for 10 minutes,
check distances of the object's free fall and free slant forward. The distance of free fall should
be or less than 100mm (3.937in), and that of free slant forward should be or less than 1°. If it is
out of the range, it should be overhauled by maintenance personnel.

Introduction for control valve

4-26
Work Hydraulic System November 2, 2020
Banked Direction Control Valve Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation of Banked Direction Control Valve Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
10#, 13#,
17#, 21#,
Inner hexagon
1 Wrench 22#, 32#, 9 3 8# 1
spanner
41#, 16#,
27#
Straight
2 1 4
screwdriver

Relevant preparation before starting

Park the machine.

Stick label identification on all the pipings, hoses, circuits and steel tubes for easier installation.
Clog up all the pipings, hoses and steel tubes. That will prevent fluid loss and prevent dirts from
entering the system.
Cleaning is the key point. All the components shall be cleaned thoroughly with cleaning solution
prior to assembly. The parts are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all the components. If the
components are worn or damaged, please replace them with new ones.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused. Method to release pressure: Put the mast system
straight first, and lower it to bottom until the cylinder does not bear force; then flame out and
power on the complete machine, and operate banked direction control valve rod back and forth
for several times to release the pressure.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter can not be removed until the engine stops
and the oil is cool enough for being touched by bare hand.
 4-27
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Banked Direction Control Valve Assembly

Figures Operation instructions

1. After removing the banked direction control
valve assembly, disconnect the wire harness,
and use tools on the list to remove hose and
steel pipe.

P22H00023

2. Unscrew and remove the marked bolts with a

wrench one by one, and pay attention to
preventing falling of the banked direction
control valve from hurting people.

P22H00024

Assembling of banked direction control valve Assembling process: In the order from 2 to 1, refer
assembly to the general table for relevant screw thread
torques.
4-28
Work Hydraulic System November 2, 2020
Banked Direction Control Valve Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly of Banked Direction Control Valve

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
20#, 22#, Inner hexagon
1 Wrench 3 2 5# 1
15# spanner

Cleaning is the key point. All the components shall be cleaned thoroughly with cleaning solution
prior to assembly. The components are allowed for natural drying. Never wipe them dry with
cloth. The fiber from the cloth will accumulate on the parts and cause fault. Check all the
components. If the components are worn or damaged, please replace them with new ones.
 4-29
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Banked Direction Control Valve Assembly

Exploded view of banked direction control valve

Lift stop valve

Secondary safety valve

Main safety valve

P22H00025

1. Solenoid valve assembly I 6. Nut 11. Spring 16. O-ring

2. Solenoid valve assembly II 7. Adjusting screw 12. Cone valve 17. O-ring
3. Banked direction control valve body 8. O-ring 13. Dust ring 18. O-ring
4. O-ring 9. Valve seat 14. O-ring 19. O-ring
5. Stop valve 10. O-ring 15. O-ring

The control valve integrates priority steering valve, main safety valve (to control pressure of lift plate) and
secondary relief valve (to control tilt and pressure of attachment plate), without steering relief valve.
4-30
Work Hydraulic System November 2, 2020
Banked Direction Control Valve Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembling and assembling steps

Figures Operation instructions

Removal and installation of solenoid valve
1. Unscrew and remove nut 2 with a wrench, and
2 remove the solenoid coil, and then screw out
the solenoid valve spool by screwing position 1
with a wrenchThe assembling process is
1 reverse to that of 1.
Notice:
Method for checking solenoid valve: If a sound
"click" (spool moving) is made once the
solenoid valve is energized, the solenoid valve
is normal; otherwise, it needs overhaul.
Method to overhaul solenoid coil: Detect the
P22H00026 resistance of solenoid coil with ohmmeter, and
the resistance should be within 9.1±7%Ω.
 4-31
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Banked Direction Control Valve Assembly

Figures Operation instructions

Removal and installation of sealing parts at the
ends of valve rod
1 2. Unscrew the four bolts with a hexagon
spanner, and remove baffle 1 and end cover 2;
3. Pull out valve rod group 4, and remove dust
ring 3 and O-ring 5;
4. The assembling process is from 4 to 3.

P22H00027

4
5
P22H00028
Removal and installation of relief valve
5. Unscrew relief valve seat 1 with a wrench, and
remove O-ring 2, spring 3 and spool 4
6. The assembling process is reverse to item 6,
and pressure test and adjustment are needed
after the assembling.
1 Refer to Pressure Adjustment and Test for detailed
test and adjustment methods
2

3
4 P22H00029
4-32
Work Hydraulic System November 2, 2020
Oil Pump Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Oil Pump Assembly

Removal and Installation of Oil Pump Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
32#, 10#,
Inner hexagon
1 Wrench 13#, 27#, 5 3 8# 1
spanner
41#
Straight
2 1 4 Oil collecting basin 1
screwdriver

Relevant preparation before starting

Park the machine.

Stick label identification on all the pipings, hoses, circuits and steel tubes for easier installation.
Clog up all the pipings, hoses and steel tubes. That will prevent fluid loss and prevent dirts from
entering the system.
Cleaning is the key point. All the components shall be cleaned thoroughly with cleaning solution
prior to assembly. The components are allowed for natural drying. Never wipe them dry with
cloth. The fiber from the cloth will accumulate on the parts and cause fault. Check all the
components. If the components are worn or damaged, please replace them with new ones.
When replacing oil suction line, pump out all hydraulic oil in the oil tank before removal or
installation. If only gear pump is removed or installed, it is unnecessary to pump out the
hydraulic oil, and only a container is needed to collect the overflowed hydraulic oil.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.
 4-33
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Oil Pump Assembly

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused. Method to release pressure: Put the mast system
straight first, and lower it to bottom until the cylinder does not bear force; then flame out and
power on the complete machine, and operate banked direction control valve rod back and forth
for several times to release the pressure.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter can not be removed until the engine stops
and the oil is cool enough for being touched by bare hand.

Figures Operation instructions

1. Remove the oil filter on transmission

P22H00030

2. Remove the hose assembly with wrench, and

the clamp on oil suction pipe with straight
screwdriver. Bend up and fix one removed end
of the oil suction pipe to prevent hydraulic oil
from draining. Meanwhile, container is needed
to collect the overflowing hydraulic oil;

P22H00031
4-34
Work Hydraulic System November 2, 2020
Oil Pump Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Remove the clamp with wrench and straight
screwdriver, and remove the oil suction pipe;
 Notice: Pump out the hydraulic oil in the
hydraulic oil tank before removing oil suction
pipe;

P22H00032

4. Remove two bolts with wrench, and the oil

suction steel pipe can be removed;

P22H00033
 4-35
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Oil Pump Assembly

Figures Operation instructions

5. Unscrew two bolts with inner hexagon spanner,
remove the gear pump, and then unscrew the
joint on the gear pump with wrench.

P22H00034

Installation of oil pump assembly Assembling process: In the order from 5 to 1, refer
to the general table for relevant screw thread
torques.
Refer to the installation instructions for gear pump
for precautions.
4-36
Work Hydraulic System November 2, 2020
Oil Pump Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly of Oil Pump 1. Oil suction port

2. Oil outlet
3. Connecting shaft of pump
Working pump of the forklift is gear pump and the
schematic diagram of gear pump is shown in the
Removal and installation of gear pump:
following Figure.
Schematic diagram of gear pump Gear pump is the power source of forklift
hydraulic system, and its volume efficiency will
influence the speed and efficiency of actuator
directly. It is not recommended to remove or
install the working pump by non-professionals as
it is a precise hydraulic element, and the broken
pump shall be returned to the manufacturer and
repaired by professionals; after repairing,
perform the test of airtightness and volume
efficiency on the working pump to ensure its
performance and normal application.
P22H00035 Installation instructions for gear pump

Working principle of gear pump: 1. Rotation direction

Due to the structure of gear pump, it is forbidden
When the engine drives the drive gear I and
to rotate it reversely. Please use it according to
driven gear II through long shaft (drive shaft) to
specified rotation direction.
rotate as shown in the Figure, closed volume on
one side of entering into meshed gear is smaller. 2. Gear pump drive
Oil is discharged from pressure oil port. Closed
1) If shaft center line deviation is too much, the
volume on the side of seceding meshed gear is
coupling may be damaged, and vibration
larger. Oil is absorbed through oil suction port.
and noise are generated. Therefore, pay
Oil in oil chamber is transferred to pressure oil
special attention to this when installing the
chamber by gear cave space with gear rotation.
pump. Allowed values of concentricity are
The pump absorbs oil and pumps oil
varied with operating conditions. Normally, it
continuously.
is below 0.05mm (0.002In), and angle error
Gear pump outline structure is as shown in the is below 0.5°.
following Figure.
2) When connecting drive shaft and pump
Gear pump outline structure chart shaft, please use flexible coupling. In
addition, pump shaft and gear are
integrated. Therefore, do not apply axial
force on the shaft. Before installing, check if
the depth of installation hole is higher than
elongation of working pump shaft. When
3 installing the coupling, do not knock on shaft
end, especially, do not apply axial impact on
the shaft. Key shaft and key sleeve shall be
1 installed flexibly.
2
P22H00036
 4-37
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Oil Pump Assembly

3. Piping
When assembling oil suction pipe, it shall not be
bent excessively and be sealed reliably. If it is
bent excessively or air leakage occurs, the pump
may be vacuumized, which will lead to noise and
cavitation and cause damage to the pump. After
the pipe is installed, air may exist in the pipe.
Therefore, air shall be discharged before normal
operation. If residual air still exists in the pipe,
sintering accident may occur when running at
high speed and full load.
4. Work fluid cleanness
After gear pump is reinstalled, oil inlet/outlet of
the pump shall be clean. The plane of inlet/outlet
shall not be scratched to ensure the sealing
performance of O-ring. At the same time,
cleanness of oil in oil tank shall be ensured.
When assembling, oil suction pipe shall be clean.
4-38
Work Hydraulic System November 2, 2020
Commissioning of Work Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Commissioning of Work Hydraulic System

Relevant preparation before starting

Park the machine.

Cleaning is the key point. All the components shall be cleaned thoroughly with cleaning solution
prior to assembly. The components are allowed for natural drying. Never wipe them dry with
cloth. The fiber from the cloth will accumulate on the parts and cause fault. Check all the
components. If the components are worn or damaged, please replace them with new ones.
Don’t adjust the pressure without permission, for additional adjustment of pressure, please
contact service personnel from professional manufacturer for confirmation. The appropriate
container shall be used to collect the liquid before removing any hydraulic oil lines or
disassembling any components that contain liquid during the inspection, maintenance, test and
adjustment of the machine. Dispose all the fluid in accordance with local laws and regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused. Method to release pressure: Put the mast system
straight first, and lower it to bottom until the cylinder does not bear force; then flame out and
power on the complete machine, and operate banked direction control valve rod back and forth
for several times to release the pressure.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter can not be removed until the engine stops
and the oil is cool enough for being touched by bare hand.

Main Technical Parameters

Parameters Service
Item Remarks
Mpa(Psi) conditions
Setting pressure of main relief valve CLG2020-30H/C 18.5(2682.5) / /
Setting pressure of main relief valve CLG2035H/C 20.5(2972.5) / /
Setting pressure of secondary relief valve 16(2320) / /
Steering safety valve pressure 12(1740) / /
 4-39
November 2, 2020 Work Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Commissioning of Work Hydraulic System

Pressure Adjustment and Test

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Inner hexagon
1 Wrench 17#, 10# 2 2 6#, 3# 2
spanner

Figures Operation instructions

Assembly of pressure measuring connector
1
1. Take down pressure port plug with inner
hexagon spanner, and connect to pressure
measuring connector (M14×1.5); connect the
pressure gauge or pressure sensor to test
main relief valve pressure (lifting block) and
secondary relief valve pressure (tilting,
attachment), and positions are as shown in
CLG2020-35H/C Work Hydraulic System.
2. Main relief valve pressure test method: under
the condition of idling, lifts it without load to the
top pressureout, and read the pressure value.
P22H00037
3. Secondary relief valve pressure test method:
under the condition of idling, tilts it without load
backwards to the bottom pressureout, and
read the pressure value.
Pressure adjustment
4. Unscrew 1 nut with the wrench, then adjust 2
adjusting screw with the hexagon wrench, turn
up the pressure clockwise,and turn down the
pressure anticlockwise.

P22H00038
4-40
Steering Hydraulic System November 2, 2020
Commissioning of Work Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Steering Hydraulic System

Steering hydraulic system CLG2020-35H/C

After removal and installation of steering

hydraulic system or disassembling and
assembling of the steering gear, following 2
tests need to be carried out:
1. Operate the steering system for 10-20
minutes, including pivot steering, travel 3
steering, the action of attachment
steering pressureout, to check if there is
oil leakage, if any, stop the operation
immediately for overhaul;
2. Check if there are abnormal symptoms
(such as clamping stagnation, heavy P22H00002
steering, etc.) during the steering, if any,
stop the operation immediately for 1. Steering 2. Steering gear 3. Steering
wheel cylinder
overhaul.
B: Overview - technical parameters of
A: Overview - components and position steering system

Steering hydraulic system is used to control the Item Parameters

steering actions of forklift. The system is a Steering 12±0.5Mpa
steering priority system (see the schematic CLG2020-35H/C
pressure (1740±72.5Psi)
diagram of hydraulic system). It consists of
Steering gear displacement 100mL/ r
steering wheel assembly, steering gear, steering
cylinder, multi-lines, other auxiliaries, etc. Layout
of work hydraulic system CLG2020-35H/C is
shown as follows:
 4-41
November 2, 2020 Steering Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly for Steering Hydraulic System

Disassembly and Assembly for Steering Hydraulic System

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
10#, 17#,
Straight
1 Wrench 22#, 13#, 5 2 1
screwdriver
27#

Relevant preparation before starting:

Park the machine.

Cleaning is the key point. All the components shall be cleaned thoroughly with cleaning solution
prior to assembly. The components are allowed for natural drying. Never wipe them dry with
cloth. The fiber from the cloth will accumulate on the parts and cause fault. Check all the
components. If the components are worn or damaged, please replace them with new ones.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused. Method to release pressure: Put the mast system
straight first, and lower it to bottom until the cylinder does not bear force; then flame out and
power on the complete machine, and operate banked direction control valve rod back and forth
for several times to release the pressure.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter can not be removed until the engine stops
and the oil is cool enough for being touched by bare hand.
4-42
Steering Hydraulic System November 2, 2020
Disassembly and Assembly for Steering Hydraulic System CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

1. Firstly remove the instrument cover, then
remove hoses with the wrench and straight
screwdriver after pipe clamp and the tie are
removed;

P22H00039

2. Unscrew joints on the steering gear with the

wrench;
3. Remove four bolts 1 with the wrench; take
down steering gear, and then take down joints
on the steering gear;

P22H00040
 4-43
November 2, 2020 Steering Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly for Steering Hydraulic System

Figures Operation instructions

4. Remove four bolts 1 with the wrench, then
remove steering wheel column assembly from
complete machine.

P22H00041

Assembly of steering hydraulic system 5. Assembly in reverse order from 4 to 2, for

screw thread tightening torque, refer to some
appendixes on the whole (general torque
specifications)
4-44
Steering Hydraulic System November 2, 2020
Disassembly of Steering Wheel Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly of Steering Wheel Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 24# 1 2 Pliers screwdriver 1
2 Cross screwdriver 1

Figures Operation instructions

1. Remove the cover located at 1 on the steering
wheel;
1
2. Unscrew 2 nut with the wrench, then remove
the steering wheel;
2

P22H00042

3. After 1 snap ring is taken off, then remove 2

handle;
4. After 3 screw is unscrewed with cross
screwdriver, remove 4 small handle;

P22H00043
 4-45
November 2, 2020 Steering Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Steering Wheel Assembly

Figures Operation instructions

5. Take down springs with plier and screwdriver.

P22H00044
4-46
Steering Hydraulic System November 2, 2020
Disassembly of Steering Gear CLG2020H/C-2035H/C,CLG2020G-2035G

Disassembly of Steering Gear

The steering gear, with low torque, is integrated with the steering relief valve whose pressure is set
before delivery and is not adjustable.
1. Structural diagram of of steering gear
Steering gear mechanism diagram

P22H00045

1. Dust ring 8. Shaft seal II 15. Couple axle 22. Spring 29. Screw plug
2. Front cover 9. Spool sleeve pair 16. Steel ball 23. Spool 30. O-ring
3. O-ring 10. Pin 17. Pin 24. Valve seat 31. Supporter
4. Retainer 11. Valve body 18. Stator and rotor 25. Filter element 32. Keeper
5. Plane bearing 12. Inlet check valve pair 26. O-ring
6. Slip ring 13. O-ring 19. Block 27. Plug
7. Shaft seal I 14. Baffle 20. Rear cover 28. Leaf spring
21. Bolt

2. Disassembly of steering gear

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 13# 1 2

Relevant preparation before starting:

Cleaning is the key point. Thoroughly clean the outer surface of the components before removal.
It will prevent foreign matters from entering the mechanism.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.
 4-47
November 2, 2020 Steering Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Steering Gear

Figures Operation instructions

1. Remove 1 bolt on the steering gear, and then
1 remove 2 rear cover, 3 block and 4 seal ring;

P22H00046

2. Remove 1 stator and rotor pair and 2 O-ring;

1

P22H00047

3. Remove 1 couple axle, 2 baffle and 3 O-ring;

1

P22H00048
4-48
Steering Hydraulic System November 2, 2020
Disassembly of Steering Gear CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

4. Remove the evacuation-proof check valve,
including 1 pin and 2 steel ball;

2
1
P22H00049

5. Place the steering gear upright, remove spool

1 sleeve pair 1, and then remove pin 2;
2
Notice: Do not knock the spool sleeve pair,
rotate the it slowly at removal;

P22H00050

6. Remove retainer 1, slip ring 2, plane bearing 3,

3 1 seal ring 4 and dust ring.

2
4

P22H00051
 4-49
November 2, 2020 Steering Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Steering Pressure Test

Figures Operation instructions

Assembly of steering gear 7. Assemble the steering gear in the order from 6
to 1, when tighten 7 bolts, pre-tighten them
with the torque 17N.m (12.538lbf.ft), and then
tighten them (as shown in the Figure) with
torque 35-40N.m (25.813-29.5lbf.ft).

P22H00052

Steering Pressure Test

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Inner hexagon
1 Wrench 17# 1 2 5# 1
spanner

Figures Operation instructions

1 is the steering relief valve, 2 is steering gear LS
port, and the pressure of the steering relief valve
1 can be measured at the port by connecting the
sensor.
 Notice: When the steering is heavy,
measure the pressure of the steering relief
valve.
2

P22H00053
4-50
Hydraulic Cooling System November 2, 2020
Steering Pressure Test CLG2020H/C-2035H/C,CLG2020G-2035G

Hydraulic Cooling System Components and position

Mast hydraulic system is used for controlling the

Refer to Removal and Installation of the Radiator lifting and lowering actions of the forklift work
Group for related information about the removal, implement mast. Mast hydraulic system includes
installation and maintenance two-stage standard mast hydraulic system, two-
stage full free mast hydraulic system, and three-
stage full free mast hydraulic system. It consists
Mast Hydraulic System of lift cylinder, explosion-proof valve, speed limit
valve, line and other accessories. In which, the
explosion-proof valve prevent the danger caused
by rapid drop of the work implement when the
line from the oil cylinder to the speed control
valve is exploded. When the mast system is
After removal and installation of mast
lifting and lowering normally, the explosion-proof
hydraulic system or disassembling and
valve is in non-working state; if the line from the
assembling of the oil cylinder, following tests
oil cylinder to the speed control valve is
need to be carried out:
exploded, the oil cylinder will drop rapidly with
1. When assemble the oil cylinder onto the little distance, and then the explosion-proof valve
mast, place the gasket at the rod head end works, and the oil cylinder drops with lower
for adjustment of the mounting distance speed. The speed limit valve is for limiting the
error. Replace the lift cylinder of which the dropping speed of the work implement within the
left stroke is different from the right one. State’s standard range 300-600mm/s. Layout of
2. Operate the banked direction control mast hydraulic system CLG2020-35H/C is
valve without load and with load for 10-20 shown as follows:
minutes, including lifting and lowering,
tilting forward and backward, and keeping
down the pressure of each block, to check
if there is oil leakage or stuck
phenomenon, if any, stop the operation
immediately for maintenance;
3. The forklift forks heavy objects with rated
load weight, and the mast gets straight for
lifting to height of 1-2m (39.37-78.74in);
the complete machine stalls, after
standing for 10 minutes, check distances
of the object's free fall and free slant
forward. The distance of free fall should
be or less than 100mm (3.937in), and that
of free slant forward should be or less
than 1°. If it is out of the range, it should
be overhauled by maintenance personnel.
4. The pressure at bottom of oil cylinder can
be tested by the pressure test port
M14×1.5 which is on the valve block
connecting the speed control valve.
 4-51
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Steering Pressure Test

Two-stage mast hydraulic system CLG2020-

Three-stage full free mast hydraulic system 35H/C
CLG2020-35H/C
3
1

5
3
4

P22H00004 P22H00005

1. Triple valve line 1. Triple valve line

2. Lift cylinder (side cylinder) 2. Lift cylinder (side cylinder)
3. Lift cylinder (center cylinder) 3. Quadruple valve line
4. Quadruple valve line 4. Speed limit
5. Speed limit valve
4-52
Mast Hydraulic System November 2, 2020
Steering Pressure Test CLG2020H/C-2035H/C,CLG2020G-2035G

Two-stage full free mast hydraulic system

CLG2020-35H/C

5
1

P22H00006

1. Triple valve line

2. Lift cylinder (right side cylinder)
3. Lift cylinder (center cylinder)
4. Lift cylinder (left side cylinder)
5. Quadruple valve line
6. Speed limit valve
 4-53
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation of Mast Hydraulic System

Removal and Installation of Mast Hydraulic System

Refer to Removal, Installation and Maintenance of the Mast System for removal and installation of mast
hydraulic system

Disassembly of Oil Cylinder

Disassembly of Two-Stage Standard Oil Cylinder

It is cushion cylinder.
1. Oil cylinder structure figure
Lift cylinder structure figure

P22H00054

1. Dust ring 7. Piston 13. U-ring

2. Steel-backed bearing 8. Copper ring 14. O-ring
3. Bushing 9. Support ring 15. Cylinder head
4. Piston rod 10. U-ring 16. Cylinder block
5. Adjusting sleeve 11. Stop plate 17. Cylindrical pin
6. Steel wire snap ring 12. Circlips for hole

2. Disassembly of lift cylinder

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Hook head wrench 1 3 Paper knife 1
Straight
2 1
screwdriver
4-54
Mast Hydraulic System November 2, 2020
Disassembly of Oil Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Relevant preparation before starting:

Cleaning is the key point. Thoroughly clean the outer surface of the components before removal.
It will prevent foreign matters from entering the mechanism.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Figures Operation instructions

1. Loosen and remove the cylinder head with
1 hook head wrench;

P22H00055

2. Remove the dust ring 1, U-ring 2, O-ring 3 and

2 bushing 4, and then take out the piston rod 5;
3

4 5
1
P22H00056
 4-55
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Oil Cylinder

Figures Operation instructions

3. Remove the support ring 1, stop plate 2 and U-
2 3 ring 3 using screwdriver;
1

P22H00057

4. Remove the circlips for hole 2 using paper

knife, and then remove the copper ring 1.
1
2

P22H00058

Assembly of oil cylinder 5. Assemble from step 4 to 1.

Disassembly of Two-Stage Full Free Cylinder

Two-stage full free cylinder includes side cylinder and center cylinder, in which the side cylinder is
cushion cylinder.
4-56
Mast Hydraulic System November 2, 2020
Disassembly of Oil Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

1. Structural diagram of oil cylinder

Lift cylinder (side cylinder) structure figure

Left lift cylinder

Right lift cylinder

P22H00059

1. Link 10. Plug 19. Spring

2. O-ring 11. Hexagon socket set screw with full 20. Piston
3. Dust ring dog point 21. Joint
4. Stop plate 12. Left plunger rod 22. O-ring
5. Seal ring for shaft 13. Cylinder block 23. Cylindrical pin
6. Steel-backed bearing 14. Buffer plunger 24. Explosion-proof plug
7. Cylinder head 15. Round wire snap ring for shaft 25. Right plunger rod
8. Bushing 16. Hexagon socket set screw with full
9. O-ring dog point
17. Support ring
18. Copper bush

Lift cylinder (center cylinder) structure figure

P22H00060

1. Piston rod 8. Cylinder block 15. Circlips for hole

2. Dust ring 9. Steel wire snap ring 16. Plug
3. Seal ring for shaft 10. Piston 17. Joint
4. O-ring 11. Support ring 18. O-ring
5. Guide sleeve 12. Valve assembly 19. Spring
6. Steel-backed bearing 13. Snap ring 20. Spool
7. O-ring 14. U-ring
 4-57
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Oil Cylinder

2. Disassembly of lift cylinder

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
40#, 36#, Straight
1 Wrench 3 4 1
30# screwdriver
Inner hexagon
2 6# 1 5 Nipping pliers 1
spanner
3 Hook head wrench 1 6

Relevant preparation before starting:

Cleaning is the key point. Thoroughly clean the outer surface of the components before removal.
It will prevent foreign matters from entering the mechanism.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Disassembly of side cylinder:

Figures Operation instructions

1. Unscrew the link 1 with wrench, and then
1 2 remove O-ring 2;

P22H00061
4-58
Mast Hydraulic System November 2, 2020
Disassembly of Oil Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

2. Firstly, unscrew the clamping screw, and then
1 remove the cylinder head 1 with hook head
wrench;

P22H00062
3. Remove the dust ring 1, stop plate 2, U-ring 3,
2 O-ring 4 and bushing 5, and then take out the
3
piston rod 6;

1 4 5

P22H00063

4. Remove the support ring with screwdriver;

P22H00064

Assembly of oil cylinder 5. Assemble from step 4 to 1.

 4-59
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Oil Cylinder

Disassembly of center cylinder:

Figures Operation instructions

1. Loosen and remove the cylinder head with
1 hook head wrench;

P22H00065

2. Remove the dust ring 1, U-ring 2, O-ring 3, O-

2 ring 4 and bushing 5, and then take out the
3 piston rod 6;
6

5
1
4
P22H00066

3. Remove the support ring 1, stop plate 2 and U-

2 3 ring 3 using screwdriver;
1

P22H00057
4-60
Mast Hydraulic System November 2, 2020
Disassembly of Oil Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

4. Remove the circlips for hole 3 using nipping
pliers, and then remove the valve group 1 and
1 2 3 O-ring 2.

P22H00067

Assembly of oil cylinder 5. Assemble from step 4 to 1.

 4-61
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Oil Cylinder

Disassembly of Three-Stage Full Free Cylinder

Three-stage full free cylinder includes side cylinder and center cylinder, in which the side cylinder is
cushion cylinder.
1. Structural diagram of oil cylinder
Lift cylinder (side cylinder) structure figure

P22H00054

1. Dust ring 7. Piston 13. U-ring

2. Steel-backed bearing 8. Copper ring 14. O-ring
3. Bushing 9. Support ring 15. Cylinder head
4. Piston rod 10. U-ring 16. Cylinder block
5. Adjusting sleeve 11. Stop plate 17. Cylindrical pin
6. Steel wire snap ring 12. Circlips for hole

Lift cylinder (center cylinder) structure figure

P22H00060

1. Piston rod 8. Cylinder block 15. Circlips for hole

2. Dust ring 9. Steel wire snap ring 16. Plug
3. Seal ring for shaft 10. Piston 17. Joint
4. O-ring 11. Support ring 18. O-ring
5. Guide sleeve 12. Valve assembly 19. Spring
6. Steel-backed bearing 13. Snap ring 20. Valve
7. O-ring 14. U-ring

2. Disassembly of oil cylinder

Refer to Disassembly of Two-Stage Standard Oil Cylinder for disassembly of side cylinder, and refer to
Central Cylinder Disassebmly for disassembly of center cylinder.
4-62
Mast Hydraulic System November 2, 2020
Speed Limit Valve and Explosion-Proof Valve CLG2020H/C-2035H/C,CLG2020G-2035G

Speed Limit Valve and Explosion- When the system is in the lifting action, oil flows
from port A to P (as shown by the thick line in
Proof Valve following left Figure), at this time, the lifting oil is
not controlled by the speed regulating spool of
Working Principle of Speed Limit Valve the speed limit valve. When the system is in the
lowering action, oil flows from port P to A (as
Outline diagram and schematic diagram of the shown by the thick line in following right Figure),
speed limit valve are as shown in the following at this time, the oil is controlled by the speed
Figure. The main function of the speed limit valve regulating spool of the speed limit valve. When
is limiting the lowering speed of the objects the lowering speed exceeds the setting value,
within the limit value. the speed limit valve spool will reduce the
opening to make the lowering speed return to the
Outline diagram and schematic diagram of the
setting value.
speed limit valve
Schematic diagram of speed limit valve

P22H00069

P22H00068
 4-63
November 2, 2020 Mast Hydraulic System
CLG2020H/C-2035H/C,CLG2020G-2035G Speed Limit Valve and Explosion-Proof Valve

Limiting flow Q (lowering speed) of the system

lowering is influenced by the pressure difference Outline diagram and schematic diagram of the
∆P from port P to port A of the speed limit valve, explosion-proof valve
the curve of limiting flow Q and pressure
difference ∆P is as shown in the following Figure.
When pressure difference ∆P from port P to port
A is too small, the lowering speed will be slow.
The internal spools of the speed limit valve are
integrated, so they can not maintained.
Limiting flow - pressure difference curve

P22H00071

When the lift cylinder is lowering normally, the oil

flows from P to A as shown in the following right
Figure, at this time, the explosion-proof valve
spool has no action. When the line at bottom of
the oil cylinder is exploded, the oil flows from P to
A as shown in the following left Figure. The oil
cylinder will drop rapidly with large lowering flow,
P22H00070 at this time, the explosion-proof valve spool will
act with the pressure difference caused by the
flow and close the old flow passage, oil will flow
Working Principle of Explosion-Proof out of a smaller orifice opening, that is, the oil
Valve cylinder will drop with slow lowering speed.
The explosion-proof valve is a safety element
Outline diagram and schematic diagram of the and cannot be maintained, if damaged, contact
explosion-proof valve are as shown in the the manufacturer immediately for replacement.
following Figure. Main function of the explosion-
proof valve is to prevent the danger caused by Schematic diagram of explosion-proof valve
the objects rapid dropping to the bottom when
the line at bottom of the oil cylinder is exploded.

P22H00072
4-64
Tilt Cylinder Mounting System November 2, 2020
Speed Limit Valve and Explosion-Proof Valve CLG2020H/C-2035H/C,CLG2020G-2035G

Tilt Cylinder Mounting Components and position

System Tilt cylinder mounting system is used for

controlling tilting forward and backward actions
of the forklift work implement mast. It consists of
tilt cylinder, pin shaft and joint, etc. Layout of tilt
cylinder mounting system CLG2020-35H/C is
shown as follows:
After removal and installation of tilt cylinder
mounting system or disassembling and Tilt cylinder mounting system diagram
assembling of the tilt cylinder, following tests
need to be carried out:
1. After removal and installation of tilt
cylinder mounting system, synchronous
commissioning of the tilt cylinder shall be
carried out:
Synchronous commissioning method of the
tilt cylinder: firstly, tilt the mast forward or 1
backward and check whether it is not
synchronous, if any, adjust the oil cylinder
with slow action of tilting forward and
backward; unscrew the captive bolts on the 2
tilt cylinder rod head, and then adjust the
piston rod clockwise (seen from the seat) to
the proper position using the wrench and P22H00007
tighten the tilt cylinder rod head.
2. Operate the banked direction control 1. Pin shaft 2. Tilt cylinder
valve without load and with load for 10-20
minutes, including lifting and lowering,
tilting forward and backward, and keeping
down the pressure of each block, to check
if there is oil leakage or stuck
phenomenon, if any, stop the operation
immediately for maintenance;
3. The forklift forks heavy objects with rated
load weight, and the mast gets straight for
lifting to height of 1-2m (39.37-78.74in);
the complete machine stalls, after
standing for 10 minutes, check distances
of the object's free fall and free slant
forward. The distance of free fall should
be or less than 100mm (3.937in), and that
of free slant forward should be or less
than 1°. If it is out of the range, it should
be overhauled by maintenance personnel.
 4-65
November 2, 2020 Tilt Cylinder Mounting System
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation of Tilt Cylinder Mounting System

Removal and Installation of Tilt Cylinder Mounting System

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
13#, 17#,
1 Wrench 3 2
19#

Relevant preparation before starting

Park the machine.

Cleaning is the key point. All the components shall be cleaned thoroughly with cleaning solution
prior to assembly. The components are allowed for natural drying. Never wipe them dry with
cloth. The fiber from the cloth will accumulate on the parts and cause fault. Check all the
components. If the components are worn or damaged, please replace them with new ones.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by hand.
4-66
Tilt Cylinder Mounting System November 2, 2020
Removal and Installation of Tilt Cylinder Mounting System CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

1. Firstly, remove the side cover and bracket on
the frame, it is not necessary to remove the
instrument cover, and then remove the hose;

P22H00073

2. Unscrew the bolts at position 1 & 2, and then

take out the pin shaft; take out the tilt cylinder
and remove the joint.

2
P22H00074

Assembly of tilt cylinder mounting system 3. Assemble it in the order from 2 to 1, and then
apply grease on the pin shaft. Conduct the tilt
angle and synchronous commissioning of the
oil cylinder.
 4-67
November 2, 2020 Tilt Cylinder Mounting System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Tilt Cylinder

Disassembly of Tilt Cylinder

1. Structural diagram of tilt cylinder

Tilt cylinder mounting system diagram

P22H00075

1. Cylinder head 8. Snap ring 15. Support ring

2. Rod head 9. Seal ring 16. O-ring
3. Cylinder block 10. Snap ring 17. O-ring
4. Piston rod 11. Seal ring 18. Sleeve
5. Washer 12. Steel sleeve 19. Adjusting sleeve
6. Bolt 13. Dust ring 20. Rod head
7. Nut 14. Snap ring

2. Disassembly of tilt cylinder

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Straight
1 Wrench 21# 1 3 1
screwdriver
2 Hook head wrench 1

Relevant preparation before starting:

Cleaning is the key point. Thoroughly clean the outer surface of the components before removal.
It will prevent foreign matters from entering the mechanism.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.
4-68
Tilt Cylinder Mounting System November 2, 2020
Disassembly of Tilt Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

1. Firstly, take out the bolt and gasket after
unscrew nut 1, and then unscrew rod head 2;
 Notice: The tightening torque of nut 1 is
125±13N.m (92.188±9.588lbf.ft)

2 P22H00076

2. Unscrew the cylinder head 2 using hook head

5 wrench and take out the dust ring 1, stop plate
1 3 7 3, seal ring 4, O-ring 5, stop plate 6 and O-ring
7 using straight screwdriver; and then take out
the piston rod 7;

2
4
6
P22H00077

3. Remove the stop plate 1 and seal ring 2 using

1 3 straight screwdriver, and then remove the
support ring 3.

2
P22H00078

Assembly of tilt cylinder 4. Assemble from step 3 to 1.

 4-69
November 2, 2020 Common Faults and Reasons Analysis
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Tilt Cylinder

Common Faults and Reasons Analysis

1. Common fault table for oil pump system

S/N Fault symptom Cause analysis Troubleshooting methods

Replace with oil filter that has
(1) Open area of oil suction filter is small or the
appropriate open area or wash clogged
filer is clogged by foreign matters
oil filter.
Oil tank is filled with hydraulic oil
(2) Oil tank level is too low
according to the specification.
The pump cannot (3) Oil temperature is too low and oil viscosity is Replace with appropriate oil or heat the
1 suck oil or sucks oil too high oil according to the seasons
unsmoothly (4) Oil seal of oil pump is damaged, which
Replace with a new oil seal
inhales air
(5) Oil pump rotation direction is not correct or Change oil pump rotation direction and
the speed is too high adjust the speed to specified value
Check oil suction and seals, replace
(6) Oil suction side leaks
ineffective seals
(1) Seals in oil pump are damaged Replace the seal ring
(2) Side plate is worn Replace side plate
Oil pump volume (3) There is dirt in oil pump or the clearance is Remove dirt, filter the oil and replace
2 efficiency is low or too large with new oil pump
pump flow is small Oil pump runs within specified speed
(4) Oil pump speed is too low or high.
range
(5) Relief valve fails Wash relief valve spool or replace it
(1) Air enters the system Tighten all joints
(2) Insufficient oil supply Refill the oil to a proper level
Refer to troubleshooting method that
(3) Oil suction is obstructed the pump cannot suck oil or sucks oil
unsmoothly
3 Oil pump is noisy
(4) Bad right alignment between pump and Check and then confirm the problem,
input shaft contact the pump manufacturer
(5) Serious resonant vibration; resonant
Check if mounting bolts of line and
vibration with the peripheral components of
components are tightened
line
4-70
Common Faults and Reasons Analysis November 2, 2020
Disassembly of Tilt Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

2. Common fault table for banked direction control valve assembly system

S/N Faults Reasons Troubleshooting methods

(1) The setting pressure of relief valve is low Adjust relief valve pressure (rotate
clockwise)
(2) The relief valve spool is stuck Remove, wash or replace spool, then
Insufficient working reassemble it
1
pressure
(3) Pressure adjusting spring is damaged Replace with new one
(4) System line pressure loss is too much Replace the line or adjust relief valve
pressure within allowed pressure range
(1) System oil supply is insufficient Check oil source and overhaul oil pump
a. Oil temperature is too high and the a. Take measures to reduce the oil
viscosity decreases temperature
Insufficient work
2 b. Oil is not appropriate b. Replace oil
flow
c. Fit clearance between slide valve and c. Replace slide valve according to
valve body is too large appropriate clearance
(2) Relief valve is faulty Overhaul or replace the relief valve
(1) The restoring spring is damaged or
Replace with new one
deformed
3 Reset failure
(2) There is dirt between valve rod and
Clean the parts
valve body
(1) Seal ring is damaged Replace with new one
(2) Each fastener is loose Tighten the corresponding fastener
4 External leakage
(3) Oil temperature is too high and the Take measures to reduce the oil
viscosity decreases temperature
(1) The setting pressure of relief valve is low Adjust the pressure of relief valve
(2) Solenoid coil of solenoid valve assembly
Replace solenoid coil
II is damaged
Fail for lifting and
5 (3) Solenoid spool of solenoid valve
tilting Replace solenoid spool
assembly II is stuck
(4) Solenoid valve assembly II is not
Repair the circuit
energized
(1) Solenoid coil of solenoid valve assembly
Replace solenoid coil
I is damaged
The mast fails for (2) Solenoid spool of solenoid valve
6 Replace solenoid spool
lowering assembly I is stuck
(3) Solenoid valve assembly I is not
Repair the circuit
energized
 4-71
November 2, 2020 Common Faults and Reasons Analysis
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly of Tilt Cylinder

3. Common faults table of steering system

S/N Faults Reasons Troubleshooting methods

(1) Steering pump efficiency is low, which
Replace gear pump
can not reach required pressure
(2) Setting pressure of steering relief valve Replace the steering relief valve spring or
1 Heavy steering is low or relief valve is stuck wash relief valve spool
(3) Steering gear leaks a lot Replace the steering gear
(4) Steering gear has high mechanical
Replace the steering gear
resistance
(1) The pump is vacuumized and the Check if oil suction pipe and oil suction filter
Steering wheels are system generates air are clogged
quilted and the
2 (2) Seals in steering cylinder is damaged Replace seals in steering cylinder
forklift does not go
straight (3) Load holding capacity for steering gear
Replace the steering gear
at L and R is decreased
(1) Connection of steering mechanism has
Adjust it to appropriate clearance
large clearance
(2) Steering gear return characteristic is
3 The forklift deviates Contact the manufacturer for maintenance
poor
(3) Steering wheel has large pressure
Adjust the pressure on both sides
difference
(1) Stator/rotor is stuck by dirt Clean stator/rotor
Steering wheel can (2) Insufficient pressure Refer to reasons 1 and 2 in fault 1
4
not be rotated (3) Internal parts in the steering gear are Contact the manufacturer to replace the
damaged steering gear
4-72
Common Faults and Reasons Analysis November 2, 2020
Disassembly of Tilt Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G
 5-1
November 2, 2020 Brake System
CLG2020H/C-2035H/C,CLG2020G-2035G

Brake System
Safety................................................................................................................................5-3
System Overview.............................................................................................................5-3
Structure and Function ...................................................................................................5-4
Brake Master Cylinder ...........................................................................................................................5-4
Technical Parameters and Specifications ..........................................................................................5-4
Wheel Brake ..........................................................................................................................................5-5
Service Brake System and Auxiliary Braking System ........................................................................5-8
Commissioning of the Service Brake Distance ................................................................................5-10
Commissioning of Pedal Height ......................................................................................................5-11
Parking Brake System .........................................................................................................................5-12
Brief Introduction of Function ...........................................................................................................5-12
Schematic Diagram .........................................................................................................................5-13
Commissioning of Ramp Parking Brake ..........................................................................................5-13

Removal & Installation and Maintenance....................................................................5-15

Brake Master Cylinder .........................................................................................................................5-15
Installation of Brake Master Cylinder ...............................................................................................5-16
Hand Brake Control Lever ...................................................................................................................5-17
Removal of Hand Brake Control Lever ............................................................................................5-17
Installation of Hand Brake Control Lever .........................................................................................5-17
Wheel Brake ........................................................................................................................................5-18
Removal of Wheel Brake .................................................................................................................5-18
Installation of Wheel Brake ..............................................................................................................5-20

Faults and Countermeasures .......................................................................................5-21

5-2
Brake System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 5-3
November 2, 2020 Safety
CLG2020H/C-2035H/C,CLG2020G-2035G

Safety System Overview

1. When components are removed, their weight The brake system consists of service brake
must be evaluated (see parameter list of system, auxiliary braking system and parking
complete machine for this manual), if brake system, whose operation mechanisms are
necessary, use the sling to protect them from installed on the front cross member panel of the
being damaged resulting from falling off. frame system.
2. Do not depress the brake pedal under the The service brake system is the main braking
disassembling state of the brake hub, system for braking the machine and stopping the
otherwise, the brake may fall apart. vehicle. The auxiliary braking system, also
known as the inching brake system, is the
3. Make sure that the pressure in the brake
protection and auxiliary of the service brake
system is released before the removal; do
system, which maintains the braking capacity of
not conduct the removal when there is still
the complete machine as the brake system fails.
pressure in the brake fluid to prevent the
The parking brake system, also known as the
injury caused by the spray of high-pressure
emergency braking system, is a system that
fluid.
keeps the machine which has been braked in the
4. Prepare a container for the fluid in advance stationary state. Three subsystems are
before replacing the brake fluid or exhausting responsible for the braking, inching braking and
air to avoid environmental pollution. parking functions of the complete machine,
which are closely related with the safe operation.
5. Conduct the commissioning of the brake
system again as per the correct methods to
make sure that it meets related requirements 1
after removal and installation of the system or
disassembly and assembly of its 3
components.
6. Conduct the operation according to 2
corresponding description at the position
pasted with safety marks to prevent potential
hazards.

P22B00001

1. Parking brake system (emergency brake system)

2. Auxiliary braking system (inching brake system)
3. Service brake system
5-4
Structure and Function November 2, 2020
Brake Master Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Structure and Function

Brake Master Cylinder

Technical Parameters and Specifications

Parameters Metric unit British unit

Pressure built-up (idle) stroke 1mm 0.04 In
Diameter of master cylinder piston 19.05mm 0.75 In

Component Structure Diagram

1 2 3 4 5 6 7 8 9 10 11

12

13 14

15
16

17
18

P22B00002

1. Push-rod fork 7. Piston assembly 13. Delivery valve assembly

2. Nut 8. Dust plug 14. Oil outlet pipe joint
3. Push rod 9. Oil inlet pipe joint 15. Shim
4. Shield 10. O-ring 19×2.65 16. Dust plug
5. Elastic washer for holes 11. Spring clip 17. Bleeder screw cap
6. Cylinder block 12. Return spring 18. Bleeder screw
 5-5
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Wheel Brake

Maintenance References

Replace the brake master cylinder if it leaks.

Wheel Brake

Technical Parameters and Specifications

Parameters Metric unit British unit

Radius of brake drum 157mm 6.18 In
Diameter of slave cylinder piston 28.50mm 1.12 In
5-6
Structure and Function November 2, 2020
Wheel Brake CLG2020H/C-2035H/C,CLG2020G-2035G

Component Structure Diagram

Hydraulic transmission oil line schematic diagram is shown in figure below.

3 27

21-1 21-2 21-3 21-4 21-5 21-6

4

7 21 21-7
20 21-8
19
18 21-9
21-10

17
8

16

9 10 11 12 13 14 15
P22B00003

1. Bolt 14. Slack adjuster assembly 21-5. Slave cylinder spring

2. Spring washer 15. Spring wire device 21-6. Brake slave cylinder
3. Rubber plug 16. Return spring (rear) 21-7. Slave cylinder bleeder screw
4. Compression spring pull rod 17. Guide block 21-8. Brake slave cylinder oil plug
5. Brake plate assembly 18. Return spring (front) 21-9. Slave cylinder bleeder screw
6. Link pin 19. Guide plate cap
7. Hand brake pull rod 20. Brake shoe with lining and 21-10. Thread protection plug
8. Brake shoe with lining assembly hanging spring pin assembly 22. Torsion spring pin
9. Compression spring seat 21. Brake slave cylinder assembly 23. Brake push rod
10. Compression spring 21-1. Slave cylinder piston rod 24. Rod pin catch spring
11. Tension spring 21-2. Slave cylinder dust cover 25. Spring washer
12. Pawl 21-3. Slave cylinder piston 26. Spring
13. Torsion spring 21-4. Rubber cup of slave cylinder 27. Brake cable assembly
 5-7
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Wheel Brake

Functional Schematic Diagram Maintenance References

Description: The force F0 to open the brake shoe 1. If the lining is slightly worn, the slack between
is achieved after depress the brake pedal to build the brake shoe and brake drum needs to be
the pressure of the brake slave cylinder, or after adjusted by adjusting the teeth;
pull the hand brake to make the flexible shaft
2. If the lining is severely worn, that is, the
produce the pull force; positive pressure F1 and
distance between the lining surface and rivet
F2 is produced by the contact of the lining and
head is less than 1mm (0.04 In), the brake
brake drum after the brake shoe is open; finally
shoe shall be replaced.
brake friction force f F1 and f F2 are produced to
achieve the braking effect.

P22B00005

P22B00004
5-8
Structure and Function November 2, 2020
Wheel Brake CLG2020H/C-2035H/C,CLG2020G-2035G

Service Brake System and Auxiliary The inching brake pedal and brake pedal have
Braking System the one-way linkage function: the depress of the
inching brake pedal can drive the action of the
Brief Introduction of Function brake pedal, but the reverse is impossible.

The service brake system is the main braking

1 8
system for braking the machine and stopping the 6
vehicle. Operate the service brake system with 2 10
pedal mechanism: Depress the service brake
pedal, via the action transmission of mechanical
mechanism, the brake master cylinder piston is 3
pushed to close the brake cylinder so that the
pressure is built. After the pressure is transmitted
to the brake slave cylinder, the piston is ejected
and the wheel brake shoe is open so that the
lining contacts the brake drum and frictional
resistance is produced to achieve the braking
effect.
The auxiliary braking system, also known as the
inching brake system, is the protection and 5 7 9
4
auxiliary of the service brake system, which
maintains the deceleration capability of the
complete machine as the brake system fails. P22B00006
Operate the auxiliary braking system with pedal
mechanism: After the inching brake pedal is 1. Oiler 6. Inching brake pedal
2. Oil filler pipe 7. Micro-braking flexible
depressed, via the action transmission of 3. Brake master cylinder shaft
mechanical mechanism, the inching valve 4. Brake pipe 8. Brake pedal
linkage is ejected, the pressure of the clutch is 5. Brake transfer 9. Inching brake transfer
mechanism mechanism
gradually reduced and the gearbox is separated
10. Wheel brake
from the lining so as to cut off the power.
 5-9
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Wheel Brake

Schematic Diagram Inching brake system

Pressure
Service brake system

Pedal
Oil storage tank

Wheel
brake
Brake master
cylinder

Inching valve rod

Inching valve characteristic
curve P22B00008

Description: After the inching brake pedal is

Wheel depressed, via the action transmission of
brake P22B00007 mechanical mechanism, the inching valve
linkage is ejected, the pressure of the clutch is
Description: Depress the service brake pedal, via gradually reduced and the gearbox is separated
the action transmission of mechanical from the lining so as to cut off the power.
mechanism, the brake master cylinder piston is
pushed to close the brake cylinder so that the
pressure is built. After the pressure is transmitted
to the brake slave cylinder, the piston is ejected
and the wheel brake shoe is open so that the
lining contacts the brake drum and frictional
resistance is produced to achieve the braking
effect.
5-10
Structure and Function November 2, 2020
Wheel Brake CLG2020H/C-2035H/C,CLG2020G-2035G

Commissioning of the Service Brake Adjustment Measures

Distance
Method for adjusting the slack between the lining
Measurement Tools and brake drum are:
1. Park the forklift on flat ground (the ground
Tape measure or measuring tape with trench is preferred) and remove the
limits of all brake systems.
Preparations
2. Find the slots of the slack adjuster
Make sure that the parking brake system of the respectively at bottom and inner side of left
forklift works normally before inspection of the and right sprockets and remove the rubber
service brake performance for the convenience cap.
of conducting the emergency brake with the 3. Move the teeth along with the turning
parking brake under emergency condition. direction (the direction without limit of flaw) of
The motion of the machine at the inspection may the slack adjuster teeth to adjust the slack
cause personal injury. between the shoe and the brake drum
smaller.
Test Method 4. As the tooth can not be moved continuously,
lift the flaw lightly and move reversely 10-16
1. Drive the forklift straightly without load at
teeth; turn the wheel manually and check that
maximum throttle speed on the flat and dry
there is no brake resistance; the diameter of
concrete road to the maximum speed, and
the slack between the lining and brake drum
then depress thoroughly and rapidly the
can be adjusted to about 0.25-0.4mm (0.01-
service brake pedal until the forklift is
0.016In) with the adjustment.
completely braked.
5. Install the rubber cap.
2. After the brake is achieved completely, push
the gear shift lever to the Neutral position, 6. Re-test the brake distance to make sure that
pull the hand brake control lever, and then the brake distance≤6m (236.22 In) and there
release the service brake pedal. is no unexpected brake in running.
3. Measure the marks, as the braking distance
of the forklift, of the left and right tires left on
the ground with tape measure or measuring
tape.

Result Evaluation

Normal state: brake distance≤6m (236.22 In) and

the length of left tire mark shall be basically in
accordance with that of the right tire mark;
Commissioning state: brake distance > 6m
(236.22 In) and there is large difference in the
length of left and right tire marks.
1
2
P22B00009

1. Flaw 2. Slack adjuster

 5-11
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Wheel Brake

Note: If the brake distance is much more than 6m

(236.22 In), or there is larger difference in the
length of left and right tire marks and the brake
performance under normal state can not be 1 3
achieved with the above methods, conduct
necessary maintenance and service for the
brake system or consider the faults and
countermeasures of the brake system.

P22B00012

1. Adjusting bolt of the inching brake pedal initial

height
2. Adjusting bolt of the pedal linkage height
3. Adjusting bolt of the brake pedal initial height
P22B00010

Commissioning of Pedal Height

P22B00011
5-12
Structure and Function November 2, 2020
Parking Brake System CLG2020H/C-2035H/C,CLG2020G-2035G

Commissioning Purpose Parking Brake System

When re-install the removed pedal, its height
shall be adjusted to achieve good capacity of Brief Introduction of Function
inching braking and brake and more comfort
operation feeling. The parking brake system, also known as the
emergency braking system, is a system that
Commissioning Methods keeps the machine which has been braked in the
stationary state. The system of the forklift is
The pedal initial height A can be adjusted by the operated by hand brake mechanism: After
adjusting bolt of the pedal initial height. The initial parking, pull the control lever backwards, the
height of inching brake pedal and brake pedal control lever flexible shaft produces pulling force
shall remain the same. which is transmitted to the wheel brake to open
the brake shoe and the lining contacts the brake
The empty stroke, that is the height difference B,
drum producing the friction resistance, finally, the
of inching brake pedal before linkage of inching
parking brake effect is achieved (share a set of
brake pedal and brake pedal can be adjusted by
brake with the service brake).
the adjusting bolt of the pedal linkage height.

Commissioning Parameters 1

Parameters Metric unit British unit

Initial height A 143±10mm 5.63±0.39In
Linkage height
8±5mm 0.31±0.2In
difference B
2

P22B00013

1. Hand brake control lever

2. Control lever flexible shaft
3. Wheel brake
 5-13
November 2, 2020 Structure and Function
CLG2020H/C-2035H/C,CLG2020G-2035G Parking Brake System

Schematic Diagram Commissioning of Ramp Parking Brake

Measurement Tools

Timekeeping tool

Preparations

Adjust the tire pressure of the forklift to specified

value and the fork off the ground 150-200mm
(5.91-7.84In) and make sure that the forklift has
good performance of service brake.
The motion of the machine at the inspection may
cause personal injury.

Test Method
P22B00014
1. Start the engine, straighten the forklift and
drive it on a 15% (8.53°) slope with flat and
dry road surface.
2. Depress the service brake pedal and stop the
forklift steadily, place the shift control lever to
neutral position, and then the engine is shut
off.
1 2 3. Pull the hand brake control lever and release
slowly the service brake pedal with timing
observations for 5min, and check visually
whether the forklift has the capability of
staying in the original position of the slope
without movement.

Result Evaluation
P22B00015
If the forklift dose not slide, the parking brake
1. Release position 2. Tensioning position
system is good;

Description: After parking, pull the control lever If the forklift slides, the parking brake system
backwards, the control lever flexible shaft needs to be adjusted.
produces pulling force which is transmitted to the
wheel brake to open the brake shoe and the
lining contacts the brake drum producing the
friction resistance, finally, the parking brake
effect is achieved
5-14
Structure and Function November 2, 2020
Parking Brake System CLG2020H/C-2035H/C,CLG2020G-2035G

Adjustment Measures Note: (1) If the ramp parking brake performance

can not recover to the normal state with the
If the forklift moves, the elasticity of the hand above method, consider the faults and
brake control lever flexible shaft shall be countermeasures of the brake system. (2)
adjusted, the adjusting method is: Excessively tightening the adjusting screw cap
may cause excessive operation force of the hand
1. Park the forklift on a flat ground and remove
brake, therefore, unscrew it properly as it meets
the limits of all brake systems.
the requirements to improve the operation
2. Turn the elasticity adjusting bolt of the hand comfort.
brake control lever flexible shaft with straight
screwdriver (minimum single turning angle:
60 ° / time), clockwise for tightening (the
operating force of the hand brake is raised
and ramp parking brake performance
increases), counterclockwise for release (the
operating force of hand brake is reduced and
the ramp parking brake performance
decreases), tightening clockwise shall be
conducted at this time.
3. Re-test the ramp parking brake effect to
make sure that the forklift parking brake
system meets the requirement.

P22B00016

1. Adjusting bolt
 5-15
November 2, 2020 Removal & Installation and Maintenance
CLG2020H/C-2035H/C,CLG2020G-2035G Brake Master Cylinder

Removal & Installation and Maintenance

Brake Master Cylinder

Removal of Brake Master Cylinder

Figures Operation instructions

1. Remove the access door (1).
For the method, please refer to the chapter of
Introduction for Covering Parts System.

P22B00017

2. Remove the oil filler pipe port (2) at one side of

the brake master cylinder and the brake pipe
joint (3) at one side of the brake master
cylinder and deal with the overflowing brake
fluid.

P22B00018
5-16
Removal & Installation and Maintenance November 2, 2020
Brake Master Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Remove the 3 bolts M10 (5) that fixing the
master cylinder (4)bracket from the front of the
base machine and take the master cylinder
and small bracket out simultaneously.

5
P22B00019
4. Remove 2 bolts M10 (5) and nut fixing the
master cylinder and separate the master
cylinder from small bracket.

P22B00020

Installation of Brake Master Cylinder

The process of installing the brake master cylinder is the reverse of removing it.
 5-17
November 2, 2020 Removal & Installation and Maintenance
CLG2020H/C-2035H/C,CLG2020G-2035G Hand Brake Control Lever

Hand Brake Control Lever

Removal of Hand Brake Control Lever

Figures Operation instructions

1. Open the access door (3), remove the steering
1 gear dust cover (1) and left instrument cover
(2) to expose the hand brake control lever
mechanism.
2
For the method, please refer to the chapter of
Introduction for Covering Parts System.

P22B00021

2. Remove the retaining nut (4) of brake flexible

shaft at one end of the hand brake control lever
and 4 bolts M10 (5) installing the hand brake
control lever on the front cross member panel,
then the control lever can be taken out.

P22B00022

Installation of Hand Brake Control Lever

The process of installing the hand brake control lever is the reverse of removing it.
5-18
Removal & Installation and Maintenance November 2, 2020
Wheel Brake CLG2020H/C-2035H/C,CLG2020G-2035G

Wheel Brake

Removal of Wheel Brake

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Sleeve 38# 1 3 Torque wrench 10#, 19# 2
Inner hexagon
2 12# 1 4 Wrench 12# 1
spanner

Figures Operation instructions

1. Place limit blocks in front of and behind rear
wheel, place wood block under the frame, lift
the front wheel and pull hand brake well, and
then apply parking brake.

P22B00023
2. Remove tire mounting nut (2), and remove
front wheel assembly (1). When installing, the
tightening torque is 550-650N.m. (38# Sleeve)

1
2
P22B00024
 5-19
November 2, 2020 Removal & Installation and Maintenance
CLG2020H/C-2035H/C,CLG2020G-2035G Wheel Brake

Figures Operation instructions

3. Unscrew drain plug 1, and drain residual oil in
the axle; check O-ring 2, and if it is damaged,
replace it with a new one, and then screw the
plugs back into the axle after oil is drained out.
(Inner hexagon spanner: 12#)

1
2
P22B00025
4. Take down captive bolts, and remove axle
shaft 4; when assembling, apply sealant again
for installation after cleaning residual sealant
on junction surface. The tightening torque of
4 3 bolts is 110-130N.m (11.22-13.26kgf·m).
(Torque wrench: 19#)

P22B00026
5. Remove locknut 8 after taking down thrust
washer 7, and then take down hub assembly 9;
9 8 7 6 5 when assembling locknut, rotative moment of
the hub should be 6-8N.m (0.61-0.82 kgf·m).
(Torque wrench: 10#)

P22B00027
5-20
Removal & Installation and Maintenance November 2, 2020
Wheel Brake CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

6. Remove the captive bolt. Remove brake
assembly 12. (Wrench: 21#)

12 11 10

P22B00028

Installation of Wheel Brake

The process of installing the wheel brake is the reverse of removing it.
 5-21
November 2, 2020 Faults and Countermeasures
CLG2020H/C-2035H/C,CLG2020G-2035G Wheel Brake

Faults and Countermeasures

S/N Fault features Main reasons Inspection and countermeasures

(1) The slack between the brake drum
and brake shoe is excessively large
Adjust the slack between the brake drum
or two wheels can not be braked
and brake shoe with slack adjuster
simultaneously with uneven
clearance
(2) The brake fluid is mixed with Open the oiler for observation, replace the
impurities fluid if it has serious change
Disassemble the access door, adjust the
(3) The empty stroke of the brake pedal pedal height and master cylinder ejector rod
is excessively large position, and adjust the stroke of the pedal
Service brake effect action according to actual condition
1
is poor
Conduct the test and adjust it to the
(4) Tire inflation pressure is improper
standard tire pressure
(5) The brake fluid in the brake system Conduct the exhaust to check whether it
(non-cylinder part) leaks and mixes mixes with air and check the leaking point
with air and replace the oil leakage part
(6) Master cylinder leaks oil Replace the master cylinder
After ruling out the possibility of other
leaking points, finally conduct the inspection,
(7) Slave cylinder leaks oil
disassemble the brake drum and replace the
slave cylinder
Check the tightening condition, replace the
(1) Brake bottom plate is deformed or
deformed components and tighten the loose
bolt is loose
part
Check the return condition and replace the
(2) Brake shoe return spring fails
spring
2 Noise in the brake (3) The brake shoe lining is worn with If the lining is worn to expose the mounting
harden surface bolt, conduct the repair and replacement
(4) Brake shoe lining surface has oil
Wipe them for cleaning
stains
Check the tightening condition and re-
(5) Wheel bearing is loose
tighten it
Turn the adjusting bolts of the hand brake
Parking brake Hand brake flexible shaft is excessively
3 clockwise and tighten it for parking on 15%
effect is poor loose
ramp
Inspect the brake fluid, refill or replace it if
(1) The brake fluid is insufficient.
The brake pedal is necessary.
weak, when it is Inspect wheel hubs, adjust the gap between
4 (2) Wheel hubs are worn.
depressed, it is so brake pad and wheel hub.
close to the floor. (3) The brake master cylinder doesn't Inspect the brake master cylinder, replace it
work. if necessary.
5-22
Faults and Countermeasures November 2, 2020
Wheel Brake CLG2020H/C-2035H/C,CLG2020G-2035G

(1) The seal of axle is worn or damaged. Replace it with a new one.
The seal of axle (2) The seal is deformed. Replace it with a new one.
5 and the brake leak After ruling out the possibility of other
oil. (3) The rubber cup of brake slave
leaking points, inspect and disassemble the
cylinder doesn't work.
brake drum and replace the slave cylinder.
The hand brake
needs too much
force to be pulled Turn the adjusting bolt of the hand brake
The adjusting bolt of hand brake is too
6 up, and it is difficult counterclockwise and tighten it for parking
tight.
to press the button on a 15% ramp.
to release the hand
brake
 6-1
November 2, 2020 Electrical System
CLG2020H/C-2035H/C,CLG2020G-2035G

Electrical System
Basic Information ............................................................................................................6-3
Overview.........................................................................................................................6-10
Power System ................................................................................................................6-11
Fuse and Relay ....................................................................................................................................6-11

Electric Lock ..................................................................................................................6-13

Instrument System ........................................................................................................6-17
Alternator .......................................................................................................................6-23
Starter .............................................................................................................................6-24
Sensor ............................................................................................................................6-27
Electronic Steering System ..........................................................................................6-29
Brake Indicator System.................................................................................................6-34
Lighting System.............................................................................................................6-37
Battery ............................................................................................................................6-40
Preheating ......................................................................................................................6-43
Horn ................................................................................................................................6-46
OPS .................................................................................................................................6-48
Fault Code Table............................................................................................................6-50
6-2
Electrical System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 6-3
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G

Basic Information The module failure diagnosis and test introduced

in the Manual does not cover all the faults, thus
please rack your brain and focus on the
Instructions of service manual accumulation of experience during the
troubleshooting.
The Manual is written by introducing the different
modules divided by the main functions of Full consideration to the relationship between the
electrical system, whereby, the maintenance general and the individual (system and
operations of maintenance technicians are component) when determining the failures will
facilitated as they are enabled to promptly find contribute to the rapid, accurate and facilitated
the chapters and sections corresponding to the troubleshooting.
failure at any time. Besides, the professional On condition that digital multimeter is applied to
descriptions are compiled to be accessible in the detect faults, the inherent measuring errors
Manual, nonetheless, the maintenance might result in a value slightly differing from that
personnel shall be provided with necessary described in the Manual. For instance, when
professional knowledge to understand the selecting the 200 Ω range of Ω gear of digital
Maintenance Manual. multimeter, the values described in the Manual
When dividing the modules, the Manual starts are comparable through shorting out the red and
from introducing the functions of the module, black probes, measuring the lead resistance and
then presents the main components of the subtracting such lead resistance from the
functions, including the principles, functions and measured resistance of other circuits.
electrical diagrams of main components.
Whereafter, operation of module function and the Precautions for welding
diagnosis and test of module failure are Be sure to comply with the correct welding
introduced. procedures, so as to safeguard the electrical
The component symbols on the schematic components and bearings against potential
diagram indicate the representing methods of damages. When welding on a loader or diesel
components on the diagram. The majority of engine equipped with electrical components,
component symbols signify the actual schematic please follow the operating steps below:
diagram of the components, whereas, the 1. Place machine on a flat ground.
exceptions are specified when introducing the
components. It will help to judge the failure 2. Turn the electric lock to "OFF" position, and
symptom of components. shut down the diesel engine.
The component failure detection methods are 3. Pull up the handbrake.
also included in the component instruction of the 4. Cut off the connection between the battery
Manual. Such methods are only for the and frame, and disconnect the controller
components, whereby, the failures are detected connector and instrument connector.
through dismounting the components from the
complete machine. It is unfeasible to detect the 5. Clamp the parts to be welded with the ground
failures in accordance with the above-mentioned cable of the welder tightly. The closer the
methods if the components are mounted on the grounding position with the welding, the
complete machine. Then determine in line with better. Check the circuit from ground cable to
the failure detection methods described behind welding components, to verify any of the
the system, or disassemble the components if below components has not been passed
necessary, to judge the condition of components through:
based on the component troubleshooting ● Bearing
method.
● Hydraulic cylinder
6-4
Basic Information November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

● Internal circuits of the controller or other

electronic components.
Doing in this way is to keep the following parts
away from the possible damage:
During welding, the grounding point of
● Bearing welder on the frame shall be close to the
● Hydraulic components welding point to the greatest extent, for
which a reliable large-area grounding shall be
● Electronic component guaranteed.
● Other available components on the machine Do not use the grounding point of any
6. The inflammables shall be away from the electrical component on the machine as the
welding site and protect the cables from the grounding point of the welder!
loss and damage resulted from the fire For welding near the grounding point of the
caused by splashing sparks and welding electrical components, you must not perform
slag. welding operation until you disconnect the
7. Perform the weldment according to the grounding point of the electric appliance and
normal welding safe performing procedure. make sure that the welding circuit of the
welder does not pass through the electric
appliance. Otherwise, it will cause damage to
the electrical component, and even lead to a
fire!
To prevent possible losses, for the machine
equipped with electronic control
components, such as the ZF control unitEST-
37A, electrical centralized control box,
instrument, and engine ECM etc., ensure that
the welding circuit is disconnected from that
of the aforementioned electronic control
components before welding, while the
connectors closest to such control
components shall be unplugged to cut the
circuit off.
 6-5
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G

The introduction of symbols on the electrical schematic

Graphic symbol of double position manual control

Graphic symbol of the control switch
switch

Descript Descript
No. Name Graphic symbol No. Name Graphic symbol
ion ion

Normall Emergency stop

1 Pressure switch 1 Hold
y open switch

Instanta
Normall
2 Pressure switch 2 Button switch neous
y closed
acting

Temperature
3 3 Knob switch Hold
switch

Instanta
4 Liquid level switch 4 Knob switch neous
acting

Induction proximity
5
switch

Magnetic induction
6
proximity switch
6-6
Basic Information November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Graphic symbol of the relay Graphic symbol of the electromagnet

Descript
No. Name Graphic symbol Description No. Name Graphic symbol
ion

One group of
General- normally- Electromagnet of
1 1
purpose relay open the switch
contacts

A group of
break-
before-make
Relay with
changeover Proportional
2 normally closed 2
contacts, coil electromagnet
contact
in parallel to
restrain
diode

Double-coil
3
electromagnet
 6-7
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G

Light and signal graphic symbol Graphic symbol of the sensor

Descript
No. Name Graphic symbol No. Name Graphic symbol
ion

1 Lamp 1 Rheostat sensor

Temperature
2 Rotating beacon 2 sensor with alarm
switch

Pressure sensor
3 Electric horn 3
with alarm switch

Inductive speed
4 Buzzer 4
sensor

5 Speaker

6 Flash relay
6-8
Basic Information November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Testing tools When performing the conduction test, it is

necessary to turn off the power of the tested
Test tool usually used by electrical system is element to ensure safety. However, +12V voltage
multimeter, multimeter on the market has many shall be used for energizing the coil of the relay
different kinds, and the function, parameter, to test the conduction condition of the relay
precision of them are different, so carefully read component controlled switch.
the multimeter manual before using, so that the
multimeter can be used correctly. Resistance test
This section provides the user with a common
guideline on multimeter correct measurement
techniques.
Digital auto-ranging multimeter and manual
ranging multimeter

P22E00003

P22E00001

Before using this device, make sure that two

probes are connected to the right ports for
testing; the black probe is connected to COM
port, and the red probe is connected to the
testing port for voltage, resistance and diode.
P22E00004
Conduction test
Select Ω position on the auto-ranging multimeter,
and select 200 Ω position on the manual ranging
meter. Measure the resistance using the probe
according to the method described in this
manual, and compare the actual measurement
result with the values listed in the manual. The
correct value for conduction should be Zero or
minimum resistance, and it indicates that the
circuit is conductive.

P22E00002
 6-9
November 2, 2020 Basic Information
CLG2020H/C-2035H/C,CLG2020G-2035G

Diode test DC voltage

P22E00005 P22E00007

Select the diode symbol. When testing the diode, Select DC voltage. Select DC voltage position on
if connect two probes to the both ends of the the auto-ranging multimeter, and select DC
diode, a very high value will be gained. In turn, voltage 200V position on the manual ranging
connect the probe to both ends of the diode in multimeter. If correctly select DC voltage, letter V
the other direction, a very low value will be and DC should be displayed on the screen.
gained. Compare the actual measurement result
and the value listed in the manual, if the
difference is large, replace the diode.
AC voltage

P22E00006

Select AC voltage. Select AC voltage position on

the auto-ranging multimeter, and select AC
voltage 200V position on the manual ranging
multimeter. If correctly select AC voltage, letter V
and AC should be displayed on the screen.
6-10
Overview November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G

Overview

Electrical system is a single circuit with negative grounding. Electrical equipment consists of charging
system, starting system, instrument and light signals. For schematic diagram of complete vehicle, see
the attachment.

P22E00008
 6-11
November 2, 2020 Power System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Power System

Fuse and Relay

Position

P22E00009

1. Secondary fuse and relay 2. Main fuse

17

P22E00010
6-12
Power System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

1 2 3
P22E00011

Parameters

4 5 6 7 8 9 10 11 12

13 14 15 16
P22E00012

Param PDM Param PDM

No. Name No. Name
eters number eters number
1 Main fuse for preheating 150A 37B2262 10 Secondary fuse for gear 5A 37B0044
2 Main fuse for alternator 80A 37B0753 11 Secondary fuse for ECM 20 A 36B0073
3 Main fuse for main power 80A 37B0753 12 Secondary fuse for wiper 10 A 37B0030
Secondary fuse for electric
4 15A 37B0062 13 Flash relay 12V 31B0434
lock
5 Secondary fuse for steering 5A 37B0044 14 Floodlight relay 12V 20A 31B0210
6 Secondary fuse for horn 5A 37B0044 15 Preheating relay 12V 70A 31B0069
7 Secondary fuse for instrument 20A 36B0073 16 Start relay 12V 70A 31B0069
12V
8 Secondary fuse for floodlight 15A 37B0062 17 Preheating relay 46C8754
100A
9 Secondary fuse for A/C 20A 36B0073
 6-13
November 2, 2020 Electric Lock
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Electric Lock

Position

P22E00013

Parameters

No. Component Model LG PDM

1 Electric lock JK411 34B0474

Terminal
2 4 1 3 Remarks
Function
OFF

1 20A

2 3A

3 2A

Operation

Insert the electric lock key and it should be in OFF position at this time. At this position, only floodlight,
horn and brake light are available.
6-14
Electric Lock November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Position diagram:

et
res
atic
Au tom

Au
t
om
at
ic
esr
et

P22E00014

When electric lock is at OFF position, rotate electric lock key clockwise to 1st position. After releasing,
electric lock will keep at this position. Instrument, preheating, turn signal light and reverse function are
available;
When electric lock is at 1st position, rotate electric lock key clockwise to 2nd position. After releasing,
electric lock will return to 1st position automatically. When electric lock key is turned to 2nd position, start
relay will be energized to drive the starter in addition that electric devices at 1st position are energized.
Notice: 3rd position for electric lock is not used.
 6-15
November 2, 2020 Electric Lock
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Wiring diagram

The black circuit is constant power circuit, the red circuit is the powered circuit after the electric lock is
unlocked.

Power
Start supply

To alternator
To
preheating

P22E00015
6-16
Electric Lock November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Troubleshooting

1. For all faults, first check if related fuse is good. For circuits related to start, preheating, flash and
lighting, check the relay.
2. Fuse diagnosis: visually check whether the fuse is blown, if any, replace it with the same type of fuse.
3. Relay diagnosis: measure the resistance between pin 85 and 86 with a multimeter, if the resistance is
between 14Ω and 28Ω, it indicates that the relay coil is good. If the resistance is 0 (or infinite), it
indicates that the relay is short (or open), replace it with the same type of fuse.
4. Electric lock diagnosis: measure the conduction condition between all position terminals of electric
lock using the multimeter with conduction position and compare it with conduction in electric lock
parameters.
If the following situations occur, replace the electric lock:
Measured conduction does not match with the parameters.
Reset function of the electric lock spring fails;
Electric lock can be inserted or pulled out at any position, not only at OFF position.
 6-17
November 2, 2020 Instrument System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Instrument System

Position

P22E00013

1. Instrument
6-18
Instrument System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

P22E00016

2. Air filter clogging sensor

P22E00010

3. Fuel water separation warning switch (located at the bottom of the fuel filter)

Parameters

Component Service voltage Working temperature LG PDM

Instrument 5V~30V -30~+70 35B0497
 6-19
November 2, 2020 Instrument System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

P22E00017

Flashing State
Attributes Color Icon Troubleshooting suggestion
attribute description

Right turn Green Flashing

If the lamp still flashes after starting,

measure whether the oil pressure
has reached 7.5kPa, if it has not
Oil pressure Low oil
Red Flashing reached this level, check whether the
alarm pressure
oil is enough or replace the oil pump;
if it has reached this level, replace
the oil pressure sensor.
If the lamp is still always on after
starting, measure the voltage of wire
#700, if the voltage is higher than 7V,
Charging Battery is not replace the instrument; if the voltage
Red Always on
indication charged is lower than 7V, check the alternator
belt for looseness, and check
whether the alternator fuse is blown
or replace the alternator.
If the lamp flashes, drain water from
the fuel filter, after the water is
drained, wait for 5 minutes, if the fault
is not eliminated, remove the fuel
Fuel water water separation warning switch,
Fuel contains
separation Red Flashing measure the resistance of two poles
water
warning of the switch, if the resistance is
more than 50kΩ, it is normal, if the
resistance is less than 50kΩ, replace
the fuel water separation warning
switch.

Left turn Green Flashing

6-20
Instrument System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Flashing State
Attributes Color Icon Troubleshooting suggestion
attribute description
If the lamp flashes, remove the air
filter element, if the lamp still flashes
after the filter element is removed,
Intake air filter Air filter is
Red Flashing replace the intake air filter alert
alert clogged
switch; if the warning lamp goes off
after removing the filter element,
replace the filter element.
Neutral LCD character
Always on In neutral gear N
indication indication
LCD character
Forward signal Always on In forward gear F
indication
Backward LCD character In backward
Always on R
signal indication gear
Preheating LCD character In preheating
Always on
indication indication process
Seat switch A person leaves
Red Always on
indication the seat
The oil
Torque convert temperature of
oil temperature Red Flashing the torque Unused
alert converter is too
high
Service braking LCD character Brake pressure
Always on Unused
pressure alarm indication is insufficient
Hand brake
Hand brake has
switch Red Always on
been pulled up
indication
Indicates
Engine coolant
engine coolant
temperature
temperature
Indicate fuel
Fuel Level
level in the tank
Record service
Service hour
time of the
meter
forklift
If the lamp is always on, see the fault
Check engine code according to the manual, and
Red Always on Engine is faulty
lamp then search the fault content by fault
code.
LCD character Vehicle working
Mode selection Always on ESH
indication mode
 6-21
November 2, 2020 Instrument System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Wiring diagram

P22E00018

Pin No. of
Signal name Signal code Signal category Remarks
the socket
OPS power-off time delay Avoid battery power loss
A-1 B+ Power +
power caused by long-time alert
A-2 —— Null interface
Instrument power positive
A-3 P+ Power +
terminal
A-4 Engine fault alarm SWL_IN2 GND alarm
A-5 CAN_L CAN_L CAN communication low
A-6 CAN_H CAN_H CAN communication high
A-7 Seat indication SW10 Digital input Normal GND
GND alarm (collected by
A-8 Engine oil pressure SW8 Digital input
EFI engine CAN)
It is effective to connect
A-9 Neutral indication SW7 Digital input
the power +
A-10 Hand brake indicator SW1 Digital input Vacant alarm
A-11 Instrument power GND GND Power GND
A-12 —— GND Power GND Spare
A-13 Fuel water separation warning SWL_IN1 Digital input GND alarm
A-14 Air filter alarm SWL_IN0 Digital input GND alarm
A-15 Service brake pressure SW9 Digital input GND alarm
It is effective to connect
A-16 Backward signal SW5 Digital input
the power +
It is effective to connect
A-17 Forward signal SW4 Digital input
the power +
A-18 Backward output DO2 High output
A-19 Speed frequency signal input SPD_IN Frequency input Unused
6-22
Instrument System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Pin No. of
Signal name Signal code Signal category Remarks
the socket
A-20 Left turn signal light Left_led Square wave signal More than 10V
A-21 —— Null interface
It is effective to connect
A-22 Preheating indication SW6 Digital input
the power +
To battery negative
A-23 Grounding wire compensation GNDCOMP
terminal
A-24 Fuel Level FULE Analog quantity
It is effective to connect
A-25 Start signal SW3 Digital input
the power +
A-26 Preheating output DO3 High output
A-27 Right turn signal light Right_led Square wave signal More than 10V
A-28 Start output DO0 High output
A-29 Forward output DO1 High output
A-30 Lock output DO4 High output
A-31 Neutral output DO5 High output Unused
Torque convert oil temperature
A-32 YOUM Analog input Alarm with more than 5V
alert
Collected by EFI engine
A-33 Water temperature WTEMP Analog input
CAN
A-34 Charging signal SW2 Digital input Normal with more than 5V

Troubleshooting for instrument

The instrument socket A-3 pin is connected with power 12V, A-11 is connected with power GND, and
other pins shall be connected for test according to the input and output in the above table to check
whether the instrument is faulty.
 6-23
November 2, 2020 Alternator
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Alternator Working principle of alternator

Position

P22E00021

P22E00019
Power
Start supply

Parameters

Voltag
No. Component Power
e
1 Alternator 14V 980W

Wiring diagram

Alternator terminal

P22E00020
P22E00022
6-24
Starter November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Troubleshooting Starter
1. Start the engine, and measure the voltage of
the alternator BAT terminal with a multimeter. Position
The voltage shall be 13.5V-14.5V.
(1) The voltage more than 14.5V indicates the
alternator regulator is damaged, please
replace the alternator immediately.
(2) If the voltage is less than 13.5V, check
whether the alternator BAT terminal is loose,
if any, tighten the terminal with wrench; check
whether the alternator belt is loose and
slipping, if any, readjust it; check whether the
alternator fuse (refer to description of power
system for the fuse location) is blown, if any,
replace it with same type of fuse. Remove S 1
terminal connector and measure the voltage
of wire #131 (normal voltage shall be 12-
14V), the wire with voltage 0V indicates the
wire is open, please replace the frame wire P22E00019
harness.
1. Starter
(3) If the voltage is normal, but the instrument
charging indicator is always on, remove the
Parameters
wire #700 at terminal P.
a) Connect directly the wire #700 with No. Component Voltage Rated power
battery positive terminal (or negative
1 Starter 12V 3KW
terminal) and the instrument charging
indicator is off (or on), which indicates the
Operation
circuit is not faulty, measure the voltage
at terminal P that shall be more than 7V, if Turn the electric lock to the START position,
it is less than 7V, please replace the check whether the steering handle is at N
alternator. position using the instrument and whether the
b) If the circuit is faulty, check whether the engine speed is more than 500 RPM using CAN
wire #700 from alternator terminal P to bus, if the steering handle is at N position and
the instrument socket is conductive, if the engine speed is less than 500 RPM, the
not, replace the frame wire harness, if engine can be started; otherwise, the engine fails
any, check the instrument using the to be started.
method in the Section “Instrument”.
 6-25
November 2, 2020 Starter
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Wiring diagram

Starter terminal
Power
Start supply

P22E00023

Working principle of starter

P22E00025

P22E00024
6-26
Starter November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Troubleshooting

If the electric lock is turned, the starter fails to

run:
1. Check whether the battery positive cable and
battery negative cable are loose, if any, re-
tighten them.
2. Check starter case and frame for continuity
using the multimeter in the conduction
position, if not, please replace the grounding
wire.
3. Check battery positive terminal and starter
positive wire for continuity using the
multimeter in the conduction position, if not,
please replace the positive wire.
4. Turn the multimeter to its voltage function
and check the battery voltage which shall be
within 12-12.8V, if it is less than 12V, please
charge the battery.
5. Turn the multimeter to its voltage function
and check the voltage of wire #184, which
shall be 12V at starting, if the starter with
voltage 12V cannot be started, please
replace it. If its voltage can not be detected,
check the voltage of wire #183 which shall be
12V at starting. If the voltage 12V exists,
please replace the relay. If not, check the
voltage of wire #182 which shall be 12V at
starting. If the voltage 12V exists, please
check whether it is in the neutral position; if it
fails to start in the neutral position, please
replace the instrument. If not, check the
electric lock according to the instruction in the
Section “Power System”.
 6-27
November 2, 2020 Sensor
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Sensor

Fuel level sensor position

Fuel level sensor is installed on fuel tank of the frame.

P22E00026

1. Fuel level sensor

Fuel level sensor operation

The instrument is energized via fuel level sensor. The fuel level in the tank influences the sensor
resistance and the measurement resistance of the instrument will indicates the fuel level on the
instrument panel within the range E~F.
6-28
Sensor November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Fuel level sensor wiring diagram

P22E00027

Troubleshooting for fuel level sensor

Measure the sensor resistance with a multimeter.

Disconnect the fuel sensor connector, measure the resistance between two terminals of the fuel sensor
connector using the ohm position on a multimeter and compare the result with the value in the following
table:
Measure the distance between the fuel sensor flange bottom and the float center, and compare the result
with the value in the following table.
Distance (mm) 422 392 354 316 278 240 202 136 126
Resistance value (ohms) 10 33 55 75 95 117 138 160 180
Parameter error (ohms) ±2 ±2 ±2 ±3 ±3 ±3 ±4 ±4 ±4
 6-29
November 2, 2020 Electronic Steering System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Electronic Steering System

Position

Solenoid directional valve is on the transmission, backup light is behind the overhead guard, and backup
buzzer is at inner side of left rear column of overhead guard.

P22E00028

P22E00029
6-30
Electronic Steering System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

P22E00008

Parameters

Component Specifications LG PDM

Solenoid directional valve Transmission accessories
Steering handle 34B1631
Backup light LED 32B0700
Backup buzzer 88dB 38B0096

Solenoid valve parameters

•VAVLE SPEC.
Maximum operatinq pressure (P.A.B) 30 kqf/cm2
moximum flow 10 L/min
Maximum permissible pressure(T) 20 kgf/cm2
Maximum internol leakage A.B port respective
290 cc/min
(neutrol position P=20 kgf/cm2 Oil temp.: 45±5
Response (rate voltage )
50 msec
(Oil temp.: 45±5 coil temp.=30±5)
 6-31
November 2, 2020 Electronic Steering System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Vibration—resisting JIS 0 1601 3-D (STAGE 90)

Maximum contamination level NAS 12
Corrosion-prevent process Phosphate coatings

♦SOLENOID SPEC.
rote votage DC 12V DC24V
Moximum current (ot 20) 2.4A 1.2A
Voltoge tolerance allowed DC12.5±2.5V DC24±4V
Allowed energizing time
12 V Voltoge 24 V Voltage energizing time energizing rate
10~13.2V(rote~110%) 20 ~28V(rote~110%) continue 100%
13.2~14.4V(110~120%) 28~30V(110~120%) 5 min 75%
14.4~15V(120~ 133.3%) 30~32V(120~133.3%) 3.5 min 50%

♦OPERATING SPEC.
Hydrulic oil:ATF DEXRON Oil temp.: -30~110
Woter proof:JIS D 0203 S2
TEMPERTURE OF TRANSMISSION AT VALVE MOUNTING:-30~110

Jacket length: 85

Wire specifications

P22E00030

The internal resistance of the solenoid valve is 6 Ω and the quality of the solenoid valve can be judged by
measuring the resistance.
6-32
Electronic Steering System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Operation

Start the engine with backward gear and check whether the hand brake is pulled up and whether the
driver is at the seat using the instrument, if the hand brake is not pulled up and the driver is at the seat,
the following actions will occur: the backup light is on, the backup buzzer sounds intermittently and the
forklift will run backwards; otherwise, no action occurs. Pull up the forward gear and check whether the
hand brake is pulled up and whether the driver is at the seat using the instrument, if the hand brake is not
pulled up and the driver is at the seat, the following action will occur: the forklift runs forwards; otherwise,
no action occurs.

Wiring diagram

Forward
1st gear
Reverse
3rd gear
Neutral
5th gear

Reverse

Forward

P22E00031
 6-33
November 2, 2020 Electronic Steering System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Troubleshooting

Fault symptom Cause analysis Troubleshooting methods

1. Fuse for the gear is blown 1. Replace the fuse
2. The hand brake is not 2. Pull down the hand brake
pulled down 3. Measure the solenoid valve coil resistance which shall be 6 Ω, if
3. Shift solenoid valve is the measured value has excessively large deviation, replace
damaged the solenoid valve
4. Instrument is damaged 4. Measure the voltage of wire #414 and #413, if their voltage is
Without forward
5. Handle is damaged 12V, the voltage of wire #451 and #452 shall also be 12V, if not,
gear and backward
6. The seat switch is not replace the instrument.
gear
closed 5. Check whether the handle pins are conductive according to the
7. Wire harness is in open schematic diagram; if not, replace the handle.
circuit 6. If it is not closed as the driver sits on the seat, please replace
the seat switch.
7. Check the conduction condition of wire harnesses according to
the schematic diagram; if not, replace them.
1. Shift solenoid valve is 1. Measure the solenoid valve coil resistance which shall be 6 Ω, if
damaged the measured value has excessively large deviation, replace
2. Instrument is damaged the solenoid valve
3. Handle is damaged 2. Measure the voltage of wire #414 and #413, if their voltage is
Only the forward
4. Wire harness is in open 12V, the voltage of wire #451 and #452 shall also be 12V, if not,
gear or backward
circuit replace the instrument.
gear is available
3. Check whether the handle pins are conductive according to the
schematic diagram; if not, replace the handle.
4. Check the conduction condition of wire harnesses according to
the schematic diagram; if not, replace them.
6-34
Brake Indicator System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Brake Indicator System

Position

Brake light switch is located on the bracket of the brake pedal and behind the overhead guard.

P22E00032

P22E00029
 6-35
November 2, 2020 Brake Indicator System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Parameters

No. Component Specifications LG PDM

1 Brake light switch 6DF 007 361-001 34B1578
2 Brake light LED 32B0700

Operation

The brake light comes on when depressing brake pedal.

Wiring diagram

P22E00033

Troubleshooting

The brake light does not come on when depressing brake pedal
1. Check whether the brake fuse is blown;
2. Check whether the brake light switch travel is maladjusted;
3. Check whether the positive terminal and negative terminal of the brake light switch are conductive
using the multimeter in the conduction position;
4. Check whether the brake light is blown.
5. Check whether the negative terminal of the brake light is conductive with the frame using the
multimeter in the conduction position;
6. Turn the multimeter to its voltage function and check whether the voltage for the positive terminal of
the brake light is 12V.
6-36
Brake Indicator System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Fault symptom Cause analysis Troubleshooting methods

1. The brake switch is 1. Remove the brake switch and check whether two pins are
damaged conductive under the normal state, if not, please replace the
2. The brake switch travel is switch.
The brake light maladjusted 2. Adjust the brake switch travel so that it can return to the normal
does not come on 3. Wire harness is in open state after the pedal is depressed completely.
when depressing circuit 3. Check the conduction condition of wire harnesses according to
the brake pedal 4. Fuse is blown the schematic diagram; if not, replace them.
5. Light emitting diode is 4. Replace them with the fuse having the same specification
blown 5. Depress the brake pedal, and then check whether the wire #
411 of light plug has 12V voltage; if yes, replace the light.
1. The brake switch is 1. Remove the brake switch and check whether two pins are
damaged conductive after press the ejector, if they are always conductive,
The brake light
2. The brake switch travel is please replace the switch.
constantly lights up
maladjusted 2. Adjust the brake switch travel so that the switch ejector is
pressed about 3-4mm before depressing the brake pedal.
 6-37
November 2, 2020 Lighting System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Lighting System

Position and principle

1
3

2 4

P22E00008

Parameters

No. Component Model LG PDM

1 Rear combination light LED 32B0700
2 Front combination light LED 32B0699
3 Combination lever 34B1632
4 Flash relay
6-38
Lighting System November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Wire and component diagram

Front floodlight

Positio
n light

Left turn signal light

Neutral
gear
Right turn signal
light

P22E00034
 6-39
November 2, 2020 Lighting System
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Troubleshooting

1. Turn the combination lever to the position light (or work light), check whether the voltage between the
position light (or work light) positive wire and the battery negative terminal is 12V, if any, check
whether the position light (or work light) negative wire is grounding, if the grounding is normal, the
work light is faulty.
2. If the measured value is 0V, check whether the corresponding position of the combination lever is
conductive with the multimeter. If not, the combination lever is faulty, if any, the wire is in open circuit
or the light fuse is blown.

Fault symptom Cause analysis Troubleshooting methods

1. Handle is damaged 1. Remove the handle and check whether the pins are conductive
2. Wire harness is in open according to the schematic diagram; if not, replace the handle.
circuit 2. Check the conduction condition of wire harnesses according to
The position light
3. Fuse is blown the schematic diagram; if not, replace them.
does not come on
4. Light emitting diode is 3. Replace them with the fuse having the same specification
blown 4. Turn the handle and then check whether the wire #406 of light
plug has 12V voltage; if any, replace the light.
1. Handle is damaged 1. Remove the handle and check whether the pins are conductive
2. Wire harness is in open according to the schematic diagram; if not, replace the handle.
circuit 2. Check the conduction condition of wire harnesses according to
Floodlight does not
3. Fuse is blown the schematic diagram; if not, replace them.
come on
4. Light emitting diode is 3. Replace them with the fuse having the same specification
blown 4. Turn the handle and then check whether the wire #410 of light
plug has 12V voltage; if any, replace the light.
1. Handle is damaged 1. Remove the handle and check whether the pins are conductive
2. Wire harness is in open according to the schematic diagram; if not, replace the handle.
circuit 2. Check the conduction condition of wire harnesses according to
3. Fuse is blown the schematic diagram; if not, replace them.
4. Light emitting diode is 3. Replace them with the fuse having the same specification
Turn signal light
blown 4. Remove the light, the wire #405 or 406 is connected directly
does not come on
5. Flash relay is damaged with the battery positive terminal by the light plug and the wire
of the light plug is connected directly with the battery negative
terminal, if the light does not come on, replace the light.
5. If all above components are normal, please replace the flash
relay.
6-40
Battery November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Battery

Position

The battery is fixed on the left of the frame and above fuel tank.
The power of the complete machine is supplied by single battery with system voltage 12V.

P22E00035

Parameters

Rated volume is 93Ah, cold start current 600CCA.

No. Electric element Model LG PDM

1 Battery BA31750T 37B0077

Operation

As reversible DC (direct current) power, the battery connects in parallel with the alternator to jointly
power the electrical equipments of the complete machine. Battery supplies great current in a short time
for the starter motor, and further drives the diesel engine to start. The battery is also equivalent to a bulk
capacitor that can absorb overvoltage appearing in the circuit at any time, thus protecting electrical
elements of the complete machine.
 6-41
November 2, 2020 Battery
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Troubleshooting

Check visually the built-in hydrometer of the battery cover in well-lighted condition, to figure out the
charge state of battery or take appropriate measures in accordance with the color displayed in the
hydrometer
Hydrometer color Green Black White
Battery state Good Need to be charged Need to replaced

When the forklift is difficult to start:

(1) First disconnect battery negative terminal cable and then disconnect battery positive terminal cable.
(2) Adjust digital multimeter to 20V voltage range
(3) Put red probe of digital multimeter to battery positive terminal and put black probe to negative
terminal; the digital multimeter displays 12.4V ~ 12.6V. If lower than the display range, the battery
shall be charged or replaced.

Battery charging

For the batteries whose hydrometer is black, recharging is required.

For the batteries whose hydrometer is white, there might be bubbles in the hydrometer. Whereupon,
remove all the battery connecting cables and shake the battery gently after it is fully cooled. The battery
shall be scrapped, provided that the above-mentioned white color remains.
1. Disassemble the battery from the machine. Disconnect the battery negative terminal cable and
positive terminal cable successively before disassembling the battery.
2. Wipe the battery terminal and surface with a clean cloth, to remove the oxide scale on the surface.
3. Connect the charger positive (+) clip to the battery positive (+) terminal, while charger negative (-)
clip to the battery negative (-) terminal at room temperature. Confirm that the battery terminals are
clean, and the charging circuit is in good connection.
4. It is recommended to charge the battery at constant voltage of 16.0V (no more than 16.2V at most
and a lot of water will be electrolyzed when this limit is exceeded, causing liquid level drop, white
hydrometer, battery scrap) with current limited to 25A until the hydrometer shows green, which
indicates that the battery is fully charged.
5. If there is no condition for charging at constant voltage, constant current charging is allowed as per
the following specification:
a) Select 1/8~1/10 amp charging current (10~12A for 37B0077 battery) of rated capacity, the
voltage at the end of charging should be reached but cannot exceed 16V (voltage less than 16V
at the end of charging is easy to cause the hydrometer to show black even after charging is
completed). When the charger cannot guarantee that the charging voltage is limited to below
16V, the charged battery terminal voltage must be manually monitored every hour; otherwise, it
can cause water loss in battery due to overvoltage charging and affect the service life of battery
and even failure.
b) The relations between the recharging time and the voltage before charging of the battery (for
reference)
6-42
Battery November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

6. For the battery suffering severe power loss, it may be non-chargeable at the beginning of charging.
As battery charging proceeds, the charging current of battery can return to normal state gradually. It
takes about 14 hours to complete the charging process.
Battery voltage 12.45~12.55V 12.45~12.35V 12.35~12.20V 12.20~12.05V
Recharging time 2 hours 3 hours 4 hours 5 hours
Battery voltage 12.05~11.95V 11.95~11.80V 11.80~11.65V 11.65~11.50V
Recharging time 6 hours 7 hours 8 hours 9 hours
Battery voltage 11.50~11.30V 11.30~11.00V Below 11.00V
Recharging time 10 hours 12 hours 14 hours

7. If the battery temperature gets too high (exceeding approximately 45 °C) during the charging
process, stop charging the battery until the battery is cooled to room temperature, then recharge it
through reducing the charging current by half.
8. Check the hydrometer state once every hour during battery charging. The green battery hydrometer
indicates that the battery has been fully charged, and stops charging at this time.
9. Coat the terminal with Vaseline after the charging is completed, to prevent galvanic corrosion.

Precautions for battery charging

1. Never charge several batteries in series.

2. If acid is sprayed from the battery vent during charging, the charging shall be stopped immediately.
3. Charge the battery in well-ventilated area, and pay attention to the electrical safety.
4. Any battery that leaks or has a broken housing, shall rather be scrapped than recharged.
5. Any battery that has a broken terminal, shall rather be scrapped than recharged.
6. Any battery that is inflated or bulged for over-discharge or overcharge, shall rather be scrapped than
recharged.
7. If the hydrometer remains black after being charged for a period of time, check whether the charging
cable is well connected, the joint point is clean, or the charging voltage reaches 16V.
 6-43
November 2, 2020 Preheating
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Preheating

Position and electrical principle

The glow plug is on the engine intake pipe and the preheating relay is in the inner side of the frame, as
shown in the following Figure:

P22E00036

1. Preheating terminal

P22E00010
6-44
Preheating November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Parameters

Rated voltage of Rated value of

No. LG PDM
coil contacts
1 Preheating relay 12V 100A 46C8754

Operation

Turn the electric lock to "ON" position, the instrument collects the engine coolant temperature, set the
preheating time according to the logics of the following table to control the the preheating relay work for
preheating.

Preheating time and coolant temperature matching table

P22E00037
 6-45
November 2, 2020 Preheating
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Wire and component diagram

P22E00038

Troubleshooting

Fault symptom Cause analysis Troubleshooting methods

1. The temperature does not 1. Measure the engine coolant temperature, if higher than 23°C,
meet the preheating the preheating can not be conducted.
requirements 2. Check the conduction condition of wire harnesses according to
2. Wire harness is in open the schematic diagram; if not, replace them.
Without preheating
circuit 3. Replace them with the fuse having the same specification
3. Fuse is blown 4. Disconnect the preheating relay plug and measure the
4. Preheating relay is resistance of the relay coil which shall be 26Ω, if the resistance
damaged is wrong, please replace the relay.
6-46
Horn November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Horn

Position and principle

The horn is on the right of the front platform and the horn switch is in the middle of steering wheel, as
shown in the Figure:

P22E00039

1. Horn switch 2. Horn

Parameters

Rated voltage Working current Sound level LG PDM

Electric horn 12V ≤3A 105±5dB 38B0280

Operation

Press down the horn button on the steering wheel to honk the electric horns.
 6-47
November 2, 2020 Horn
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Wire and component diagram

P22E00040

Troubleshooting

Fault symptom Cause analysis Troubleshooting methods

1. Horn is damaged 1. Remove the horn, connect the horn positive terminal to the
2. Wire harness is in open battery positive terminal, connect the horn negative terminal to
circuit the battery negative terminal; if horn does not honk, replace the
3. Fuse is blown horn.
4. Horn switch is damaged 2. Check the conduction condition of wire harnesses according to
Horn does not honk
the schematic diagram; if not, replace them.
3. Replace them with the fuse having the same specification
4. Disconnect the horn switch plug, press down the horn switch to
check whether the two pins of the horn switch plug are
conductive; if not, replace the horn switch.
6-48
OPS November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

OPS

Function description:

1. The vehicle can be started only at the neutral gear.

2. The vehicle can run only releasing the hand brake.
3. The functions of running and operating the mast will be disabled if the driver leaves the seat for 2
seconds during the normally running of the vehicle or operating the mast. As the driver returns to the
seat, the function of operating the mast will be restored immediately, but the running function can be
restored only neutral gear is shifted again.
4. The instrument will alarm for reminding the driver of pulling up the hand brake if the driver turns off
the electric lock and leaves from the seat without pulling up the hand brake. The instrument will
automatically power off for canceling the alarm if the driver does not pull up the hand brake after the
instrument alarms for 1 minute.
 6-49
November 2, 2020 OPS
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Wire and component diagram

Forward
1st gear
Reverse
3rd gear
Neutral
5th gear
Reverse

Forward

P22E00041
6-50
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Fault Code Table

General code
Fault
SPN
No. code / level Description
FMI
indicator
131 1001 None None Gear lever failure

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
629 Engine Control Module Critical Internal Failure - Bad intelligent
1 111 Stop (Solid)
12 device or component
612 Engine Magnetic Speed/Position Lost Both of Two Signals -
4 115 Stop (Solid)
2 Data erratic, intermittent or incorrect
102 Intake Manifold 1 Pressure Sensor Circuit - Voltage above
10 122 Warning (Solid)
3 normal, or shorted to high source
102 Intake Manifold 1 Pressure Sensor Circuit - Voltage below
11 123 Warning (Solid)
4 normal, or shorted to low source
102 Intake Manifold 1 Pressure - Data Valid But Above Normal
12 124 Warning (Solid)
16 Operating Range - Moderately Severe Level
091 Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage
13 131 Stop (Solid)
3 above normal, or shorted to high source
091 Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage
14 132 Stop (Solid)
4 below normal, or shorted to low source
974 Remote Accelerator Pedal or Lever Position Sensor 1
15 133 Stop (Solid)
3 Circuit - Voltage above normal, or shorted to high source
974 Remote Accelerator Pedal or Lever Position Sensor 1
16 134 Stop (Solid)
4 Circuit - Voltage below normal, or shorted to low source
100 Engine Oil Rifle Pressure - Data Valid But Below Normal
19 143 Warning (Solid)
18 Operating Range - Moderately Severe Level
110 Engine Coolant Temperature 1 Sensor Circuit - Voltage above
20 144 Warning (Solid)
3 normal, or shorted to high source
110 Engine Coolant Temperature 1 Sensor Circuit - Voltage below
21 145 Warning (Solid)
4 normal, or shorted to low source
110 Engine Coolant Temperature - Data Valid But Above
22 146 Warning (Solid)
16 Normal Operating Range - Moderately Severe Level
Accelerator Pedal or Lever Position 1 Sensor Circuit
091
23 147 Stop (Solid) Frequency - Data valid but below normal operational range
1
- Most Severe Level
 6-51
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
091 Accelerator Pedal or Lever Position Sensor 1 - Data valid
24 148 Stop (Solid)
0 but above normal operational range - Most Severe Level
110 Engine Coolant Temperature - Data valid but above normal
25 151 Stop (Solid)
0 operational range - Most Severe Level
105 Intake Manifold 1 Temperature Sensor Circuit - Voltage above
26 153 Warning (Solid)
3 normal, or shorted to high source
105 Intake Manifold 1 Temperature Sensor Circuit - Voltage below
27 154 Warning (Solid)
4 normal, or shorted to low source
105 Intake Manifold 1 Temperature - Data valid but above normal
28 155 Stop (Solid)
0 operational range - Most Severe Level
3510 Sensor Supply 2 Circuit - Voltage below normal, or shorted
29 187 Warning (Solid)
4 to low source
111 Coolant Level Sensor 1 Circuit - Voltage above normal, or
30 195 Warning (Solid)
3 shorted to high source
111 Coolant Level Sensor 1 Circuit - Voltage below normal, or
31 196 Warning (Solid)
4 shorted to low source
111 Coolant Level - Data Valid But Below Normal Operating
32 197 Warning (Solid)
18 Range - Moderately Severe Level
108 etric Pressure Sensor Circuit - Voltage above normal, or
34 221 Warning (Solid)
3 shorted to high source
108 Barometric Pressure Sensor Circuit - Voltage below normal, or
35 222 Warning (Solid)
4 shorted to low source
190 Engine Crankshaft Speed/Position - Data valid but above
42 234 Stop (Solid)
0 normal operational range - Most Severe Level
111 Coolant Level - Data valid but below normal operational range
43 235 Stop (Solid)
1 - Most Severe Level
3511 Sensor Supply 3 Circuit - Voltage below normal, or shorted
45 238 Warning (Solid)
4 to low source
3511 Sensor Supply 3 Circuit - Voltage above normal, or shorted
46 239 Warning (Solid)
3 to high source
84 Wheel-Based Vehicle Speed - Data erratic, intermittent or
47 241 Warning (Solid)
2 incorrect
84 Wheel-Based Vehicle Speed Sensor Circuit tampering has
48 242 Warning (Solid)
10 been detected - Abnormal rate of change
647 Fan Control Circuit - Voltage below normal, or shorted to
49 245 Warning (Solid)
4 low source
1347 Engine Fuel Pump Pressurizing Assembly 1 Circuit -
57 271 Warning (Solid)
4 Voltage below normal, or shorted to low source
1347 Engine Fuel Pump Pressurizing Assembly 1 Circuit -
58 272 Warning (Solid)
3 Voltage above normal, or shorted to high source
639 SAE J1939 Multiplexing PGN Timeout Error - Abnormal
59 285 Warning (Solid)
9 update rate
6-52
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
639 SAE J1939 Multiplexing Configuration Error - Out of
60 286 Warning (Solid)
13 Calibration
974 SAE J1939 Multiplexing Remote Accelerator Pedal or Lever
61 288 Stop (Solid)
19 Position Sensor System - Received Network Data In Error
441
62 292 Stop (Solid) Auxiliary Temperature Sensor Input 1 - Special Instructions
14
441 Auxiliary Temperature Sensor Input 1 Circuit - Voltage
63 293 Warning (Solid)
3 above normal, or shorted to high source
441 Auxiliary Temperature Sensor Input 1 Circuit - Voltage
64 294 Warning (Solid)
4 below normal, or shorted to low source
1388
65 296 Stop (Solid) Auxiliary Pressure Sensor Input 2 - Special Instructions
14
651 Injector Solenoid Driver Cylinder 1 Circuit - Current below
71 322 Warning (Solid)
5 normal or open circuit
653 Injector Solenoid Driver Cylinder 3 Circuit - Current below
73 324 Warning (Solid)
5 normal or open circuit
652 Injector Solenoid Driver Cylinder 2 Circuit - Current below
75 331 Warning (Solid)
5 normal or open circuit
654 Injector Solenoid Driver Cylinder 4 Circuit - Current below
76 332 Warning (Solid)
5 normal or open circuit
629 Engine Control Module Warning Internal Hardware Failure -
77 343 Warning (Solid)
12 Bad intelligent device or component
3597
80 351 Warning (Solid) Injector Power Supply - Bad intelligent device or component
12
100 Engine Oil Rifle Pressure - Data valid but below normal
82 415 Stop (Solid)
1 operational range - Most Severe Level
Warning 97 Water in Fuel Indicator - Data Valid But Above Normal
83 418
(Blinking) 15 Operating Range - Least Severe Level
639
87 427 None SAE J1939 Datalink - Abnormal update rate
9
97 Water in Fuel Indicator Sensor Circuit - Voltage above
88 428 Warning (Solid)
3 normal, or shorted to high source
97 Water in Fuel Indicator Sensor Circuit - Voltage below
89 429 Warning (Solid)
4 normal, or shorted to low source
558 Accelerator Pedal or Lever Idle Validation Switch - Data
90 431 Warning (Solid)
2 erratic, intermittent or incorrect
558 Accelerator Pedal or Lever Idle Validation Switch Circuit -Out
91 432 Stop (Solid)
13 of Calibration
100 Engine Oil Rifle Pressure - Data erratic, intermittent or
92 435 Warning (Solid)
2 incorrect
168 Battery 1 Voltage - Data Valid But Below Normal Operating
93 441 Warning (Solid)
18 Range - Moderately Severe Level
 6-53
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
168 Battery 1 Voltage - Data Valid But Above Normal Operating
94 442 Warning (Solid)
16 Range - Moderately Severe Level
157 Injector Metering Rail 1 Pressure - Data valid but above
95 449 Stop (Solid)
0 normal operational range - Most Severe Level
157 Injector Metering Rail 1 Pressure Sensor Circuit - Voltage
96 451 Warning (Solid)
3 above normal, or shorted to high source
157 Injector Metering Rail 1 Pressure Sensor Circuit - Voltage
97 452 Warning (Solid)
4 below normal, or shorted to low source
Warning 98 Engine Oil Level - Data Valid But Below Normal Operating
101 471
(Blinking) 17 Range - Least Severe Level
611 Auxiliary Intermediate (PTO) Speed Switch Validation -
108 523 Warning (Solid)
2 Data erratic, intermittent or incorrect
702 Auxiliary Input/Output 2 Circuit - Voltage above normal, or
109 527 Warning (Solid)
3 shorted to high source
93 Auxiliary Alternate Torque Validation Switch - Data
110 528 Warning (Solid)
2 erratic,intermittent or incorrect
703 Auxiliary Input/Output 3 Circuit - Voltage above normal, or
111 529 Warning (Solid)
3 shorted to high source
157 Injector Metering Rail 1 Pressure - Data Valid But Below
116 559 Warning (Solid)
18 Normal Operating Range - Moderately Severe Level
677 Starter Relay Driver Circuit - Voltage above normal, or
117 584 Warning (Solid)
3 shorted to high source
677 Starter Relay Driver Circuit - Voltage below normal, or
118 585 Warning (Solid)
4 shorted to low source
640 Auxiliary Commanded Dual Output Shutdown - Special
119 599 Stop (Solid)
14 Instructions
Warning 1378
121 649 Engine Oil Change Interval - Condition Exists
(Blinking) 31
190 Engine Crankshaft Speed/Position - Data erratic,
122 689 Warning (Solid)
2 intermittent or incorrect
1136 Engine ECU Temperature Sensor Circuit - Voltage above
123 697 Warning (Solid)
3 normal, or shorted to high source
1136 Engine ECU Temperature Sensor Circuit - Voltage below
124 698 Warning (Solid)
4 normal, or shorted to low source
Engine Speed / Position Camshaft and Crankshaft
723
127 731 Warning (Solid) Misalignment - Mechanical system not responding or out of
7
adjustment
723 Engine Camshaft Speed / Position Sensor - Data erratic,
130 778 Warning (Solid)
2 intermittent or incorrect
131 1001 None None Gear lever failure
3597 Power Supply Lost With Ignition On - Data erratic,
132 1117 None
2 intermittent or incorrect
6-54
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
2623 Accelerator Pedal or Lever Position Sensor 2 Circuit -
133 1239 Warning (Solid)
3 Voltage above normal, or shorted to high source
2623 Accelerator Pedal or Lever Position Sensor 2 Circuit -
134 1241 Warning (Solid)
4 Voltage below normal, or shorted to low source
91 Accelerator Pedal or Lever Position Sensor 1 - Data erratic,
135 1242 Stop (Solid)
2 intermittent or incorrect
91
136 1515 Stop (Solid) J39_MUX_ACCEL_DATA_ERROR
19
1387
137 1539 Warning (Solid) OEM_PRESSURE_HIGH_ERROR
3
1387 Auxiliary Pressure Sensor Input 1 Circuit - Voltage below
138 1621 Warning (Solid)
4 normal, or shorted to low source
3513 Sensor Supply 5 - Voltage above normal, or shorted to high
139 1695 Warning (Solid)
3 source
3513 Sensor Supply 5 - Voltage below normal, or shorted to low
140 1696 Warning (Solid)
4 source
97 Water in Fuel Indicator - Data Valid But Above Normal
141 1852 Warning (Solid)
16 Operating Range - Moderately Severe Level
1072 Engine Brake Actuator Driver 1 Circuit - Voltage above
142 2182 Warning (Solid)
3 normal, or shorted to high source
1072 Engine Brake Actuator Driver 1 Circuit - Voltage below
143 2183 Warning (Solid)
4 normal, or shorted to low source
3512 Sensor Supply 4 Circuit - Voltage above normal, or shorted
144 2185 Warning (Solid)
3 to high source
3512 Sensor Supply 4 Circuit - Voltage below normal, or shorted
145 2186 Warning (Solid)
4 to low source
633 Electronic Fuel Injection Control Valve Circuit - Condition
146 2311 Warning (Solid)
31 Exists
190 Engine Crankshaft Speed/Position - Data erratic,
147 2321 None
2 intermittent or incorrect
723 Engine Camshaft Speed / Position Sensor - Data erratic,
148 2322 None
2 intermittent or incorrect
647 Fan Control Circuit - Voltage above normal, or shorted to
149 2377 Warning (Solid)
3 high source
651
150 2442 Warning (Solid) Injector Solenoid Driver Cylinder 1 - Out of Calibration
13
652
151 2443 Warning (Solid) Injector Solenoid Driver Cylinder 2 - Out of Calibration
13
653
152 2444 Warning (Solid) Injector Solenoid Driver Cylinder 3 - Out of Calibration
13
654
153 2445 Warning (Solid) Injector Solenoid Driver Cylinder 4 - Out of Calibration
13
 6-55
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
655
154 2446 Warning (Solid) Injector Solenoid Driver Cylinder 5 - Out of Calibration
13
656
155 2447 Warning (Solid) Injector Solenoid Driver Cylinder 6 - Out of Calibration
13
111 Coolant Level - Data Valid But Below Normal Operating
156 2448 Warning (Solid)
17 Range - Least Severe Level
729 Engine Intake Air Heater 1 Circuit - Voltage above normal,
157 2555 Warning (Solid)
3 or shorted to high source
729 Engine Intake Air Heater 1 Circuit - Voltage below normal,
158 2556 Warning (Solid)
4 or shorted to low source
110 Engine Coolant Temperature - Data Valid But Above
159 2963 None
15 Normal Operating Range - Least Severe Level
105 Intake Manifold 1 Temperature - Data Valid But Above
160 2964 None
15 Normal Operating Range - Least Severe Level
1623
161 3186 Warning (Solid) Tachograph Output Shaft Speed - Abnormal update rate
9
1623 Tachograph Output Shaft Speed - Received Network Data
162 3213 Warning (Solid)
19 In Error
91 SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor
163 3326 Stop (Solid)
9 System - Abnormal update rate
191
164 3328 Warning (Solid) Transmission Output Shaft Speed - Abnormal update rate
9
191 Transmission Output Shaft Speed - Received Network Data
165 3418 Warning (Solid)
19 In Error
84 Wheel-Based Vehicle Speed - Received Network Data In
166 3525 Warning (Solid)
19 Error
84
167 3526 Warning (Solid) Wheel-Based Vehicle Speed - Abnormal update rate
9
558 Accelerator Pedal or Lever Idle Validation Switch -
168 3527 Stop (Solid)
19 Received Network Data In Error
558 Accelerator Pedal or Lever Idle Validation Switch -
169 3528 Stop (Solid)
9 Abnormal update rate
1213
170 3535 Warning (Solid) Malfunction Indicator Lamp - Abnormal update rate
9
111
171 3613 Warning (Solid) Coolant Level Sensor - Abnormal update rate
9
111
172 3614 Warning (Solid) Coolant Level Sensor - Received Network Data In Error
19
748
173 3641 Warning (Solid) Transmission Output Retarder - Abnormal update rate
9
630 Engine Control Module Calibration Memory - Bad intelligent
174 3697 Stop (Solid)
12 device or component
6-56
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Cummins fault code

Fault
SPN
No. code / level Description
FMI
indicator
5571 High Pressure Common Rail Fuel Pressure Relief Valve -
175 3727 None
7 Mechanical system not responding or out of adjustment
High Pressure Common Rail Fuel Pressure Relief Valve -
5571
176 3741 Warning (Solid) Data valid but above normal operational range - Most
0
Severe Level
521
179 4526 Warning (Solid) Brake Pedal Position - Data erratic, intermittent or incorrect
2
97 Water in Fuel Indicator - Data Valid But Above Normal
180 4642 Stop (Solid)
0 Operating Range - Most Severe Level
701
181 4734 Stop (Solid) Auxiliary Input/Output 1 - Special Instructions
14
1639 Fan Speed - Data Valid but Above Normal Operational
182 4789 Warning (Solid)
0 Range - Most Severe Level
1639 Fan Speed - Data Valid but Below Normal Operational
183 4791 Warning (Solid)
1 Range - Most Severe Level
920 Audible Alarm Circuit - Voltage Above Normal or Shorted to
184 6228 Warning (Solid)
3 High Source
920 Audible Alarm Circuit - Voltage Below Normal or Shorted to
185 6229 Warning (Solid)
4 Low Source
741 Transmission 1 Forward Solenoid Valve Driver Circuit -
186 6231 Warning (Solid)
3 Voltage Above Normal or Shorted to High Source
741 Transmission 1 Forward Solenoid Valve Driver Circuit -
187 6232 Warning (Solid)
4 Voltage Below Normal or Shorted to Low Source
4216 Transmission 1 Reverse Solenoid Valve Driver Circuit -
188 6233 Warning (Solid)
3 Voltage Above Normal or Shorted to High Source
4216 Transmission 1 Reverse Solenoid Valve Driver Circuit -
189 6234 Warning (Solid)
4 Voltage Below Normal or Shorted to Low Source
768 Transmission Range High Actuator Circuit - Voltage Above
190 6235 Warning (Solid)
3 Normal or Shorted to High Source
768 Transmission Range High Actuator Circuit - Voltage Below
191 6236 Warning (Solid)
4 Normal or Shorted to Low Source
520973 Forklift Mast Actuator Driver Circuit - Voltage Above Normal
192 6242 Warning (Solid)
3 or Shorted to High Source
520973 Forklift Mast Actuator Driver Circuit - Voltage Above Normal
193 6243 Warning (Solid)
4 or Shorted to High Source
 6-57
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
1 1621 0 31 RS-485 Rx Inactive
2 1622 0 31 RS-485 Rx Noise
3 1623 0 31 RS-485 Invalid Packet Format
4 1624 0 31 RS-485 Shutdown Request
5 1220 27 3 BPS1 high voltage
6 1221 27 4 BPS1 low voltage
7 1224 27 0 BPS1 higher than BPS2
8 1225 27 1 BPS1 lower than BPS2
9 1226 27 7 Unable to reach higher BPS
10 1228 27 31 BPS1/2 simultaneous voltages out of range
11 2128 29 3 FPP2 high voltage
12 2127 29 4 FPP2 low voltage
13 2116 29 0 FPP2 higher than IVS limit
14 2140 29 1 FPP2 lower than IVS limit
15 123 51 3 TPS1 high voltage
16 122 51 4 TPS1 low voltage
17 221 51 0 TPS1 higher than TPS2
18 121 51 1 TPS1 lower than TPS2
19 2112 51 7 Unable to reach higher TPS
20 2135 51 31 TPS1/2 simultaneous voltages out of range
21 2118 51 6 DBW drive current high
22 502 84 8 Roadspeed loss
23 2122 91 3 FPP1 high voltage
24 2123 91 4 FPP1 low voltage
25 2115 91 0 FPP1 higher than IVS limit
26 2139 91 1 FPP1 lower than IVS limit
27 2126 91 16 FPP1 higher than FPP2
28 2121 91 18 FPP1 lower than FPP2
29 1121 91 31 FPP1/2 simultaneous voltages out of range (redundancy lost)
30 1630 91 19 J1939 ETC message receipt lost
31 1651 91 9 J1939 ETC message loss while in-gear
32 92 94 3 Primary FP high voltage
33 91 94 4 Primary FP low voltage
34 88 94 0 Primary fuel pressure high
35 87 94 1 Primary fuel pressure low
36 524 100 1 Oil pressure low (switch)
37 520 100 18 Oil pressure low stage 1 (sender)
6-58
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
38 524 100 1 Oil pressure low stage 2 (sender)
39 521 100 0 Oil pressure high (sender)
40 523 100 3 Oil pressure sender high voltage
41 522 100 4 Oil pressure sender low voltage
42 238 102 3 TIP/TOP high voltage
43 237 102 4 TIP/TOP low voltage
44 236 102 2 TIP/TOP active
45 234 102 0 Control overboost
46 299 102 1 Control underboost
47 113 105 3 IAT high voltage
48 112 105 4 IAT low voltage
49 111 105 15 IAT higher than expected 1
50 127 105 0 IAT higher than expected 2
51 108 106 16 MAP high pressure
52 107 106 4 MAP low voltage
53 2229 108 0 BP high pressure
54 129 108 1 BP low pressure
55 118 110 3 ECT / CHT high voltage
56 117 110 4 ECT / CHT low voltage
57 116 110 15 ECT higher than expected 1
58 217 110 0 ECT higher than expected 2
59 1521 110 16 CHT higher than expected 1
60 1522 110 0 CHT higher than expected 2
61 128 110 31 Failed to reach operating temperature
62 2560 110 1 Cooling water flow lower than expected
63 563 168 15 Vbat Voltage high
64 562 168 17 Vbat Voltage low
65 2428 173 0 Exhaust gas temperature high
66 183 174 3 FT gasoline high
67 182 174 4 FT gasoline low
68 1411 441 3 EMWT 1 high voltage
69 1413 441 4 EMWT 1 low voltage
70 1415 441 15 EMWT 1 higher than expected level 1
71 1417 441 0 EMWT 1 higher than expected level 2
72 1412 442 3 EMWT 2 high voltage
73 1414 442 4 EMWT 2 low voltage
74 1416 442 15 EMWT 2 higher than expected level 1
75 1418 442 0 EMWT 2 higher than expected level 2
 6-59
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
76 726 515 15 Max govern speed override
77 219 515 15 RPM higher than expected
78 1111 515 16 Fuel rev limit
79 1112 515 0 Spark rev limit
80 1114 515 31 Unable to achieve low target speed
81 2130 558 5 IVS stuck at-idle, FPP1/2 match
82 2131 558 6 IVS stuck off-idle, FPP1/2 match
83 601 628 13 Flash checksum invalid
84 606 629 31 COP failure
85 1612 629 31 RTI 1 loss
86 1613 629 31 RTI 2 loss
87 1614 629 31 RTI 3 loss
88 1615 629 31 A/D loss
89 1616 629 31 Invalid interrupt
90 604 630 12 RAM failure
91 148 632 31 Fuel run-out longer than expected
92 6 632 4 Lockoff open / ground short
93 7 632 3 Lockoff short to power
94 337 636 4 Crank loss
95 336 636 2 Crank sync noise
96 16 636 8 Never crank synced at start
97 1626 639 12 CAN1 Tx failure
98 1627 639 12 CAN1 Rx failure
99 1628 639 13 CAN1 address conflict failure
100 2618 645 4 Tach output ground short
101 2619 645 3 Tach output short to power
102 261 651 5 1 Injector Loop Open or Low-Side Short to Ground
103 262 651 6 1 Injector Coil Shorted
104 264 652 5 2 Injector Loop Open or Low-Side Short to Ground
105 265 652 6 2 Injector Coil Shorted
106 267 653 5 3 Injector Loop Open or Low-Side Short to Ground
107 268 653 6 3 Injector Coil Shorted
108 270 654 5 4 Injector Loop Open or Low-Side Short to Ground
109 271 654 6 4 Injector Coil Shorted
110 273 655 5 5 Injector Loop Open or Low-Side Short to Ground
111 274 655 6 5 Injector Coil Shorted
112 276 656 5 6 Injector Loop Open or Low-Side Short to Ground
113 277 656 6 6 Injector Coil Shorted
6-60
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
114 279 657 5 7 Injector Loop Open or Low-Side Short to Ground
115 280 657 6 7 Injector Coil Shorted
116 282 658 5 8 Injector Loop Open or Low-Side Short to Ground
117 283 658 6 8 Injector Coil Shorted
118 285 659 5 9 Injector Loop Open or Low-Side Short to Ground
119 286 659 6 9 Injector Coil Shorted
120 288 660 5 10 Injector Loop Open or Low-Side Short to Ground
121 289 660 6 10 Injector Coil Shorted
122 670 676 11 Glow Plug Control Unit Failure
123 1629 695 9 J1939 TSC1 message receipt lost
124 1631 697 5 PWM1-Gauge1 open / ground short
125 1632 697 6 PWM1-Gauge1 short to power
126 1633 698 5 PWM2-Gauge2 open / ground short
127 1634 698 3 PWM2-Gauge2 short to power
128 1635 699 5 PWM3-Gauge3 open / ground short
129 1636 699 3 PWM3-Gauge3 short to power
130 1637 700 5 PWM4-Gauge4 open / ground short
131 1638 700 3 PWM4-Gauge4 short to power
132 1511 701 3 AUX analog PU1 high
133 1512 701 4 AUX analog PU1 low
134 1513 702 3 AUX analog PU2 high
135 1514 702 4 AUX analog PU2 low
136 1517 703 3 AUX analog PU3 high
137 1518 703 4 AUX analog PU3 low
138 1441 703 0 AUX Temperature 3 high
139 1442 703 1 AUX Temperature 3 low
140 1454 703 0 AUX Pressure 3 high
141 1455 703 1 AUX Pressure 3 low
142 1541 704 3 AUX analog PUD1 high
143 1542 704 4 AUX analog PUD1 low
144 1443 704 0 AUX Temperature 4 high
145 1444 704 1 AUX Temperature 4 low
146 1456 704 0 AUX Pressure 4 high
147 1457 704 1 AUX Pressure 4 low
148 1543 705 3 AUX analog PUD2 high
149 1544 705 4 AUX analog PUD2 low
150 1545 706 3 AUX analog PUD3 high
151 1546 706 4 AUX analog PUD3 low
 6-61
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
152 1551 707 3 AUX DIG1 high
153 1552 707 4 AUX DIG1 low
154 1553 708 3 AUX DIG2 high
155 1554 708 4 AUX DIG2 low
156 1558 709 3 Water Intrusion Detection
157 1555 709 3 AUX DIG3 high
158 1556 709 4 AUX DIG3 low
159 1515 710 3 AUX analog PD1 high
160 1516 710 4 AUX analog PD1 low
161 1561 711 3 AUX analog PD2 high
162 1562 711 4 AUX analog PD2 low
163 1563 712 3 AUX analog PD3 high
164 1564 712 4 AUX analog PD3 low
165 1547 713 3 AUX analog PUD4 high
166 1548 713 4 AUX analog PUD4 low
167 1567 714 3 AUX analog PUD6 high
168 1568 714 4 AUX analog PUD6 low
169 1569 715 3 AUX analog PUD7 high
170 1571 715 4 AUX analog PUD7 low
171 1572 716 3 AUX DIG4 high
172 1573 716 4 AUX DIG4 low
173 342 723 4 Cam loss
174 341 723 2 Cam sync noise
175 327 731 4 Knock 1 sensor open
176 326 731 2 Knock 1 excessive signal
177 1325 731 15 Knock retard at limit
178 1641 920 4 Buzzer control ground short
179 1642 920 5 Buzzer open
180 1643 920 3 Buzzer control short to power
181 1639 924 5 PWM5 open / ground short
182 1640 924 3 PWM5 short to power
183 1661 925 5 PWM6 open / ground short
184 1662 925 3 PWM6 short to power
185 1663 926 5 PWM7 open / ground short
186 1664 926 3 PWM7 short to power
187 1531 972 31 IVS/Brake/Trans-Park interlock failure
188 1671 1074 4 Brake output open / ground short
189 1672 1074 3 Brake output short to power
6-62
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
190 643 1079 3 5VE1 high voltage
191 642 1079 4 5VE1 low voltage
192 1611 1079 31 5VE1/2 simultaneous out-of-range
193 653 1080 3 5VE2 high voltage
194 652 1080 4 5VE2 low voltage
195 1625 1110 31 J1939 Shutdown Request
196 1211 1188 3 APS1 high voltage
197 1212 1188 4 APS1 low voltage
198 1215 1188 0 APS1 higher than APS2
199 1216 1188 1 APS1 lower than APS2
200 1217 1188 7 Unable to reach higher APS
201 1213 1189 3 APS2 high voltage
202 1214 1189 4 APS2 low voltage
203 1218 1189 7 Unable to reach lower APS
204 1131 1192 3 WGP high voltage
205 1132 1192 4 WGP low voltage
206 1644 1213 4 MIL control ground short
207 650 1213 5 MIL open
208 1645 1213 3 MIL control short to power
209 1646 1231 12 CAN2 Tx failure
210 1648 1231 12 CAN2 Rx failure
211 1650 1231 13 CAN2 address conflict failure
212 1647 1235 12 CAN3 Tx failure
213 1649 1235 12 CAN3 Rx failure
214 1653 1235 13 CAN3 address conflict failure
215 1351 1268 11 1 Spark Plug or Coil Failure
216 2300 1268 5 1 Primary Loop Open or Low-Side Short to Ground
217 2301 1268 6 1 Primary Coil Shorted
218 351 1268 31 1 External Spark Module Coil Failure
219 350 1268 31 External Spark Module Failure
220 1352 1269 11 2 Spark Plug or Coil Failure
221 2303 1269 5 2 Primary Loop Open or Low-Side Short to Ground
222 2304 1269 6 2 Primary Coil Shorted
223 352 1269 31 2 External Spark Module Coil Failure
224 1353 1270 11 3 Spark Plug or Coil Failure
225 2306 1270 5 3 Primary Loop Open or Low-Side Short to Ground
226 2307 1270 6 3 Primary Coil Shorted
227 353 1270 31 3 External Spark Module Coil Failure
 6-63
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
228 1354 1271 11 4 Spark Plug or Coil Failure
229 2309 1271 5 4 Primary Loop Open or Low-Side Short to Ground
230 2310 1271 6 4 Primary Coil Shorted
231 354 1271 31 4 External Spark Module Coil Failure
232 1355 1272 11 5 Spark Plug or Coil Failure
233 2312 1272 5 5 Primary Loop Open or Low-Side Short to Ground
234 2313 1272 6 5 Primary Coil Shorted
235 355 1272 31 5 External Spark Module Coil Failure
236 1356 1273 11 6 Spark Plug or Coil Failure
237 2315 1273 5 6 Primary Loop Open or Low-Side Short to Ground
238 2316 1273 6 6 Primary Coil Shorted
239 356 1273 31 6 External Spark Module Coil Failure
240 1357 1274 11 7 Spark Plug or Coil Failure
241 2318 1274 5 7 Primary Loop Open or Low-Side Short to Ground
242 2319 1274 6 7 Primary Coil Shorted
243 357 1274 31 7 External Spark Module Coil Failure
244 1358 1275 11 8 Spark Plug or Coil Failure
245 2321 1275 5 8 Primary Loop Open or Low-Side Short to Ground
246 2322 1275 6 8 Primary Coil Shorted
247 358 1275 31 8 External Spark Module Coil Failure
248 1359 1276 11 9 Spark Plug or Coil Failure
249 2324 1276 5 9 Primary Loop Open or Low-Side Short to Ground
250 2325 1276 6 9 Primary Coil Shorted
251 359 1276 31 9 External Spark Module Coil Failure
252 1360 1277 11 10 Spark Plug or Coil Failure
253 2327 1277 5 10 Primary Loop Open or Low-Side Short to Ground
254 2328 1277 6 10 Primary Coil Shorted
255 360 1277 31 10 External Spark Module Coil Failure
256 616 1321 4 Start relay control ground short
257 615 1321 5 Start relay coil open
258 617 1321 3 Start relay coil short to power
259 1311 1323 11 1 Misfire detected
260 301 1323 31 1 Emissions/catalyst damaging misfire
261 1312 1324 11 2 Misfire detected
262 302 1324 31 2 Emissions/catalyst damaging misfire
263 1313 1325 11 3 Misfire detected
264 303 1325 31 3 Emissions/catalyst damaging misfire
265 1314 1326 11 4 Misfire detected
6-64
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
266 304 1326 31 4 Emissions/catalyst damaging misfire
267 1315 1327 11 5 Misfire detected
268 305 1327 31 5 Emissions/catalyst damaging misfire
269 1316 1328 11 6 Misfire detected
270 306 1328 31 6 Emissions/catalyst damaging misfire
271 1317 1329 11 7 Misfire detected
272 307 1329 31 7 Emissions/catalyst damaging misfire
273 1318 1330 11 8 Misfire detected
274 308 1330 31 8 Emissions/catalyst damaging misfire
275 1319 1331 11 9 Misfire detected
276 309 1331 31 9 Emissions/catalyst damaging misfire
277 1320 1332 11 10 Misfire detected
278 310 1332 31 10 Emissions/catalyst damaging misfire
279 2632 1347 5 FPump motor loop open or high-side shorted to ground
280 2634 1347 6 FPump motor high-side shorted to power
281 628 1348 4 FPump relay control ground short
282 627 1348 5 Fpump relay coil open
283 629 1348 3 Fpump relay coil short to power
284 1604 1350 31 Service Interval Expired
285 1419 1385 3 ERWT 1 high voltage
286 1421 1385 4 ERWT 1 low voltage
287 1423 1385 15 ERWT 1 higher than expected level 1
288 1425 1385 0 ERWT 1 higher than expected level 2
289 1439 1385 0 AUX Temperature 1 high
290 1440 1385 1 AUX Temperature 1 low
291 1445 1385 0 AUX Temperature delta T 1 high
292 1446 1385 1 AUX Temperature delta T 1 low
293 1420 1386 3 ERWT 2 high voltage
294 1422 1386 4 ERWT 2 low voltage
295 1424 1386 15 ERWT 2 higher than expected level 1
296 1428 1386 0 ERWT 2 higher than expected level 2
297 1438 1386 0 AUX Temperature 2 high
298 1437 1386 1 AUX Temperature 2 low
299 1447 1386 0 AUX Temperature delta T 2 high
300 1448 1386 1 AUX Temperature delta T 2 low
301 1450 1387 0 AUX Pressure 1 high
302 1451 1387 1 AUX Pressure 1 low
303 1458 1387 0 AUX Pressure delta P 1 high
 6-65
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
304 1459 1387 1 AUX Pressure delta P 1 low
305 1452 1388 0 AUX Pressure 2 high
306 1453 1388 1 AUX Pressure 2 low
307 1460 1388 0 AUX Pressure delta P 2 high
308 1461 1388 1 AUX Pressure delta P 2 low
309 2296 1390 3 Secondary FP high voltage
310 2295 1390 4 Secondary FP low voltage
311 1088 1390 0 Secondary fuel pressure high
312 1087 1390 1 Secondary fuel pressure low
313 686 1485 4 Power relay control ground short
314 685 1485 5 Power relay coil open
315 687 1485 3 Power relay coil short to power
316 1602 1485 0 Relay off high voltage
317 1603 1485 1 Relay on low voltage
318 1674 1634 2 Hardware ID Failure
319 1673 1634 13 Calibration Configuration Error
320 1675 1675 3 Start command stuck active
321 1665 2646 5 PWM8 open / ground short
322 1666 2646 3 PWM8 short to power
323 1669 2647 5 PWM9 open / ground short
324 1670 2647 3 PWM9 short to power
325 1676 2648 5 PWM10 open / ground short
326 1677 2648 3 PWM10 short to power
327 1678 2649 5 PWM11 open / ground short
328 1679 2649 3 PWM11 short to power
329 1680 2650 5 PWM12 open / ground short
330 1681 2650 3 PWM12 short to power
331 2261 2651 5 1 CR Injector High-Side Short to Ground
332 2262 2651 3 1 CR Injector Low-Side Short to Power
333 1682 2651 5 PWM13 open / ground short
334 1683 2651 3 PWM13 short to power
335 2264 2652 5 2 CR Injector High-Side Short to Ground
336 2265 2652 3 2 CR Injector Low-Side Short to Power
337 1684 2652 5 PWM14 open / ground short
338 1685 2652 3 PWM14 short to power
339 2267 2653 5 3 CR Injector High-Side Short to Ground
340 2268 2653 3 3 CR Injector Low-Side Short to Power
341 1686 2653 5 PWM15 open / ground short
6-66
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
342 1687 2653 3 PWM15 short to power
343 2270 2654 5 4 CR Injector High-Side Short to Ground
344 2271 2654 3 4 CR Injector Low-Side Short to Power
345 1688 2654 5 PWM16 open / ground short
346 1689 2654 3 PWM16 short to power
347 2273 2655 5 5 CR Injector High-Side Short to Ground
348 2274 2655 3 5 CR Injector Low-Side Short to Power
349 1690 2655 5 PWM17 open / ground short
350 1691 2655 3 PWM17 short to power
351 2276 2656 5 6 CR Injector High-Side Short to Ground
352 2277 2656 3 6 CR Injector Low-Side Short to Power
353 1692 2656 5 PWM18 open / ground short
354 1693 2656 3 PWM18 short to power
355 2279 2657 5 7 CR Injector High-Side Short to Ground
356 2280 2657 3 7 CR Injector Low-Side Short to Power
357 1694 2657 5 PWM19 open / ground short
358 1695 2657 3 PWM19 short to power
359 2282 2658 5 8 CR Injector High-Side Short to Ground
360 2283 2658 3 8 CR Injector Low-Side Short to Power
361 1696 2658 5 PWM20 open / ground short
362 1697 2658 3 PWM20 short to power
363 1698 2659 5 PWM21 open / ground short
364 1699 2659 3 PWM21 short to power
365 1700 2660 5 PWM22 open / ground short
366 1701 2660 3 PWM22 short to power
367 1702 2661 5 PWM23 open / ground short
368 1703 2661 3 PWM23 short to power
369 3001 2899 3 1 Glow Plug Open/Power Short
370 3002 2899 3 2 Glow Plug Open/Power Short
371 3003 2899 3 3 Glow Plug Open/Power Short
372 3004 2899 3 4 Glow Plug Open/Power Short
373 3005 2899 3 5 Glow Plug Open/Power Short
374 3006 2899 3 6 Glow Plug Open/Power Short
375 3007 2899 3 7 Glow Plug Open/Power Short
376 3008 2899 3 8 Glow Plug Open/Power Short
377 3009 2899 3 9 Glow Plug Open/Power Short
378 3010 2899 3 10 Glow Plug Open/Power Short
379 671 2899 4 1 Glow Plug Short to Ground
 6-67
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
380 672 2899 4 2 Glow Plug Short to Ground
381 673 2899 4 3 Glow Plug Short to Ground
382 674 2899 4 4 Glow Plug Short to Ground
383 675 2899 4 5 Glow Plug Short to Ground
384 676 2899 4 6 Glow Plug Short to Ground
385 677 2899 4 7 Glow Plug Short to Ground
386 678 2899 4 8 Glow Plug Short to Ground
387 679 2899 4 9 Glow Plug Short to Ground
388 680 2899 4 10 Glow Plug Short to Ground
389 8906 3056 3 UEGO1 return voltage shorted high
390 8907 3056 4 UEGO1 return voltage shorted low
391 3040 3057 3 UEGO2 return voltage shorted high
392 3041 3057 4 UEGO2 return voltage shorted low
393 3100 3100 4 CR Injection Bank Boost Voltage Low Bank 1
394 3101 3101 4 CR Injection Bank Boost Voltage Low Bank 2
395 3102 3102 31 CR Injection Bank Internal Fault Bank 1
396 3103 3103 31 CR Injection Bank Internal Fault Bank 2
397 3104 3104 5 IMV Loop Open or Short to Ground
398 3105 3105 6 IMV Coil Short or Short to Power
399 134 3217 5 EGO open / lazy pre-cat 1
400 8910 3217 3 UEGO1 sense cell voltage high
401 8911 3217 4 UEGO1 sense cell voltage low
402 8908 3218 3 UEGO1 pump voltage shorted high
403 8909 3218 4 UEGO1 pump voltage shorted low
404 8901 3221 31 UEGO1 internal processor fault
405 8920 3221 0 UEGO1 internal supply voltage low
406 8921 3221 15 UEGO1 drift is out-of-tolerance
407 3030 3221 16 UEGO1 drift is out-of-tolerance - level 2
408 8904 3221 3 UEGO1 cal resistor voltage high
409 8905 3221 4 UEGO1 cal resistor voltage low
410 31 3222 4 EGOH1 open / ground short
411 32 3222 3 EGOH1 short to power
412 8902 3222 3 UEGO1 heater supply high voltage
413 8903 3222 4 UEGO1 heater supply low voltage
414 8914 3222 10 UEGO1 sense cell slow to warm up
415 8916 3222 0 UEGO1 sense cell impedance high
416 3031 3222 4 UEGO1 heater open / ground short
417 3032 3222 3 UEGO1 heater short to power
6-68
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
418 8912 3225 3 UEGO1 pump voltage at high drive limit
419 8913 3225 4 UEGO1 pump voltage at low drive limit
420 8915 3225 10 UEGO1 pump cell slow to warm up
421 8917 3225 0 UEGO1 pump cell impedance high
422 8918 3225 1 UEGO1 pump cell impedance low
423 154 3227 5 EGO open / lazy pre-cat 2/post-cat 1
424 51 3232 4 EGOH2 open / ground short
425 52 3232 3 EGOH2 short to power
426 140 3256 5 EGO open / lazy post-cat 1
427 3044 3256 3 UEGO2 sense cell voltage high
428 3045 3256 4 UEGO2 sense cell voltage low
429 3042 3257 3 UEGO2 pump voltage shorted high
430 3043 3257 4 UEGO2 pump voltage shorted low
431 3033 3260 31 UEGO2 internal processor fault
432 3055 3260 1 UEGO2 internal supply voltage low
433 3034 3260 15 UEGO2 drift is out-of-tolerance
434 3035 3260 16 UEGO2 drift is out-of-tolerance - level 2
435 3038 3260 3 UEGO2 cal resistor voltage high
436 3039 3260 4 UEGO2 cal resistor voltage low
437 37 3261 4 EGOH3 open / ground short
438 38 3261 3 EGOH3 short to power
439 3036 3261 3 UEGO2 heater supply high voltage
440 3037 3261 4 UEGO2 heater supply low voltage
441 3048 3261 10 UEGO2 sense cell slow to warm up
442 3050 3261 0 UEGO2 sense cell impedance high
443 3053 3261 4 UEGO2 heater open / ground short
444 3054 3261 3 UEGO2 heater short to power
445 3046 3264 3 UEGO2 pump voltage at high drive limit
446 3047 3264 4 UEGO2 pump voltage at low drive limit
447 3049 3264 10 UEGO2 pump cell slow to warm up
448 3051 3264 0 UEGO2 pump cell impedance high
449 3052 3264 1 UEGO2 pump cell impedance low
450 160 3266 5 EGO open / lazy post-cat 2
451 57 3271 4 EGOH4 open / ground short
452 58 3271 3 EGOH4 short to power
453 1219 3464 31 APS1/2 simultaneous voltages out of range
454 188 3468 3 FT gaseous fuel high
455 187 3468 4 FT gaseous fuel low
 6-69
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
456 186 3468 1 FT gaseous fuel extremely low
457 699 3511 3 5VE3 high voltage
458 698 3511 4 5VE3 low voltage
459 1068 3563 15 MAP higher than expected
460 89 3601 17 CFV RLV charge pressure low
461 2665 3601 7 CFV RLV test failed
462 223 3673 3 TPS2 high voltage
463 222 3673 4 TPS2 low voltage
464 2111 3673 7 Unable to reach lower TPS
465 1222 3822 3 BPS2 high voltage
466 1223 3822 4 BPS2 low voltage
467 1227 3822 7 Unable to reach lower BPS
468 1601 4490 18 Envirotech receipt lost
469 2170 4755 1 Catalyst monitor - exhaust P low
470 2171 4755 0 Catalyst monitor - exhaust P high
471 1230 5264 6 HBB drive current high
472 1229 5386 6 HBA drive current high
473 332 520197 4 Knock 2 sensor open
474 331 520197 2 Knock 2 excessive signal
FPP1 invalid voltage and FPP2 disagrees with IVS
475 2120 520199 11
(redundancy lost)
FPP2 invalid voltage and FPP1 disagrees with IVS
476 2125 520199 11
(redundancy lost)
477 1122 520199 11 FPP1/2 do not match each other or the IVS (redundancy lost)
478 171 520200 0 AL high gasoline bank1
479 172 520200 1 AL low gasoline bank1
480 174 520201 0 AL high gasoline bank2
481 175 520201 1 AL low gasoline bank2
482 508 520201 6 IAC ground short
483 509 520201 5 IAC coil open/short
484 1574 520202 3 AUX DIG5 high
485 1575 520202 4 AUX DIG5 low
486 1161 520202 0 AL high LPG
487 1162 520202 1 AL low LPG
488 1576 520203 3 AUX DIG6 high
489 1577 520203 4 AUX DIG6 low
490 1163 520203 0 AL high NG
491 1164 520203 1 AL low NG
6-70
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
492 1578 520204 3 AUX DIG7 high
493 1579 520204 4 AUX DIG7 low
494 1155 520204 0 CL high gasoline bank1
495 1156 520204 1 CL low gasoline bank1
496 1581 520205 3 AUX DIG8 high
497 1582 520205 4 AUX DIG8 low
498 1157 520205 0 CL high gasoline bank2
499 1158 520205 1 CL low gasoline bank2
500 1583 520206 3 AUX DIG9 high
501 1584 520206 4 AUX DIG9 low
502 1151 520206 0 CL high LPG
503 1152 520206 1 CL low LPG
504 1585 520207 3 AUX DIG10 high
505 1586 520207 4 AUX DIG10 low
506 1153 520207 0 CL high NG
507 1154 520207 1 CL low NG
508 1589 520209 3 AUX DIG11 high
509 1591 520209 4 AUX DIG11 low
510 1592 520210 3 AUX DIG12 high
511 1593 520210 4 AUX DIG12 low
512 420 520211 10 Gasoline cat monitor bank 1
513 430 520212 10 Gasoline cat monitor bank 2
514 1165 520213 10 LPG cat monitor
515 1166 520214 10 NG cat monitor
516 916 520226 3 Shift actuator feedback out-of-range
517 919 520226 7 Shift unable to reach desired gear
518 920 520226 31 Shift actuator or drive circuit failure
519 1171 520260 0 EPR / CFV regulation pressure higher than expected
520 1172 520260 1 EPR / CFV regulation pressure lower than expected
521 1173 520260 31 EPR / CFV comm lost
522 1174 520260 3 EPR / CFV voltage supply high
523 1175 520260 4 EPR / CFV voltage supply low
524 1176 520260 7 EPR / CFV internal actuator fault detection
525 1177 520260 12 EPR / CFV internal circuitry fault detection
526 1178 520260 12 EPR / CFV internal comm fault detection
527 1179 520260 15 CFV flow higher than commanded
528 1180 520260 17 CFV flow lower than commanded
529 1565 520273 3 AUX analog PUD5 high
 6-71
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

PSI fault code

Flash
No. SPN FMI Fault Description
Code
530 1566 520273 4 AUX analog PUD5 low
531 1705 520274 3 AUX analog PUD8 high
532 1706 520274 4 AUX analog PUD8 low
533 1707 520275 3 AUX analog PUD9 high
534 1708 520275 4 AUX analog PUD9 low
535 1709 520276 3 AUX analog PUD10 high
536 1710 520276 4 AUX analog PUD10 low
537 1711 520277 3 AUX analog PUD11 high
538 1712 520277 4 AUX analog PUD11 low
539 1713 520278 3 AUX analog PUD12 high
540 1714 520278 4 AUX analog PUD12 low
541 1715 520279 3 AUX analog PUD13 high
542 1716 520279 4 AUX analog PUD13 low
543 1717 520280 3 AUX analog PUD14 high
544 1718 520280 4 AUX analog PUD14 low
545 1719 520281 3 AUX analog PUD15 high
546 1720 520281 4 AUX analog PUD15 low
547 1721 520282 3 AUX analog PUD16 high
548 1722 520282 4 AUX analog PUD16 low
549 1723 520283 3 AUX analog PUD17 high
550 1724 520283 4 AUX analog PUD17 low
551 1725 520284 3 AUX analog PUD18 high
552 1726 520284 4 AUX analog PUD18 low
553 1727 520285 3 AUX analog PUD19 high
554 1728 520285 4 AUX analog PUD19 low
555 1729 520286 3 AUX analog PUD20 high
556 1730 520286 4 AUX analog PUD20 low
557 1731 520287 3 AUX analog PUD21 high
558 1732 520287 4 AUX analog PUD21 low
559 1733 520288 3 AUX analog PUD22 high
560 1734 520288 4 AUX analog PUD22 low
561 1735 520289 3 AUX analog PUD23 high
562 1736 520289 4 AUX analog PUD23 low
563 1737 520290 3 AUX analog PUD24 high
564 1738 520290 4 AUX analog PUD24 low
565 1739 520291 3 AUX analog PUD25 high
566 1740 520291 4 AUX analog PUD25 low
567 1741 520292 3 AUX DIG13 high
6-72
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

PSI fault code

Flash
No. SPN FMI Fault Description
Code
568 1742 520292 4 AUX DIG13 low
569 1743 520293 3 AUX DIG14 high
570 1744 520293 4 AUX DIG14 low
571 1745 520294 3 AUX DIG15 high
572 1746 520294 4 AUX DIG15 low
573 1747 520295 3 AUX DIG16 high
574 1748 520295 4 AUX DIG16 low
575 1749 520296 3 AUX DIG17 high
576 1750 520296 4 AUX DIG17 low
577 1751 520297 3 AUX DIG18 high
578 1752 520297 4 AUX DIG18 low
579 1753 520298 3 AUX DIG19 high
580 1754 520298 4 AUX DIG19 low
581 1755 520299 3 AUX DIG20 high
582 1756 520299 4 AUX DIG20 low
583 1757 520300 3 AUX DIG21 high
584 1758 520300 4 AUX DIG21 low
585 1759 520301 3 AUX DIG22 high
586 1760 520301 4 AUX DIG22 low
587 1761 520302 3 AUX DIG23 high
588 1762 520302 4 AUX DIG23 low
589 1763 520303 3 AUX DIG24 high
590 1764 520303 4 AUX DIG24 low
591 1765 520304 3 AUX DIG25 high
592 1766 520304 4 AUX DIG25 low
593 1182 520401 0 Fuel impurity level high
594 11 520800 7 Intake cam / distributor position
595 24 520801 7 Exhaust cam position
596 1183 520803 31 EPR autozero / lockoff failed
 6-73
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Sensor or wiring harness short to power
106 16 Engine Air Inlet Pressure
Manifold - Sensor malfunction
Absolute - Sensor or wiring harness open or short to
Pressure 106 4 Engine Air Inlet Pressure ground
- Sensor malfunction
- Sensor or wiring harness short to power
94 3 Engine Fuel Delivery Pressure
- Sensor malfunction
- Sensor or wiring harness open or short to
Fuel Pressure 94 4 Engine Fuel Delivery Pressure ground
(Gasoline only) - Sensor malfunction
94 0 Engine Fuel Delivery Pressure - Fuel pressure abnormality (High side)

94 1 Engine Fuel Delivery Pressure - Fuel pressure abnormality (Low side)

- Operating in a hot environment
174 3 Engine Fuel Temperature 1
- Sensor out of calibration
Fuel - Operating in a frigid atmosphere
Temperature 174 4 Engine Fuel Temperature 1
- Sensor out of calibration
3468 1 Engine Fuel Temperature 2 - Not vaporized completely
- Sensor or wiring harness open or short to power
110 3 Engine Coolant Temperature
- Sensor malfunction
- Sensor or wiring harness short to ground
110 4 Engine Coolant Temperature
Engine Coolant - Sensor malfunction
Temperature - Engine coolant temperature abnormality (High
110 15 Engine Coolant Temperature
side stage 1)
- Engine coolant temperature abnormality (High
110 0 Engine Coolant Temperature
side stage 2)
Engine Intake Manifold 1 - Sensor or wiring harness open or short to power
105 3
Temperature - Sensor malfunction
Engine Intake Manifold 1 - Sensor or wiring harness short to ground
105 4
Intake Air Temperature - Sensor malfunction
Temperature Engine Intake Manifold 1 - Intake air temperature abnormality (High side
105 15
Temperature stage 1)
Engine Intake Manifold 1 - Intake air temperature abnormality (High side
105 0
Temperature stage 2)
- Sensor or wiring harness open or short to power
731 4 Engine Knock Sensor
- Sensor malfunction
Knock
- Knock signal abnormality (High side)
731 2 Engine Knock Sensor
- Sensor malfunction
168 15 Battery Potential / Power Input 1 - System voltage abnomality (High side)
Battery Voltage - Wiring harness open or short or damage
168 17 Battery Potential / Power Input 1
- Battery abnormality
6-74
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
Sensor Supply Voltage 1 (+5V
- Wiring harness short to 12 V power
1079 3 DC)
- ECU malfunction
(obsolete)
Sensor Supply Voltage 1 (+5V
- Wiring harness short to ground
1079 4 DC)
- ECU malfunction
(obsolete)
Sensor Supply Voltage 2 (+5V
- Wiring harness short to 12 V power
5V External 1080 3 DC)
- ECU malfunction
(obsolete)
Sensor Supply Voltage 2 (+5V
- Wiring harness short to ground
1080 4 DC)
- ECU malfunction
(obsolete)
Sensor Supply Voltage 1 (+5V
- Wiring harness short to 12 V power or ground
1079 31 DC)
- ECU malfunction
(obsolete)
- TPS circuit in the harness short to power
51 3 Engine Throttle Position
- TPS malfunction
- TPS circuit in the harness short to ground
51 4 Engine Throttle Position
- TPS malfunction
- TPS circuit in the harness short to power
3673 3 TPS2 Signal Voltage High
- TPS malfunction
Throttle Position - TPS circuit in the harness short to ground
Sensor 3673 4 Engine Throttle 2 Position
- TPS malfunction
51 0 Engine Throttle Position - TPS malfunction
51 1 Engine Throttle Position - TPS malfunction
51 7 Engine Throttle Position - TPS malfunction
51 7 Engine Throttle Position - TPS malfunction
51 31 Engine Throttle Position - TPS malfunction
- Sensor out of calibration
Barometric
108 1 Barometric Pressure - Loss for 5 V reference feed (5V_ext1) to MAP
Pressure
- Signal wire open or shorted to ground
 6-75
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Wiring harness open or short or damage
91 3 Accelerator Pedal Position 1
- Accelerator position sensor malfunction
- Wiring harness open or short or damage
91 4 Accelerator Pedal Position 1
- Accelerator position sensor malfunction
- Wiring harness open or short or damage
29 3 Accelerator Pedal Position 2
- Accelerator position sensor malfunction
FPP - Wiring harness open or short or damage
29 4 Accelerator Pedal Position 2
- Accelerator position sensor malfunction
- Wiring harness open or short or damage
91 16 Accelerator Pedal Position 1
- Accelerator position sensor malfunction
- Wiring harness open or short or damage
91 18 Accelerator Pedal Position 1
- Accelerator position sensor malfunction
91 31 Accelerator Pedal Position 1 - Accelerator position sensor malfunction
- Engine over speed condition, stuck throttle,
Engine's Desired Operating
515 15 large vacuum leak into intake manifold after
Speed
throttle blade
Engine Speed Engine's Desired Operating - Engine overspeed condition, faulty crank sensor
515 16
Speed or input
Engine's Desired Operating - Engine overspeed condition, faulty crank sensor
515 0
Speed or input
Oil Pressure 100 1 Engine Oil Pressure - Low oil pressure
6-76
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Exhaust leaks upstream or near the EGO
sensor
- Reduced fuel supply pressure to the fuel
4237 0 Long-term Fuel Trim - Bank 1 injection system
- A inoperative sensor
- An injector that is stuck closed or dirty
- Weak spark or lack of spark to a cylinder
- An inoperative EGO sensor
- High fuel supply pressure or temperature
4237 1 Long-term Fuel Trim - Bank 1
- Internal mechanical engine damage
- An injector that is stuck open or leaking
- Exhaust leaks upstream or near the EGO
sensor
- Reduced fuel supply pressure to the gaseous
4237 0 Long-term Fuel Trim - Bank 1
Adaptive Learn fuel control system
- A fuel supply or manifold leak
- A non-responsive EGO sensor
- High fuel supply pressure to the gaseous fuel
4237 1 Long-term Fuel Trim - Bank 1 control or faulty pressure regulator
- A non-responsive EGO sensor
- Exhaust leaks upstream or near the EGO
sensor
- Reduced fuel supply pressure to the gaseous
4237 0 Long-term Fuel Trim - Bank 1
fuel control system
- A fuel supply or manifold leak
- A non-responsive EGO sensor
- High fuel supply pressure to the gaseous fuel
4237 1 Long-term Fuel Trim - Bank 1 control or faulty pressure regulator
- A non-responsive EGO sensor
 6-77
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Exhaust leaks upstream or near the EGO
sensor
4236 0 Short-term Fuel Trim - Bank 1
- Reduced fuel supply pressure
- An injector that is stuck closed
- High fuel supply pressure to the fuel injection
system
4236 1 Short-term Fuel Trim - Bank 1
- A non-responsive EGO sensor
- An injector that is stuck open
- Exhaust leaks upstream or near the EGO
sensor
- Reduced fuel supply pressure to the gaseous
4236 0 Short-term Fuel Trim - Bank 1
fuel control system
- A fuel supply or manifold leak
Closed Loop - A non-responsive EGO sensor
- High fuel supply pressure to the gaseous fuel
4236 1 Short-term Fuel Trim - Bank 1 control or faulty pressure regulator
- A non-responsive EGO sensor
- Exhaust leaks upstream or near the EGO
sensor
- Reduced fuel supply pressure to the gaseous
4236 0 Short-term Fuel Trim - Bank 1
fuel control system
- A fuel supply or manifold leak
- A non-responsive EGO sensor
- High fuel supply pressure to the gaseous fuel
4236 1 Short-term Fuel Trim - Bank 1 control or faulty pressure regulator
- A non-responsive EGO sensor
- Physically damaged catalyst
3050 11 Catalyst 1 System Monitor - Contaminated catalyst element
- Post signal circuit shorted to pre signal
- Physically damaged catalyst
Catalyst Monitor 3050 11 Catalyst 1 System Monitor - Contaminated catalyst element
- Post signal circuit shorted to pre signal
- Physically damaged catalyst
3050 11 Catalyst 1 System Monitor - Contaminated catalyst element
- Post signal circuit shorted to pre signal
- Open feed circuit to oxygen heater
- Open or shorted to ground oxygen signal wire
3217 5 Aftertreatment 1 Intake O2
- Open sensor ground (5Vrtn1)
- Inoperative sensor
EGO Sensors
- Open feed circuit to oxygen heater
- Open or shorted to ground oxygen signal wire
3227 5 Aftertreatment 1 Outlet O2
- Open sensor ground (5Vrtn1)
- Inoperative sensor
6-78
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Loss of 12 V feed to injector
- Open injector coil
651 5 Engine Injector Cylinder #01
- Open or shorted to ground injector driver circuit
in engine harness
- Loss of 12 V feed to injector
- Open injector coil
652 5 Engine Injector Cylinder #02
- Open or shorted to ground injector driver circuit
in engine harness
- Loss of 12 V feed to injector
- Open injector coil
653 5 Engine Injector Cylinder #03
- Open or shorted to ground injector driver circuit
in engine harness
- Loss of 12 V feed to injector
- Open injector coil
Injectors 654 5 Engine Injector Cylinder #04
- Open or shorted to ground injector driver circuit
in engine harness
- Injector coil shorted internally
651 6 Engine Injector Cylinder #01 - Injector driver circuit shorted to voltage between
injector and ECU
- Injector coil shorted internally
652 6 Engine Injector Cylinder #02 - Injector driver circuit shorted to voltage between
injector and ECU
- Injector coil shorted internally
653 6 Engine Injector Cylinder #03 - Injector driver circuit shorted to voltage between
injector and ECU
- Injector coil shorted internally
654 6 Engine Injector Cylinder #04 - Injector driver circuit shorted to voltage between
injector and ECU
- A short to ground or open circuit in the harness
1268 5 Engine Ignition Coil #1
- An open internal to the primary coil
- A short to ground or open circuit in the harness
1269 5 Engine Ignition Coil #2
- An open internal to the primary coil
- A short to ground or open circuit in the harness
1270 5 Engine Ignition Coil #3
- An open internal to the primary coil
- A short to ground or open circuit in the harness
1271 5 Engine Ignition Coil #4
Spark Coil - An open internal to the primary coil
Primary - A short to power in the harness
1268 6 Engine Ignition Coil #1
- A short internal to the primary coil
- A short to power in the harness
1269 6 Engine Ignition Coil #2
- A short internal to the primary coil
- A short to power in the harness
1270 6 Engine Ignition Coil #3
- A short internal to the primary coil
- A short to power in the harness
1271 6 Engine Ignition Coil #4
- A short internal to the primary coil
 6-79
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Leak fuel at solenoid
Lockoff/Fuel
632 31 Engine Fuel Shutoff 1 Control - Faulty solenoid
Diagnostics
- Open or short to ground
Engine Fuel Pump Pressurizing
Fuel 1347 5
Assembly #1
PumpMotor
Feedback Engine Fuel Pump Pressurizing
1347 6
Assembly #1
- Relay pull in coil shorted internally
Engine Fuel Pump Pressurizing
1348 4 - Relay driver circuit shorted to ground in wire
Assembly #2
harness
Fuel Pump
Engine Fuel Pump Pressurizing - Open coil in relay
Relay Control/ 1348 5
Assembly #2 - Open in relay driver circuit in engine harness
Coil
- Shorted relay pull in coil
Engine Fuel Pump Pressurizing
1348 3 - Relay driver circuit shorted to voltage in wire
Assembly #2
harness
- Short to ground in relay pull in coil
1485 4 ECM Main Relay - Short to ground in relay driver circuit in wire
Power Relay harness
Control/Coil - Shorted relay pull in coil
1485 3 ECM Main Relay - Relay driver circuit shorted to voltage in wire
harness
52026 Megajector/EPR Delivery
0 - Inlet pressure to DEPR is too high.
0 Pressure Higher Than Expected
- Inlet pressure to DEPR is too low.
52026 Megajector/EPR Delivery
1 - Malfunctioning lock off valve, plugged fuel filter,
0 Pressure Lower Than Expected
closed manual valve or fuel tank out of fuel
52026 - Faulty CAN connection
31 Megajector/EPR Comm Lost
0 - CAN termination incorrect
EPR 52026 Megajector/EPR Voltage Supply
3 - Wiring harness open or short or damage
Diagnostics 0 High
52026 Megajector/EPR Voltage Supply - Wiring harness open or short or damage
4
0 Low - Faulty EPR power circuit
- Short or open circuit in actuator coil
52026 Megajector/EPR Internal Actuator
12 - Associated wiring
0 Fault Detection
- Overheating of actuator drive electronics
52026 Megajector/EPR Internal Circuitry - DEPR internal microprocessor or memory
12
0 Fault Detection failure, fuel temperature sensor failure.
6-80
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Kubota fault code

Flash
code SPN Name
DTC Detection item
SAE J1939
SPN FMI
- Loss of feed voltage to Cam sensor
723 4 Engine Speed 2 - Loss of signal or ground circuits
- Faulty sensor
- Loss of sensor feed
636 4 Engine Position Sensor - Open sensor ground
Cam/Crank - Open or shorted to ground signal wire
Sensors - Cam+ or Cam- circuits in wrong connector
723 2 Engine Speed 2
terminal slot
- Crank+ or Crank- circuits in wrong connector
636 2 Engine Position Sensor
terminal slot
- Mechanical misalignment between cam and
636 8 Engine Position Sensor
crank
629 31 Controller #1 - Faulty ECU
629 31 Controller #1 - Faulty ECU
629 31 Controller #1 - Faulty ECU

Internal 629 31 Controller #1 - Faulty ECU

Processor 629 31 Controller #1 - Faulty ECU
Diagnostics 629 31 Controller #1 - Faulty ECU
628 13 Program Memory - Faulty ECU
630 12 Calibration Memory - Faulty ECU
1634 2 Calibration Vertification Number - Faulty ECU
J1939 Network 695 9 Engine Override Control Mode
 6-81
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Mitsubishi D04EG fault code

No. level SPN FMI Fault Description

1 L 677 3 Glow relay failure,battery short circuit

2 L 677 4 Glow relay failure,GND short circuit
3 L 677 2 Glow relay failure,disconnected
4 L 677 12 Glow relay failur, overload
5 L 168 3 Abnormaly,voltage high voltage
6 L 168 4 Abnormaly, voltage low voltage
7 H 102 12 Boost pressure low,boost pressure is lower than the
8 SP 1614 3 Over Speed,engine speed is greater than the limit
9 L 2008 2 A/D converter failure,test pulse conversion error
10 L 2008 12 A/D converter failure,conversion processing time long
11 M 1235 4 EEPROM failure,read error
12 M 1235 2 EEPROM failure,Write error
13 M 1235 12 EEPROM failure,Delete error
14 SP 2080 12 ECU internal error
Internal bus (SPI) failure,Communication failure between CPU and
15 L 1231 3
internal IC
16 M 3509 3 Abnomal supply voltage for sensor 1,Supply voltage failure
17 L 3511 3 Abnomal supply voltage for sensor 2,Supply voltage failure
18 SP 620 3 Abnomal supply voltage for sensor 3,Supply voltage failure
19 L 2010 4 Watch Dog
20 M 1671 3 CAN 1 bus-off
PLV open Pressure Limiting Valve,Rail pressure exceeds
21 L 2042 4
the limit value.
22 SP 2042 4 PLV forced open,Operate MPROP, and open PLV
23 SP 2019 3 PLV pressure high,Rail pressure high during PLV open
PLV pressure deviation high,Pressure deviation high during PLV
24 SP 2045 4
open
25 SP 2042 2 PLV open count over,PLV open count overs the limit
26 SP 2043 2 PLV open time over,PLV open time overs the limit
27 SP 2011 3 Rail pressure signal out of range,Disconnected
28 SP 2011 4 Rail pressure signal out of range,Short circuit
29 SP 2017 4 Rail pressure high,Rail pressure exceeds the limit value.
Rail pressure deviation high,Rail pressure is higher than target
30 SP 2013 3
pressure
6-82
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G

Mitsubishi D04EG fault code

No. level SPN FMI Fault Description

Rail pressure deviation low,Rail pressure is lower than target

31 SP 2015 3
pressure
32 SP 2000 2 MPROP failure,MPROP overcurrent
33 SP 2000 12 MPROP failure,MPROP disconnected
34 SP 2001 3 MPROP full close,MPROP stays closed and does not open.
35 SP 2002 4 MPROP full open,MPROP stays open and does not close.
36 SP 2002 4 MPROP full open
Injector driver circuit1 failure,More than one cylinder is detected
37 L 651 12
failure on the same
Injector driver circuit2 failure,More than one cylinder is detected
38 L 653 12
failure on the same
39 L 655 12 Injector driver IC failure
40 SP 657 12 Injector 1 failure,short circuit
41 L 658 2 Injector 1 failure,disconnected
42 L 2081 2 Injector 1 IQA error,No adjustment data
43 SP 659 12 Injector 2 failure,short circuit
44 L 660 2 Injector 2 failure,disconnected
45 L 2082 2 Injector 2 IQA error,No adjustment data
46 SP 661 12 Injector 3 failure,short circuit
47 L 662 2 Injector 3 failure,disconnected
48 L 2083 2 Injector 3 IQA error,No adjustment data
49 SP 663 12 Injector 4 failure,short circuit
50 L 664 2 Injector 4 failure,disconnected
51 L 2084 2 Injector 4 IQA error,No adjustment data
52 L 29 3 Accel sensor 1 failure,High input voltage
53 L 29 4 Accel sensor 1 failure,Low input voltage
54 L 91 3 Accel sensor 2 failure,rHigh input voltage
55 L 91 4 Accel sensor 2 failure,Low input voltage
56 L 29 12 Accel sensor 1 /Accel sensor 2
57 M 108 3 Ambient air pressure sensor failure,Disconnected
58 M 108 4 Ambient air pressure sensor failure,Short circuit
59 M 105 3 Intake manifold air temperature sensor failure, Disconnected
60 M 105 4 Intake manifold air temperature sensor failure,Short circuit
61 M 102 3 Intake manifold air pressure sensor failure, Disconnected
62 M 102 4 Intake manifold air pressure sensor failure,Short circuit
63 L 174 3 Fuel temperature sensor failure,Disconnected
 6-83
November 2, 2020 Fault Code Table
CLG2020H/C-2035H/C,CLG2020G-2035G Fuse and Relay

Mitsubishi D04EG fault code

No. level SPN FMI Fault Description

64 L 174 4 Fuel temperature sensor failure,Short circuit

65 M 110 3 Coolant temperature sensor failure,Disconnected
66 M 110 4 Coolant temperature sensor failure,Short circuit
67 L 636 3 Camshaft speed sensor failure,No Cam pulse input
68 L 636 4 Camshaft speed sensor failure,Cam pulse number error
69 L 637 3 Crankshaft speed sensor failure,No Crank pulse input
70 L 637 4 Crankshaft speed sensor failure,Crank pulse number error
71 L 228 3 Cam / Crankshaft speed signal,Phase failure
72 M 2062 12 Valve drive duty too
73 M 2061 12 Motor short circuit
74 M 2061 2 Motor disconnected
75 M 2067 2 Position Sensor
76 M 2068 2 Valve sticking warning 1,Valve opening position error
77 M 2032 2 ECU signal lost,CAN signal from ECU is lost
78 M 27 2 Valve over range,Valve opening command exceed the
79 M 2031 2 EGR signal lost,CAN signal from EGR
80 M 2031 2 EGR signal lost
81 M 2063 3 Abnormaly Supply voltage,Over voltage
82 L 2063 4 Abnormaly Supply voltage,Low voltage
83 M 2066 2 Valve sticking,Valve opening
84 M 2066 12 EGR valve initialization overtime
85 L 2064 4 Thermistor failure,High temperature Thermistor failure
86 L 2065 4 Thermistor failure,Low temperature Thermistor failure
6-84
Fault Code Table November 2, 2020
Fuse and Relay CLG2020H/C-2035H/C,CLG2020G-2035G
 7-1
November 2, 2020 Frame System
CLG2020H/C-2035H/C,CLG2020G-2035G

Frame System
Safety................................................................................................................................7-3
Frame System Overview .................................................................................................7-3
Structure and Function ...................................................................................................7-4
Subsystem Overview .............................................................................................................................7-4
Frame Assembly ................................................................................................................................7-4
Balancing Weight Assembly...............................................................................................................7-4

Removal and Installation ................................................................................................7-5

Front Crossbeam Plate ..........................................................................................................................7-5
The removal for Front Crossbeam Plate ............................................................................................7-5
Installation for Front Crossbeam Plate...............................................................................................7-6
Rear Crossbeam Plate...........................................................................................................................7-7
Removal for Rear Crossbeam Plate ..................................................................................................7-7
Installation of Rear Crossbeam Plate.................................................................................................7-7
Front Side Hood .....................................................................................................................................7-8
Removal for Front Side Hood.............................................................................................................7-8
Installation for Front Side Hood..........................................................................................................7-8
Rear Side Hood .....................................................................................................................................7-9
Removal for Rear Side Hood .............................................................................................................7-9
Installation of Rear Side Hood ........................................................................................................7-10
Steering Axle Rubber Gasket ..............................................................................................................7-11
Removal of Steering Axle Rubber Gasket .......................................................................................7-11
Installation of Steering Axle Rubber Gasket ....................................................................................7-12
Steering Axle Bracket ..........................................................................................................................7-13
Removal of Steering Axle Bracket ...................................................................................................7-13
Installation of Steering Axle Support ................................................................................................7-14
Balancing Weight Assembly ................................................................................................................7-15
Removal of Balancing Weight Assembly .........................................................................................7-15
Installation of Balancing Weight Assembly ......................................................................................7-16

Faults and Countermeasures .......................................................................................7-17

7-2
Frame System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 7-3
November 2, 2020 Safety
CLG2020H/C-2035H/C,CLG2020G-2035G

Safety Frame System Overview

(1) When parts are removed, weight and the Frame system is the integrated system of frame
center of gravity for parts must be evaluated assembly and balancing weight assembly, of
(see parameter list of complete machine for which the entirety forms frame-type structure,
this manual), if necessary, use the sling to becoming the carrier for skel of the whole main
protect them from being damaged resulting machine and many parts.
from falling off.
(2) The integrated system of the frame is made 2
up of frame assembly and balancing weight
assembly together, the removal of its 1
connection will damage the frame structure
of the main machine and thus make the main
machine out of balance, therefore, stable
measures and external bracing must be
made in advance, and the connection will be
removed only after the reliability is sufficiently
evaluated.
(3) There is diesel oil and hydraulic oil
respectively inside the left and right of frame P22S00001
cavity, and diesel oil possesses flammability,
hydraulic oil may keep higher temperature 1. Frame assembly
2. Balancing weight assembly
within a period of time after the operation of
the complete machine, therefore, before
maintenance, the work for fire and explosion
protection should be done sufficiently and
guard against the risk for high temperature
scalding.
(4) Conduct the operation according to
corresponding description at the position
pasted with safety marks to prevent potential
hazards.
7-4
Structure and Function November 2, 2020
Subsystem Overview CLG2020H/C-2035H/C,CLG2020G-2035G

Structure and Function Balancing Weight Assembly

The main body of balancing weight assembly is

Subsystem Overview balancing weight cast-iron, balancing weight
assembly is connected with frame assembly by
bolts to form the frame structure of frame
Frame Assembly system.
The main body of the frame assembly is welding The main function of balancing weight ito keep
pieces of the left and right frames, and front and balance when forklift truck is under load and to
rear crossbeam plates that welding pieces are avoid instability.
connected with. Above function mainly provides the installation
Above assembly mainly provides front axle position for parts, such as rear axle assembly,
system, working device system, engine system, LPG support, overhead guard (or cab) and so
cooling system, covering parts system, control on.
system, steering system, brake mechanism, the
installation site for parts, such as various panels,
lines and so on.

7
1 2
3 4 5 6
P22S00002

1. Frame-rh 2 3
2. Front crossbeam plate 1 4
3. Frame-lh
4. Rear crossbeam plate P22S00003
5. Front side hood
6. Antislip step 1. Balancing weight (large)
7. Rear side hood 2. Balancing weight (small)
8. The seal cover for filler of the diesel tank 3. Steering axle support
4. Steering axle rubber gasket
 7-5
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Front Crossbeam Plate

Removal and Installation

Front Crossbeam Plate

The removal for Front Crossbeam Plate

Figures Operation instructions

1. Remove the overhead guard (or cab) (1),
instrument cover and steering wheel cover (2).
Please refer to the introduction of chapter
"Covering Parts System" for detailed methods.
1

P22S00004
7-6
Removal and Installation November 2, 2020
Front Crossbeam Plate CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

2. Disconnect the connection of control system,
steering system, the pipelines (3) of braking
system and the wiring harness of electric
3 system on the front crossbeam plate.

P22S00005

3. Remove six M16 bolts (5) and two M12 bolts

4 (4) between front crossbeam plate and left and
right frames, then take out the front crossbeam
plate (6).

5
6
P22S00006

Installation for Front Crossbeam Plate

The process of installing front crossbeam plate is the reverse process of removing it.
 7-7
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Rear Crossbeam Plate

Rear Crossbeam Plate

Removal for Rear Crossbeam Plate

Figures Operation instructions

1. Remove four M16 bolts (1) between rear
crossbeam plate and left and right frames, then
take out rear crossbeam plate (2).

P22S00007

Installation of Rear Crossbeam Plate

The process of installing rear crossbeam plate is the reverse process of removing it.
7-8
Removal and Installation November 2, 2020
Front Side Hood CLG2020H/C-2035H/C,CLG2020G-2035G

Front Side Hood

Removal for Front Side Hood

Figures Operation instructions

1. Remove two M8 bolts (1) connecting antislip
step with frame, and take out antislip (2).

P22S00008
2. Remove two M8 bolts (1) connecting front side
hood with frame, and remove one M6 bolt (3)
3 connecting front side hood with instrument
cover, and take out the front side hood (4).

1
4
P22S00009

Installation for Front Side Hood

The process of installing front side hood is the reverse of removing it.
 7-9
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Rear Side Hood

Rear Side Hood

Removal for Rear Side Hood

Figures Operation instructions

1. Remove two M8 bolts (1) connecting antislip
step with frame, and take out antislip (2).

P22S00008
2. Remove two M8 bolts (1) connecting front side
hood with frame, and remove one M6 bolt (3)
3 connecting front side hood with instrument
cover, and take out the front side hood (4).

1
4
P22S00009
7-10
Removal and Installation November 2, 2020
Rear Side Hood CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Screw out the seal cover (5) for filler of the
diesel tank.
 Notice: There is no need to go on the
operation for rear side hood of the right side of
car body.

P22S00010
4. Remove four M8 bolts (1) connecting rear side
hood with frame, and under the condition of
engine hood open, please take out rear side
hood (6) and oil filler hood as a whole together.
 Notice: Rear side hood of the right side of
car body has no oil filler hood, therefore, only
take out rear side hood.
6

P22S00011

Installation of Rear Side Hood

The process of installing rear side hood is the reverse of removing it.
 7-11
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Steering Axle Rubber Gasket

Steering Axle Rubber Gasket

Removal of Steering Axle Rubber Gasket

Figures Operation instructions

1. Make sure oil in steering hydraulic pipelines
has been sufficiently cooled, after prepare the
collection of hydraulic oil, disconnect the
connector on the side of steering axle for
steering oil pipelines (1).

P22S00012
2. Hang balancing weight (large) with load lifting
device, remove M20 bolt (2) for installation of
steering axle. Hoist the lifting device, and hang
counterweight and take out steering axle.

P22S00013
7-12
Removal and Installation November 2, 2020
Steering Axle Rubber Gasket CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Remove two M8 bolts (4) connecting steering
axle rubber gasket (3) with steering axle
support, and take out steering axle rubber
gasket.

4
3

P22S00014

Installation of Steering Axle Rubber Gasket

The process of installing steering Axle rubber gasket is the reverse of removing it.
 7-13
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Steering Axle Bracket

Steering Axle Bracket

Removal of Steering Axle Bracket

Figures Operation instructions

1. Make sure oil in steering hydraulic pipelines
has been sufficiently cooled, after prepare the
collection of hydraulic oil, disconnect the
connector on the side of steering axle for
steering oil pipelines (1).

P22S00012
2. Hang balancing weight (large) with load lifting
device, take out traction pin (2) from the end of
balancing weight (large), and remove three
M30 bolts (3) connecting steering axle support
with balancing weight (large).

3
P22S00015
7-14
Removal and Installation November 2, 2020
Steering Axle Bracket CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Hoist hoisting equipment, and uplift the end of
fork lift truck to the position that take out
exactly steering axle support (4), steering axle
and balancing weight (small) which are
regarded as the whole together.

P22S00016

4. Remove two M20 bolts (5) connecting

5 balancing weight (small) (6) with steering axle
support (7), and take out balancing weight
6 (small), then remove steering axle (9) and
steering axle rubber gasket (8) to disassemble
and get steering axle support from the whole.

7 8

9
P22S00017

Installation of Steering Axle Support

The process of installing steering axle support is the reverse of removing it.
 7-15
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Balancing Weight Assembly

Balancing Weight Assembly

Removal of Balancing Weight Assembly

Figures Operation instructions

1. Remove engine hood, overhead guard (or cab)
and the cover, high exhaust pipe (or LPG
support) from the top of balancing weight and
so on.

P22S00018

2. Make sure oil in steering hydraulic pipelines

has been sufficiently cooled, after prepare the
collection of hydraulic oil, disconnect the
connector on the side of steering axle for
steering oil pipelines (1).

P22S00012
7-16
Removal and Installation November 2, 2020
Balancing Weight Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Place limited block at the front and rear of
driving wheel, and place wood block under the
car frame, which make rear wheel 50-100mm
above the earth, and pull hand brake well, then
exert parking brake.

P22S00019

4. Remove the connection of balancing weight

assembly and left, right frames and four M30
(2) bolts in the connection, then regard
balancing weight assembly (3) and steering
2
axle as the whole to take out them by load
lifting device.

P22S00020

Installation of Balancing Weight Assembly

The process of installing balancing weight assembly is the reverse of removing it.
 7-17
November 2, 2020 Faults and Countermeasures
CLG2020H/C-2035H/C,CLG2020G-2035G Balancing Weight Assembly

Faults and Countermeasures

Ref.
Fault features Main reasons Inspection and troubleshooting
No.
Take the cover on the top of the balancing
weight apart, and check fastening condition
(1) Connecting bolts of balancing weight
for four M30 connecting bolt. If there is
and car frame loosen
looseness, tightening should be done
according to standard torque.
Check fastening condition for three M30
connecting bolt from the end of complete
(2) Connecting bolts of balancing weight
machine. If there is looseness, tightening
and steering axle support loosen
should be done according to standard
The abnormal noise torque.
of balancing weight
Check fastening condition for four M16
or the extent that
1 (3) Connecting bolts of rear crossbeam connecting bolts of rear crossbeam plate. If
the end of complete
plate loosen there is looseness, tightening should be
machine jitters
done according to standard torque.
increases
Check the fastening condition of
(4) Cover, high exhaust pipe (or LPG
corresponding connecting bolts. If there is
support) and others parts on the top of
looseness, tightening should be done
balancing weight loosen
according to standard torque.
Deflect the steering wheel, and observe the
(5) Steering axle rubber gasket that plays a appearance of rubber gasket between
role for the improvement of stability steering axle and steering axle support, if
becomes ageing there is obvious ageing, please remove it
and replace parts.
Directly check the fastening condition of six
M16 bolts that locates on the head of main
machine and connects the front crossbeam
(1) Connecting bolts of front crossbeam plate with frame; besides, remove overhead
plate and frame loosen guard and instrument cover to check the
fastening condition of two M12 bolts. If there
Abnormal noise for is looseness, tightening should be done
2 front crossbeam according to standard torque.
plate Take the access door of instrument cover
apart, furthermore, instrument cover and
(2) Inside parts installed for braking, steering wheel cover are removed to check
steering, control system and so on fastening conditions of the parts on the front
loosen crossbeam plate. If there is looseness,
tightening should be done according to
standard torque.
Open the seal cover for filler, and visually
(1) Diesel oil is overfilled inspect oil mass. Generally oil mass does
not exceed 80% of volume of tank
The opening of the When the seal cover for filler is screwed
3
diesel filler leaks together, looseness is felt obviously, even
(2) The thread of the seal cover for filler is
there is no fastening effect, therefore, the
worn
seal cover is removed and replaced for
parts.
7-18
Faults and Countermeasures November 2, 2020
Balancing Weight Assembly CLG2020H/C-2035H/C,CLG2020G-2035G
 8-1
November 2, 2020 Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G

Mast System
Mast System Overview....................................................................................................8-3
Two-stage Wide View Mast ...................................................................................................................8-4
Two-stage Full-free Mast .......................................................................................................................8-4
Three-stage Full-free Mast.....................................................................................................................8-4

Mast System Parameters ................................................................................................8-5

Removal and Installation of Mast System....................................................................8-6
Removal and Installation of the Fork..................................................................................................8-6
Removal and Installation of the Fork Arm Carrier ..................................................................................8-8
Removal of the Fork Arm Carrier .......................................................................................................8-8
Installation of the Fork Arm Carrier ..................................................................................................8-10
Removal and Installation of Mast Assembly ........................................................................................8-11
Disassembly and Assembly of Mast Assembly....................................................................................8-13
Disassembly of Mast Assembly .......................................................................................................8-13
Assembly of Mast Assembly ............................................................................................................8-15
Removal and Installation of Lift Cylinder (Side Cylinder) .................................................................8-18
Removal and Installation of Lift Cylinder (Center Cylinder) .................................................................8-20
Removal and Installation of Tilt Cylinder..............................................................................................8-22

Installation of Mast Pipe ...............................................................................................8-24

Two-stage Wide View Mast .................................................................................................................8-24
Connect Lifting Pipe .........................................................................................................................8-24
Installation of Triple Pipe..................................................................................................................8-26
Installation of Quadruple Pipe ..........................................................................................................8-27
Two-stage Full-free Mast .....................................................................................................................8-28
Connect Lifting Pipe .............................................................................................................................8-28
Installation of Triple Pipe..................................................................................................................8-30
Installation of Quadruple Pipe ..........................................................................................................8-32
Three-stage Full-free Mast...................................................................................................................8-33
Connect Lifting Pipe .............................................................................................................................8-33
Installation of Triple Pipe..................................................................................................................8-36
Installation of Quadruple Pipe ..........................................................................................................8-37

Common Fault Analysis and Troubleshooting...........................................................8-38

8-2
Mast System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 8-3
November 2, 2020 Mast System Overview
CLG2020H/C-2035H/C,CLG2020G-2035G

Mast System Overview

Mast system is consist of mast, fork arm carrier, fork, load-backrest, lifting chain, roller, lift cylinder, tilt
cylinder, hydraulic connecting line and so on (see mast diagram), which is the work implement of forklift
to perform stacking operation. According to mast structure type, common mast is divided into two-stage,
two-stage full-free and three-stage full-free masts. CLG2020HC~CLG2035HC Forklifts manufactured by
our company can be equipped with two-stage wide view, two-stage full-free, three-stage full-free wide
view masts.
Forklift attachments can be selected according to actual requirements, such as side shifter, adjusting-
distance fork, tip-over fork and ejector etc. Side shifter is the common attachment.

1
3
2

6
5

10

P22S00021

1. Outer mast 5. Lift cylinder 9. Fork arm carrier

2. Inner mast 6. Chain assembly 10. Fork
3. Hydraulic oil line 7. Tilt cylinder
4. Fixed group of cylinders 8. Load-backrest
8-4
Mast System Overview November 2, 2020
Two-stage Wide View Mast CLG2020H/C-2035H/C,CLG2020G-2035G

Two-stage Wide View Mast

Two-stage mast consists of inner mast and outer mast. Lift cylinder bottom is fixed on lower beam of
outer mast, located by pin. Upper end of the piston is connected with upper beam of inner mast by bolts.
cylinder is installed on mounting base of outer mast by retaining clamp. Two lift cylinders are located
behind the mast to achieve wide view.
One end of the chain hanging around the inner mast sprocket is fixed on the outer mast while the other
end is connected with fork arm carrier. The fork is hung on fork arm carrier via hook. Fork arm carrier is
installed with main roller and side roller. Lower end of inner mast and upper end of outer mast are
provided with main roller and side roller.
Hydraulic oil from multi-way valve goes into lift cylinder through speed limit valve, pushing up the piston
and piston rod, and thus lift up the inner mast. With the rising of inner mast, the fork arm carrier and
related parts are pulled up to lift goods.

Two-stage Full-free Mast

The major difference between the two-stage full-free mast and the two-stage wide view mast is that there
is a short lift cylinder in the middle of inner mast, which is called free lift cylinder. Two sprockets are
installed on the top of free lift cylinder. One end of the chain hanging around the sprocket is fixed on the
inner mast while the other end is connected with fork arm carrier.
Hydraulic oil from multi-way valve goes into lift side cylinder through speed limit valve, and enters into
the bottom of free lift cylinder via the central passage of lift side cylinder, and pushing up the piston and
piston rod, thus pull up the fork arm carrier and related parts to lift goods. When free lift cylinder rising or
lowering, the inner mast does not rise and the fork can lift or lower with the forklift height unchanged.
Free lift height (with load-backrest) is about 560~2560mm (22.05-100.79 In). Only when the piston rod of
free lift cylinder is pushed to the limit, the hydraulic oil can push the piston and piston rod of lift cylinder to
rise.

Three-stage Full-free Mast

Three-stage full-free mast consists of outer mast, middle mast and inner mast. Middle mast and inner
mast can lift and lower. The main difference with the two-stage full-free mast is that there is one more
middle mast.
 8-5
November 2, 2020 Mast System Parameters
CLG2020H/C-2035H/C,CLG2020G-2035G Three-stage Full-free Mast

Mast System Parameters

Mast tilt angle (forward°/backward°):

Front/rear Mast information
6°/12° Two stage 2~4m, two-stage full-free 3m
Two stage 4.5~5m, three-stage full-free
6°/6°
4~5m
3°/6° Two stage 5.5~6m, three-stage 5.5~7m
Total height of mast (maximum lifting height & with

Backward tilt
Forward tilt
angle
angle

Maximum lifting height

Total height of mast (not lifted)

goods shelf)

Load center distance Front overhang P22S00023

P22S00022
8-6
Removal and Installation of Mast System November 2, 2020
Three-stage Full-free Mast CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation of Mast System

Fork, fork arm carrier, mast are heavy parts. Be careful when removing and installing.

Removal and Installation of the Fork

● During the course of removing, keep your hands and feet away from the fork and fork arm carrier.
● Be careful when removing the fork! Prevent the fork from falling off, which leads to personal hurt.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Wrench 18mm 1

Figures Operation instructions

1. Remove the bolts at the bottom of fork arm
carrier.

P22S00024
2. Pull out the dowel pin on the top of the fork and
rotate it 90 degrees , then move the fork to the
middle notch of fork arm carrier.

P22S00025
 8-7
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Three-stage Full-free Mast

Figures Operation instructions

3. Hold the tip of the fork, and pull the fork up and
forward away the fork arm carrier.

P22S00026

Installation sequence is in the reverse order of the removal.

8-8
Removal and Installation of Mast System November 2, 2020
Removal and Installation of the Fork Arm Carrier CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation of the Fork Arm Carrier

Removal of the Fork Arm Carrier

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Hoisting equipment 1 3 Nipping pliers 1
22mm,
2 Wrench 2 4
30mm

Figures Operation instructions

1. Lift fork arm carrier by hoisting equipment until
the chain is loose and keep it.

P22S00027

● Remove the split pin and nut on chain end of

fork arm carrier, and remove the chain from
fork arm carrier.
● If there is attachment hose, remove it together.

P22S00028

P22S00029
 8-9
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation of the Fork Arm Carrier

Figures Operation instructions

2. Start the forklift to lift up the mast, and keep
lower part of inner mast higher than fork arm
carrier, remove fork arm carrier as from inner
mast by hoisting equipment.

The fork arm carrier can also be removed from the mast after removing the whole mast from the
forklift and placing the mast horizontally.
8-10
Removal and Installation of Mast System November 2, 2020
Removal and Installation of the Fork Arm Carrier CLG2020H/C-2035H/C,CLG2020G-2035G

Installation of the Fork Arm Carrier

Installation sequence is in the reverse order of the removal. The side roller clearance and lifting chain
shall be adjusted during the installation.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
18mm,
1 Wrench 2 2
30mm

Figures Operation instructions

1. Push the fork arm carrier on both upper and
Side roller of fork arm carrier
lower end transversely in the reverse direction,
make the two diagonal side rollers of fork arm
carrier contact with channel steel, and check
Fork arm carrier

the clearance A between side roller of the other

side and inner mast channel steel, if clearance
A is not within 0.5~1mm (0.02-0.04 In), adjust it
by increasing or decreasing the adjusting shim
of side roller; reverse push the fork arm carrier
and adjust the other side according to the
process above.
Inner mast flange
P22S00030
2. After the clearance is adjusted, move the fork
arm carrier within full range of inner mast, and
check if it runs smoothly.
3. Install fork arm carrier into inner mast, and
wind the chain as shown in the Fig. Keep the
mast upright and lower completely; adjust the
nut on lower end of the chain to make the
distance between lower cross beam of fork arm
carrier and the ground within 70~76mm (2.76-
2.99 In) or the fork touch the ground, and keep
the same tension on left and right chain (Press
the middle of the chain by finger with the same
force, the horizontal movement amount of left
and right chain are the same).

P22S00031
 8-11
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation of Mast Assembly

Removal and Installation of Mast Assembly

Installation sequence is in the reverse order of the removal.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Straight
1 1 4 Hoisting equipment 1
screwdriver
16mm,
2 Scissor 1 5 Wrench 2
24mm
22mm,
27mm,
32mm,
3 Open-end wrench 46mm, 7 6
10mm,
13mm,
24mm

Figures Operation instructions

1. Remove all oil pipes and speed limit valves.
Notice: Pull the control lever of the control
valve repeatedly before removing hydraulic
tube fittings to release the pressure in the
pipeline to zero, so as to prevent causing
injury to operator when removing the the
pipeline in pressure state

P22S00032

2. Remove the roller assembly on the top of the

cylinder, baffle chain plate, crossbeam, fixing
clamp and central lift cylinder. (Two-stage and
three-stage full-free mast assembly)

P22S00033
8-12
Removal and Installation of Mast System November 2, 2020
Removal and Installation of Mast Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Hold mast assembly by hoisting equipment to
avoid personal injury or equipment damage
caused by uncontrolled mast after further
removal.

P22S00034

4. Remove pin shaft on front end of tilt cylinder.

P22S00035

5. Remove support cover from outer mast.

P22S00036

6. Remove mast as from the forklift.

 8-13
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly of Mast Assembly

Disassembly and Assembly of Mast Assembly

Mast is heavy. Be careful when removing and installing.

Disassembly of Mast Assembly

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
24mm,
18mm, Straight
1 Wrench 4 4 1
15mm, screwdriver
16mm
2 Hoisting equipment 1 5 Inner circlip pliers 1
3 Crowbar 1 6 Puller 1

Figures Operation instructions

1. Place the mast on a flat ground, and remove
bolts on the top and bottom of lifting cylinder
and fixed clamps of cylinder.

P22S00037
2. Slide inner mast, and remove lift cylinder.

P22S00038
8-14
Removal and Installation of Mast System November 2, 2020
Disassembly and Assembly of Mast Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Extend inner mast downwards and remove the
main roller and side roller.

P22S00039

4. Tie up steel ropes around the middle of upper

cross beam of inner mast and pull it out by
hoisting equipment.

P22S00040

5. Check if roller, roller shaft and other parts are

damaged.
6. According to the requirements, replace parts.
 8-15
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly of Mast Assembly

Assembly of Mast Assembly

Assembly sequence is in the reverse order of the disassembly. The clearances between side roller and
mast channel steel, guide plate and mast channel steel shall be adjusted over during assembly.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Straight 16mm,
1 1 5 Socket wrench 2
screwdriver 18mm
External circlip
2 1 6 Hoisting equipment 1
pliers
Inner hexagon
3 Copper hammer 1 7 5mm 1
spanner
16mm,
4 Wrench 2 8
18mm

Figures Operation instructions

1. Slide the inner mast into outer mast and extend
it downwards, then install the main roller and
side roller. (Notice: Do not knock on outer ring
of roller)

P22S00039

2. Increase or decrease the adjusting shim to

Outer mast Inner mast adjust the clearance between side roller and
channel steel to 0~0.5mm (0-0.02 In).

Main roller
Side roller
P22S00041
8-16
Removal and Installation of Mast System November 2, 2020
Disassembly and Assembly of Mast Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Adjust the adjusting screw (2) in main roller to
make the clearance between sliding sleeve (3)
1 and channel steel within 0.5~1mm (0.02-0.04
In), and tighten the locknut (1).

P22S00042

4. Use adjusting pad to adjust the clearance

between guide plate (above the outer mast)
and inner mast column to 0.5~1mm (0.02-0.04
In).

P22S00041

5. Install the left and right cylinders into the mast,

and install dowel pin into the locating hole that
corresponds to lower cross beam of outer
mast.

P22S00038

6. Put the upper end of piston rod into cylinder

support of inner mast. Add appropriate
adjusting shims between the inner mast
support and the upper end of piston rod to
make the left and right in the same height.

P22S00037
 8-17
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly of Mast Assembly

Figures Operation instructions

7. Tighten the bolts on the bottom of cylinder.

P22S00043

8. Put the fixed component of cylinder on the lift

cylinder and tighten the mounting bolt.

P22S00044
8-18
Removal and Installation of Mast System November 2, 2020
Disassembly and Assembly of Mast Assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation of Lift Cylinder (Side Cylinder)

Keep your body away from the equipment as far as possible.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
Straight
1 1 4 Hoisting equipment 1
screwdriver
2 Scissor 1 5 Plier 1
22mm,
27mm, 24mm,
3 Open-end wrench 32mm, 5 6 Wrench 18mm, 3
46mm, 15mm
30mm

Figures Operation instructions

1. Shut down the engine, retract the lift cylinder,
lower the mast and fork arm carrier to a
minimum, and make hydraulic oil in cylinder
back to oil tank completely.

P22S00045

2. Remove all oil pipes and speed limit valves.

(Notice: Pull the control lever of the control
valve repeatedly before removing hydraulic
tube fittings to release the pressure in the
pipeline to zero, so as to prevent causing injury
to operator when removing the the pipeline in
pressure state)

P22S00032
 8-19
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Disassembly and Assembly of Mast Assembly

Figures Operation instructions

3. Remove bolts on the top and bottom of lift
cylinder and remove the fixed clamps for
fastening cylinder body.

P22S00045

4. Remove the chain from the mast.

P22S00046

5. Lift inner mast to remove left and right lift

cylinders.

P22S00047

Installation sequence is in the reverse order of the removal.

8-20
Removal and Installation of Mast System November 2, 2020
Removal and Installation of Lift Cylinder (Center Cylinder) CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation of Lift Cylinder (Center Cylinder)

Keep your body away from the equipment as far as possible.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
1 Hoisting equipment 1 3 Plier 1
18mm, 10mm,
2 Wrench 22mm, 3 4 Open-end wrench 13mm, 3
30mm 24mm

Figures Operation instructions

1. Remove the fork and fork arm carrier (remove
the related chains and hydraulic pipeline
together).

P22S00048
 8-21
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation of Lift Cylinder (Center Cylinder)

Figures Operation instructions

2. Remove the roller assembly on the top of the
cylinder, baffle chain plate,beam, and cylinder
retaining clamp.

P22S00049

3. Remove the center lift cylinder from the inner

mast.
8-22
Removal and Installation of Mast System November 2, 2020
Removal and Installation of Tilt Cylinder CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation of Tilt Cylinder

Lift outer mast or hold it by hoisting equipment to prevent the mast from falling down after tilt
cylinder is removed; keep the body away from the equipment as far as possible. Anybody is
forbidden to stand under fork carrier with fork.

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
19mm,
1 Wrench 16mm 1 2 Open-end wrench 2
17mm

Figures Operation instructions

1. Operate the forklift to lower the fork to a
minimum and make it contact with the ground,
the chain is loose.
2. Remove the floor and bracket
3. Remove bolts from left and right supports of
outer mast, and pull out pin shaft.

P22S00050

4. Remove oil pipe and joint from oil inlet of tilt

cylinder.

P22S00051
 8-23
November 2, 2020 Removal and Installation of Mast System
CLG2020H/C-2035H/C,CLG2020G-2035G Removal and Installation of Tilt Cylinder

Figures Operation instructions

5. Remove bolts from frame support, pull pin
shaft out and remove tilt cylinder.

P22S00051

Installation: Installation procedures are in reverse order of removal, the front inclination angle and caster
angle shall be adjusted according to the mast corresponding parameters.
8-24
Installation of Mast Pipe November 2, 2020
Two-stage Wide View Mast CLG2020H/C-2035H/C,CLG2020G-2035G

Installation of Mast Pipe

During the course of handling, keep hydraulic components clean.

Two-stage Wide View Mast

Connect Lifting Pipe

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
27mm,
32mm,
Straight
1 Wrench 46mm, 5 3 1
screwdriver
13mm,
24mm
2 Scissor 1 4

Figures Operation instructions

1. Install anti-explosion valve, joint and speed
limit valve.

P22S00052
 8-25
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Two-stage Wide View Mast

Figures Operation instructions

2. Install hose assembly.

P22S00053

3. Install the oil return pipe tee.

P22S00053

4. Install left and right oil return pipe and main

return pipe, and fix the return pipe with cable
tie.

P22S00054
8-26
Installation of Mast Pipe November 2, 2020
Two-stage Wide View Mast CLG2020H/C-2035H/C,CLG2020G-2035G

Installation of Triple Pipe

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
24mm,
1 Wrench 2 2
13mm

Figures Operation instructions

1. Install guide roller.

P22S00055

2. Install the joint block and bracket on fork arm

carrier, then install joint and O-ring (The front 2
are plane seal connector which shall be
installed with O-ring).
Notice: Keep the connector clean.

P22S00056

3. Install filter steel pipe joint and tighten it with

fixed clamps.

P22S00057
 8-27
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Two-stage Wide View Mast

Figures Operation instructions

a. Install the long hose around the guide roller
(one end is connected to steel pipe joint, the
other end is connected to the joint block via
cone seal joint, while the other end of the
joint block is connected to attachment hose
through plane seal joint).
b. Loosen the fixed clamp, adjust the steel
pipe joint to keep the tightness of hose
appropriate, then tighten it with fixed clamps.

P22S00058

c. Connected to the hose of multi-way valve.

P22S00059

Installation of Quadruple Pipe

Quadruple pipe is similar to triple pipe, which is symmetrically arranged on the other side of the mast.
8-28
Installation of Mast Pipe November 2, 2020
Two-stage Full-free Mast CLG2020H/C-2035H/C,CLG2020G-2035G

Two-stage Full-free Mast

Connect Lifting Pipe

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
27mm,
32mm,
1 Wrench 4 2
46mm,
10mm

Figures Operation instructions

1. Install anti-explosion valve, joint and speed
limit valve.

P22S00060
2. Install hose assembly.

P22S00061
 8-29
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Connect Lifting Pipe

Figures Operation instructions

3. Install filter joint and steel pipe assembly, and
fix the lower end of steel pipe.

P22S00062

4. Install hose assembly.

P22S00063
8-30
Installation of Mast Pipe November 2, 2020
Connect Lifting Pipe CLG2020H/C-2035H/C,CLG2020G-2035G

Installation of Triple Pipe

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
10mm,
13mm,
1 Wrench 4 2
24mm,
22mm

Figures Operation instructions

1. Install guide roller.

P22S00064

2. Install the joint block on fork arm carrier, then

install joint and O-ring (The front 2 are plane
seal connector which shall be installed with O-
ring).
Notice: Keep the connector clean.

P22S00065
 8-31
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Connect Lifting Pipe

Figures Operation instructions

3. Install steel pipe joint and tighten it with fixed
clamps.

P22S00066

4. Install rails and fix them respectively on the

side cylinder and inner mast beam with fixed
clamps and bolts. Adjust the rail to proper
direction and height.

P22S00067

a. Install the long hose around the guide roller

(one end is connected to steel pipe joint, the
other end is connected to the joint block via
cone seal joint, while the other end of the
joint block is connected to attachment hose
through plane seal joint).
b. Fix the hose on rail with clamps to
appropriate tightness.
c. Make the hose in smooth route by adjusting
the direction of rail.

P22S00068
8-32
Installation of Mast Pipe November 2, 2020
Connect Lifting Pipe CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

d. Connected to the hose of multi-way valve.

P22S00069

Installation of Quadruple Pipe

Quadruple pipe is similar to triple pipe, which is symmetrically arranged on the other side of the mast.
 8-33
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Three-stage Full-free Mast

Three-stage Full-free Mast

Connect Lifting Pipe

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
13mm,
27mm,
Straight
1 Wrench 46mm, 5 3 1
screwdriver
32mm,
24mm
2 Scissor 1 4

Figures Operation instructions

1. Install tee, speed limit valve, anti-explosion
valve and joint.

P22S00070

2. Connected to the hose assembly of side

cylinder.

P22S00071
8-34
Installation of Mast Pipe November 2, 2020
Connect Lifting Pipe CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

3. Install left and right oil return pipe and main
return pipe, and fix the return pipe with cable
tie.

P22S00072

4. Install steel pipe assembly that connects the

center cylinder.

P22S00073

5. Install guide roller.

P22S00074
 8-35
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Connect Lifting Pipe

Figures Operation instructions

a. Install the long hose around the guide roller
(one end is connected to steel pipe joint, the
other end is connected to the joint block of
tee).
b. Fix the hose on bracket with clamps to
appropriate tightness.

P22S00075
8-36
Installation of Mast Pipe November 2, 2020
Connect Lifting Pipe CLG2020H/C-2035H/C,CLG2020G-2035G

Installation of Triple Pipe

Tools required Tools required

Tool(s) Part description Standard Quantity Tool(s) Part description Standard Quantity
10mm,
13mm,
1 Wrench 4 5
24mm,
22mm

Figures Operation instructions

1. Install guide roller.

P22S00076

2. Install the joint block on fork arm carrier, then

install joint and O-ring (The front 2 are plane
seal connector which shall be installed with O-
ring).
Notice: Keep the connector clean.

P22S00077
 8-37
November 2, 2020 Installation of Mast Pipe
CLG2020H/C-2035H/C,CLG2020G-2035G Connect Lifting Pipe

Figures Operation instructions

3. Install steel pipe joint and tighten it with fixed
clamps.

P22S00078

a. Install the long hose around the guide roller

(one end is connected to steel pipe joint, the
other end is connected to the joint block via
cone seal joint, while the other end of the
joint block is connected to attachment hose
through plane seal joint).
b. Fix the hose on inner mast (two places) with
clamps to appropriate tightness.

P22S00079

c. Connected to the hose of multi-way valve.

P22S00080

Installation of Quadruple Pipe

Quadruple pipe is similar to triple pipe, which is symmetrically arranged on the other side of the mast.
8-38
Common Fault Analysis and Troubleshooting November 2, 2020
Connect Lifting Pipe CLG2020H/C-2035H/C,CLG2020G-2035G

Common Fault Analysis and Troubleshooting

S/N Fault symptom Cause analysis Troubleshooting methods

(1) Generally, roller clearance is too large Adjust the clearance between roller on
both sides and the mast
(2) Bearing or mast track is worn after it is used
Adjust the clearance between roller
Mast is shaking for a long period
1 and the mast, or replace bearing and
seriously (3) Swing bush of the mast is damaged mast
(4) cylinder lifts to the top, but both sides are Adjust the stroke and keep
not synchronous synchronous
Replace the bearing and apply
The mast has The bearing is damaged and does not rotate
2 lubricating oil to the mast
abnormal noise Swing bush of the mast is short of oil
Fill lubricant
(1) Fork arm carrier roller and inner mast are
Confirm if there is part worn
worn after a long period and the clearance is
abnormally, replace it if necessary;
excessive
(2) Improper operation, and frequent eccentric Confirm whether the side roller is
Fork arm carrier
load work. damaged, replace it if necessary;
3 shakes violently
from side to side Increase the adjusting shim of side
roller to adjust the clearance between
(3) The clearance between side roller and inner
side roller and inner mast channel
mast channel steel is greater than 1mm.
steel to the range of 0.5mm~1mm
(0.02-0.04In).
Uneven and deformed fork result from lifting
The fork is difficult heavy goods by single side of the fork, the Replace the fork or return to factory for
4
to go into the pallet height difference of fork tip exceeds 3% of repair
horizontal length
Fork arm carrier
5 cannot be kept in Lifting chain tension is not uniform Adjust chain tension
vertical position
 9-1
November 2, 2020 Covering Part System
CLG2020H/C-2035H/C,CLG2020G-2035G

Covering Part System

Safety................................................................................................................................9-3
System Overview.............................................................................................................9-3
Introduction of the function.....................................................................................................................9-3
Location diagram ..................................................................................................................................9-3

Removal and Installation ................................................................................................9-4

Floor assembly.......................................................................................................................................9-4
Removal of floor assembly.................................................................................................................9-4
Installation of floor assembly..............................................................................................................9-5
Access door ...........................................................................................................................................9-6
Removal of access door.....................................................................................................................9-6
Installation of repair access................................................................................................................9-6
Steering wheel cover .............................................................................................................................9-7
Removal of steering wheel cover .......................................................................................................9-7
Installation of steering wheel cover ....................................................................................................9-8
Instrument cover ....................................................................................................................................9-9
Removal of instrument cover .............................................................................................................9-9
Installation of instrument cover ..........................................................................................................9-9
Front cover plate and rear cover plate .................................................................................................9-10
Removal of front cover plate and rear cover plate ...........................................................................9-10
Installation of front cover plate and rear cover plate ........................................................................9-10
Seat and engine hood ..........................................................................................................................9-11
Removal of seat and engine hood ...................................................................................................9-11
Installation of seat and engine hood ................................................................................................9-12
Overhead guard ...................................................................................................................................9-13
Removal of overhead guard.............................................................................................................9-13
Installation of overhead guard..........................................................................................................9-14
9-2
Covering Part System November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 9-3
November 2, 2020 Safety
CLG2020H/C-2035H/C,CLG2020G-2035G Introduction of the function

Safety

1. When parts are removed, weight and the center of gravity for parts must be evaluated (see
parameter list of complete machine for this manual), if necessary, use the sling to protect them from
being damaged resulting from falling off.
2. Conduct the operation according to corresponding description at the position pasted with safety
marks to prevent potential hazards.

System Overview

Introduction of the function

The covering parts system comprises a group or several groups of functional components on the frame
and provide protection and shield for driver and internal parts. It is an important component for the
outlook of the frame and has many functions, including safety protection, facilitation for drive and co-
worker, maintenance access for spare parts, vibration and noise absorption, etc.

Location diagram

1
2 8 9
3 4 5 6 7
P22C00001

1. Instrument cover 6. Engine hood

2. Steering wheel cover 7. Overhead guard
3. Access door 8. Front cover plate
4. Floor assembly 9. Rear cover plate
5. Seats
9-4
Removal and Installation November 2, 2020
Floor assembly CLG2020H/C-2035H/C,CLG2020G-2035G

Removal and Installation

Floor assembly

Removal of floor assembly

Figures Operation instructions

1. Adjust steering wheel column (1) to the
foremost, and then open the engine hood (2)
1 2

P22C00002

2. Directly remove the floor pad (4), then directly

remove rear floor (3).

P22C00003
 9-5
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Floor assembly

Figures Operation instructions

3. Remove the two M8 (6) bolts that fix front floor,
disconnect the harness connector of
accelerator pedal (5), then remove the front
floor (7) and accelerator pedal as a whole.

P22C00004

Installation of floor assembly

The process of installing floor assembly is the reverse of removing it.

9-6
Removal and Installation November 2, 2020
Access door CLG2020H/C-2035H/C,CLG2020G-2035G

Access door

Removal of access door

Figures Operation instructions

1. Remove button head screw (3), then remove
the plate (4) bottom-up from access door (5).
2. Remove the two M6 (2) bolts that fix access
door and instrument cover at the left and right
respectively, then take down the access door
up-bottom from instrument cover (1).
1

2 5
3 4 P22C00005

Installation of repair access

The process of installing repair access is the reverse of removing it.

 9-7
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Steering wheel cover

Steering wheel cover

Removal of steering wheel cover

Figures Operation instructions

1. Remove the four M6 (3) bolts at the right side
(2) of the steering wheel cover, directly
2 separate the steering wheel cover into two
parts as left side (1) and right side.
Caution: that there are shaped clamps
between the left steering wheel cover and the
right steering wheel cover.
1

P22C00006

2. Use nose plier to clamp the clip (5), and

remove the locking handle (4).
5
3. Use straight screwdriver to pry the left bulge
4
(6), disconnect the three clamps formed by the
left and right bulges, and separate them from
the right bulge.

P22C00007
9-8
Removal and Installation November 2, 2020
Steering wheel cover CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

4. Open the cap (7), and remove the two M6 (8)
screws with cross screwdriver.
5. Remove the two M6 bolts that connect the right
bulge (9) and the front crossbeam plate.
Use straight screwdriver to pry the right bulge from
7 8 9 instrument cover, and separate the shaped clamp
between them.
Circumvent the reset lever, and take out the right
bulge.

P22C00008

Installation of steering wheel cover

The process of installing steering box is the reverse of removing it.

 9-9
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Instrument cover

Instrument cover

Removal of instrument cover

Figures Operation instructions

1. For the process to remove floor assembly,
Omitted access door and steering wheel cover, to see
the above.
2. Remove one M6 (1) bolt that fix the left
instrument cover and the left front cover;
1
remove the upper two M6 bolts and one
internal M6 bolt that fix the left instrument
cover and the front crossbeam plate (the
internal bolt can be removed from the moving
slot of the front tilt cylinder), then remove the
left instrument cover.

1
P22C00009

3. Remove one M6 bolt that fix the right

2 instrument cover and the right front cover;
remove the four upper M6 bolts and one
internal M6 bolt that fix the right instrument
cover and the front crossbeam plate (the
position of the above bolts are basically
symmetric with the left instrument cover).
4. Disconnect the instrument (3) joints and LPG
adapter (2) (if any), and remove the right
instrument cover.
3

P22C00010

Installation of instrument cover

The process of installing instrument cover is the reverse of removing it.

9-10
Removal and Installation November 2, 2020
Front cover plate and rear cover plate CLG2020H/C-2035H/C,CLG2020G-2035G

Front cover plate and rear cover plate

Removal of front cover plate and rear cover plate

Figures Operation instructions

1. Unscrew the button head screws (1), then
carefully lift and remove the front cover plate
(2) and rear cover plate (3).
1

2
P22C00011

Installation of front cover plate and rear cover plate

The process of installing front cover plate and rear cover plate is the reverse of removing it.
 9-11
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Seat and engine hood

Seat and engine hood

Removal of seat and engine hood

Figures Operation instructions

1. Adjust steering column (1) to the foremost, and
then open the engine hood (2)
1 2

P22C00012

2. Disconnect the seat OPS harness switch

(4)(locate at the bottom of the left rear column
3 of overhead guard).
3. Loosen the locking nuts at top ends of the left
and right air spring and let the top ends of air
springs (3) to separate from engine hood, then
4 lay flat the air springs.
With stay cord or support part sustaining the
engine hood, lay down engine hood slowly.

P22C00013

4. Unscrew the button head screws (5), then

carefully lift and remove the front cover plate
5 (6) and rear cover plate.

6
P22C00011
9-12
Removal and Installation November 2, 2020
Seat and engine hood CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

5. Engine hood is installed on rear crossbeam
plate of overhead guard, locate the installing
hinge, take out the cotter pin, draw out hinge
pin (7), then remove the seat and engine hood
as a unit from crossbeam.

P22C00014

Installation of seat and engine hood

The process of installing seat and engine hood is the reverse of removing it.
 9-13
November 2, 2020 Removal and Installation
CLG2020H/C-2035H/C,CLG2020G-2035G Overhead guard

Overhead guard

Removal of overhead guard

Figures Operation instructions

1. Use sling to hoist overhead guard as protection
measure, to prevent its unexpected falling
during removal.

P22C00015

2. See above for the detailed steps to remove

floor assembly, access door, steering wheel
Omitted
cover, instrument cover, seat and engine hood,
to see the above.
3. Remove the grommets both at left and right
side of the overhead guard front end,
disconnect the combination lamp harness plug
(1) (one at left side and one at right side), and
unscrew the four M12 (2) bolts that fix
overhead guard and front crossbeam plate
together (two at left side and two at right side).

1
2

P22C00016
9-14
Removal and Installation November 2, 2020
Overhead guard CLG2020H/C-2035H/C,CLG2020G-2035G

Figures Operation instructions

4. At left rear side of overhead guard, disconnect
all harness plugs (3) that connect to overhead
guard.

P22C00017

5. At the right rear side of overhead guard, loosen

the clamp (4) and remove intake pipe (5).

P22C00018

6. At rear side of overhead guard, remove the

four M12 (6) bolts (two at left side and two at
6 right side) that fix overhead guard and
counterweight together, and lift the sling to
hoist out the overhead guard.

P22C00019

Installation of overhead guard

The process of installing overhead guard is the reverse of removing it.

 10-1
November 2, 2020 Appendix
CLG2020H/C-2035H/C,CLG2020G-2035G

Appendix
Hydraulic System Schematic Diagram ........................................................................10-3
Electrical System Schematic Diagram ........................................................................10-6
Brake System Schematic Diagram ............................................................................10-15
10-2
Appendix November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G
 10-3
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Hydraulic System Schematic Diagram

Hydraulic System Schematic Diagram

Double Spools
 10-4
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Hydraulic System Schematic Diagram

Three Spools
 10-5
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Hydraulic System Schematic Diagram

Four Spools
 10-6
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

Electrical System Schematic Diagram

50Y1116 Yanmar Engine
 10-7
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y1079 Cummins Engine

 10-8
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y1928 Mitsubishi S4S Engine

 10-9
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y2131 Mitsubishi D04EG Engine

36B0734

36B0734
 10-10
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y1315 PSI Engine(dual fuel)

 10-11
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y2070 PSI Engine(single fuel)

36b1920

后退电磁阀控制输出

预热继电器控制输出

起动继电器控制输出
前进电磁阀控制输出
阀锁电磁阀控制输出
延时断电

后退信号
前进信号

起动信号

空档输出
36B0098
36B0734

36B0734
36B0647 X4
36B0276
36B0086 36B0647
36B0277 36B1143

303YL
36B0734
x101

303
36b1921

x105
36b1923 36B0734

X22
36B0652

X67
38B0239 36B0046 36B0651

36B1092

36B1108

X26
36B0647

34B0007 38B0053
D4
36J2057
38J2004

D3
36J2057
38J2004

C1
36B1619
X27
VSW 36B0649
UNUSED
FUEL PUMP-
FUEL PUMP+ 303
AUX PWM2
START COMMAND
303YL
FUEL SELECT
FPP1 D5
5V RTN 1 36J2057
5V EXT 1 38J2004
CAN1 +
CAN1 -

x
1
3
FPP2
5V RTN 2 36B0647
5V EXT 2

x
1
4
X88
36B0825

X87
36B0259
 10-12
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y2308 Kubota Engine(dual fuel)

 10-13
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y2365 Kubota Engine(singal fuel)

 10-14
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Electrical System Schematic Diagram

50Y1803 NISSAN Engine

 10-15
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Brake System Schematic Diagram

Brake System Schematic Diagram

50Y1497
 10-16
November 2, 2020
CLG2020H/C-2035H/C,CLG2020G-2035G Brake System Schematic Diagram