201910000

CLG856H WHEEL LOADER

64F0670 GCIC T2 POWER/ AP3000 WET AXLE/ 4BPZF210 GEARBOX
( 英语 )

OPERATION AND
MAINTENANCE MANUAL
 Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown following.

The meaning of this safety alert symbol is as follows:

Attention. Be alert. Your safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
LiuGong cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by LiuGong is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged or
made unsafe by the operation, lubrication, maintenance or require procedures you choose.
The information, specification, and illustrations in this publication are on the basis of information
available at the time when it was written. The specification, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service
given to the product. Obtain the complete and most current information before starting any job. LiuGong
has the most current information available.

CALIFORNIA PROPOSITION 65

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.
 1
October 12, 2019 CONTENTS
CLG856H

CONTENTS

Preface Operation Manual

Before Operation ............................................. 41
Safety Information
Operator Controls and Instrument Panels ....... 41
Safety Decals and Decal Locations ...................5
Engine Starting ................................................ 79
General Hazard Information .............................16
Operation Techniques ..................................... 80
Crushing and Cutting Prevention .....................20
Transportation Information .............................. 89
Burn Prevention ...............................................20

Fire & Explosion Prevention .............................21 Maintenance Manual

Fire Extinguishers and First-aid Kit ..................22 Maintenance Guidance .................................... 94

Electrical Storm Injury Prevention ....................23 Run-in .............................................................. 96

Tire Explosion Prevention ................................23 Maintenance Interval Schedule ...................... 97

ROPS/FOPS ....................................................24 General Torque Specifications ...................... 101

Operator Station ...............................................24 Tire Inflation Information ................................ 102

Steering Frame Lock ........................................24 Lubrication Specifications .............................. 103

Attachment Cautions ........................................24 Important Maintenance Procedures .............. 106

Cautions about Machine Operation .................24 Fault Diagnosis and Troubleshooting ............ 166

Cautions about Machine Maintenance .............31

INDEX
Sound and Vibration ........................................33

Key Spare Parts to be Periodically Changed ...34

Application and Specification

Applications ......................................................35

Main Specifications ..........................................36

2
CONTENTS October 12, 2019
CLG856H
 1
October 12, 2019 Preface
CLG856H

Preface Safety

The safety section lists basic safety precautions.

In addition this section identifies the text and
This manual includes important instructions locations of warning signs and labels used on the
concerning operation, lubrication, checking machine.
testing, adjusting the machine and permanent
key components. Read and understand the basic precautions
listed in the safety section before operating or
This manual should always be kept safe, clean performing lubrication, maintenance or repairs
and with the machine where it is convenient to on this machine.
find for operators to use. This manual should not
be separated from the machine even when Operation
reselling or leasing.
Some photographs and illustrations in this The operation section is a reference for the new
manual show details of attachments those may operator and a refresher for the experienced
be different from your machine. Guards and operator. Read, understand and reference it
covers may have been removed for the purpose whenever necessary. This section includes a
of illustration. description of gauges, machine controls,
switches and other controls at the operators’
Read this manual carefully and follow all station. It also provides transportation and towing
instructions for proper operation and information.
maintenance of this machine. Instructions in this
manual should help the reader avoid possible Photographs and illustrations guide the operator
personal injury or damage to the machine. The through correct procedures of checking, starting,
operator should proficiently and correctly operate operating and stopping the machine.
the machine to ensure safety. Operating techniques outlined in this publication
Use this machine only for the purpose described are basic. Skill and techniques develop as the
in this manual. Contact your Liugong dealer for operator gains knowledge of the machine and its
approval before making any modifications or capabilities.
adding attachments to the machine. The addition
of any unauthorized attachment may cause Maintenance
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi The maintenance section is a guide for
Liugong accepts no liability for any damage equipment care. The illustrated, step-by-step
resulting from the use of unapproved instructions are grouped by servicing intervals.
attachments or working practices. Items without specific intervals are listed under
the "When Required" service interval. Items in
Only trained or experienced personnel should be the "Maintenance Intervals" are referenced to
allowed to operate or maintain this machine. detailed instructions that follow.
Correctly record the machine type, serial
number, engine serial number and all major For the replacement of environment-friendly key
component serial numbers for your reference parts and components when maintaining an
when ordering parts or in the event of theft. engine, please use the OEM parts and
Record the correct numbers to both the components of the same type and the same
operator’s manual and a secure place outside specifications. Otherwise, LiuGong accepts no
the machine. legal liability for any consequence resulting from
the use of unapproved parts.
2
Preface October 12, 2019
CLG856H

Maintenance Intervals

Use the service hour meter to determine

servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 10 service hours or daily.
All the information, figures, tables and
specifications are the latest product information
obtainable at the time of publication. Guangxi
Liugong Company will reserve the right to make
change without notice.
 3
October 12, 2019 Preface
CLG856H

Main Components

4 5
7
3

9
11 10
12
14 13

Left 21

Front
22

15

16

Rear 19
20
17 18
Right
1. Bucket 7. Rear fender 13. Front wheel 19. Fuel tamk
2. Lever 8. Rear frame 14. Boom 20. Front frame
3. Tilting cylinder 9. Rear wheel 15. Engine hood 21. Front combination light-RH
4. Front combination light-LH 10. Ladder 16. Rear combination light-LH 22. Rear work light
5. Front work light 11. Hydraulic oil tank 17. Rear combination light-RH
6. Cab 12. Front fender 18. Counterweight
4
Preface October 12, 2019
CLG856H

Type and Serial Number of the Machine and Parts

Manufacturer's Name Guangxi Liugong Machinery Co., Ltd.

Type of the Machine

Serial Number of the Machine

Type of Engine

Serial Number of Engine

Type of Transmission

Serial Number of Transmission

Type of Front Axle

Serial Number of Front Axle

Type of Rear Axle

Serial Number of Rear Axle

Type of Hydraulic Pump

Serial Number of Hydraulic Pump

Cab Manufacturer

Serial Number of Cab

Note: After receiving the machine the user should fill out the above table according to the specific configuration.
 5
October 12, 2019 Safety Information
CLG856H Safety Decals and Decal Locations

Safety Information "Caution" is also used to indicate safety

information relating to unsafe operations which
may cause personal injuries. "Danger"
represents the most dangerous conditions. The
Safety Symbol safety signs "Danger" or "Warning" are placed
near particular dangerous places. General notice
information is placed on the safety sign
The symbol for safety alerting appears
"Caution."
on machines, safety signs, manuals or
for important safety information at
other places. When you see this
symbol, you should follow the instructions in the Safety Decals and Decal
safety information, guarding against any
possibility of personal injuries or death. Locations

Safety Signs There are several specific safety decals on your

machine. The exact location of and description of
the hazards are reviewed in this section. Take
Definitions of the safety signs with the words time to read, understand and familiarize yourself
"Danger", "Warning" and "Caution" which appear with each and every one of these safety decals.
in this manual and on the machine are as
follows: Make sure that you can read all safety decals.
Clean or replace if you cannot read the words or
see the pictures. When cleaning the decals use a
cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the
● Danger: this word denotes an impending safety decals. Solvents, gasoline or harsh
danger, failure to observe instructions could chemicals could loosen the adhesive backing of
result in death or serious injuries. decals causing them to fall off the machine.
You must replace a decal if it is damaged,
missing or cannot be read. If a decal is on a part
that is replaced, make sure a new decal is
● Warning: this word denotes potential danger, installed on the replacement part. Pay attention
failure to observe instructions could result in to the instructional and safety decals located in
death or serious injuries. the cab before starting.

● Caution: this word denotes potential danger,

failure to observe instructions could result in
minor to medium degree of injury.
6
Safety Information October 12, 2019
Safety Decals and Decal Locations CLG856H

Decal Location

1. WARNING DECAL 9. CAUTION DECAL 26.WARNING DECAL

2. DANGER DECAL 10.WARNING DECAL 32.WARNING DECAL
3. DANGER DECAL 12.NOTICE DECAL 33.WARNING DECAL
4. WARNING DECAL 15.NOTICE DECAL 36.DECAL
5. WARNING DECAL 16.DANGER DECAL
7. NOTICE DECAL 20.DANGER DECAL
8. NOTICE DECAL 25.NOTICE DECAL
 7
October 12, 2019 Safety Information
CLG856H Safety Decals and Decal Locations

Decal Location

1. WARNING DECAL 4. WARNING DECAL 30.WARNING DECAL

2. DANGER DECAL 9. CAUTION DECAL 38.DECAL
3. DANGER DECAL 15.WARNING DECAL
8
Safety Information October 12, 2019
Safety Decals and Decal Locations CLG856H

Decal information

Fig.1 WARNING DECAL

(Located near the crush area)
CRUSH HAZARD. Keep clear.

74A3167

Fig. 2 DANGER DECAL

(Located on the arm)
CRUSH HAZARD. Keep away from raised
loader arm or bucket.

74A3153

Fig. 3 DANGER DECAL

(Located on the arm or arm cylinder)
CRUSH HAZARD. Install arm support before
maintenance or repair with loader arm raised.

74A3165
 9
October 12, 2019 Safety Information
CLG856H Safety Decals and Decal Locations

Decal information

Fig. 4 WARNING DECAL

(Located at the frame articulation joint )
CRUSH HAZARD. Keep clear.

74A3254
Fig. 5 WARNING DECAL
(Located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations.Operate only from
operator's seat.Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral.Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator's compartment, park on level
ground, lower attachments to ground, make
sure hydraulic control lever is in lockout
position. All control levers are in neutral.
Engage parking brake. Never operate
machine downhill with stalled engine and
gear in neutral. Avoid contacting overhead
obstacles when operating or hauling
machine. 74A4777
10
Safety Information October 12, 2019
Safety Decals and Decal Locations CLG856H

Decal information

Fig. 7 NOTICE DECAL

(Located in the cab)
Do not clean inside of cab with water under
pressure, electrical component damage will
result. Prevent loss of electrical power, turn
battery disconnect switch to off position when
machine not in use or being parked overnight.
74A4780

Fig. 8 NOTICE DECAL

(Located in the cab)
Avoid damaging electronic components when
welding:
● Position machine on level ground, engage
parking brake.
● Shut off engine and turn off battery
disconnect switch.
Remove electrical connectors from
transmission, engine control units and
instrument panel plug.
74A4769

Fig. 9 CAUTION DECAL

(Located on the hot surface)
Hot surface, keep clear.

74A3168
 11
October 12, 2019 Safety Information
CLG856H Safety Decals and Decal Locations

Decal information

Fig. 10 WARNING DECAL

(Located on the engine)
RUNOVER HAZARD. Start engine from
operator's seat, transmission in NEUTRAL.

74A3183
Fig. 12 NOTICE DECAL
(Located on the front side of the air tank)
Drain water of air tank out every 10h or
everyday. Operating procedure: Park
machine on flat ground, apply the parking
brake. Press down and loosen the brake
pedal in turn to release pressure in the air
tank, then push up the water valve at bottom
of air tank to drain of water. Leave go of water
valve closing automatically. 74A3049

Fig. 15 WARNING DECAL

(Located near the engine fan)
CUTTING HAZARD. Keep clear or stop
engine before servicing.

74A3161
12
Safety Information October 12, 2019
Safety Decals and Decal Locations CLG856H

Decal information
Fig.16 DANGER DECAL
(Located near the battery)
Fumes given off by batteries are combustible.
Keep flame and sparks away, do not store
tools or metal objects near batteries. Risk of
explosion if metal objects cause a short
circuit. Sulphuric acid contained in batteries is
poisonous, do not allow acid to contact skin,
clothing or your eyes. If you spill acid on
yourself, immediately:
● Flush your skin with water.
● Apply a neutralizing agent such as lime.
Flush eyes with water for 10-15 minutes.
Immediately seek medical attention. 74A4506

Fig. 20 DANGER DECAL

(Located on arm or arm support)
CRUSH HAZARD. Install arm support before
maintenance or repair with loader arm raised.

74A4509
 13
October 12, 2019 Safety Information
CLG856H Safety Decals and Decal Locations

Decal information

74A2868

Fig. 25 NOTICE DECAL

(Located near the coolant filler on engine
hood)
Engine coolant contains antifreeze protection
to -15°C\-30°C\-45°C. Change coolant
annually.
74A2867

74A2863

Fig. 26 WARNING DECAL

(Located near the coolant filler cap)
Hot liquid under pressure, service when cool.

74A4512

Fig. 30 WARNING DECAL

(Located on the tail of machine)
RUNOVER HAZARD. Keep clear.

74A3178
14
Safety Information October 12, 2019
Safety Decals and Decal Locations CLG856H

Decal information
Fig. 32 WARNING DECAL
(Located in the cab)
Improper engagement of work tools could
result in serious injury or death. Do not
operate this machine unitl you have positive
indication that:
1. Tool is firmly attached to coupler.
2. Handle of diverter valve is in Aux position
as picutured.
3. Mechanical lock on control lever of
coupler is in locked position.
Never operate machine without locks in
locked position. To change tool, turn hydraulic
diverter valve to Coupler position. Ensure that
work area is clear of personnel.Tool must be
in rolled back position and indicators visible to
operator. Release mechanical interlock on
control lever and withdraw locking pins.
Lower tool to ground and roll forward to
release. When attaching tool, roll back fully
and extend locking pins. Check attachment
by rolling tool forward against ground. Tool
should remain attached. Bucket engaged,
indicators point towards each other at top.
Bucket disengaged, indicators point away
from each other at top.Relock the mechanical
interlock on the coupler control lever and
reset the hydraulic diverter valve to Aux
position. Do not operate machine with a faulty
coupler or with the mechanical interlock on
the control lever not engaged at all times. 74A4779
 15
October 12, 2019 Safety Information
CLG856H Safety Decals and Decal Locations

Decal information
Fig. 33 WARNING DECAL
(Located near the joint of coupler)
CRUSH HAZARD. Inspect coupler locking
pins extension before operating. Bucket
engaged, indicators point towards each other
at top. Bucket disengaged, indicators point
away from each other at top. Improperly
locked attachment could release and cause
serious injury. Failure to comply could result
in death or serious injury. Only use
attachments specifically degigned for and
approved for use with the coupler fitted. If the
attachment is damaged or can not be secured
to the coupler, it must not be used. Never
move the machine with attachments not
secured. 74A3184
Fig. 36 DECAL
1. Refer to the manufacturer plate on the
machine for the machine mass.
2. The steering frame lock must be in place
for lifting.
3. Use proper rated cables and slings for
lifting .position crane for level machine lift.
4. Spreader bar witch should be sufficient to
prevent contact with machine. 74A4255

Fig. 38 DECAL
(Located in the cab)

74A2875
16
Safety Information October 12, 2019
General Hazard Information CLG856H

General Hazard Information

Be familiar with all safety cautions, failure to

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

Wear relevant personal protective equipment

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

Do not operate the machine if you feel sick,

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

Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high
G

pressure liquids, when maintaining storage

IN
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AR
W

batteries, by flying scraps when the engine is in

er ot
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op o n

e
at

operation or you are using tools. When you

d

remove springs or resilient parts, add acid/

r:
te
ra
pe

electrolyte to batteries, you should wear a full

O

:
ate
D

face protective mask. When carrying out welding

Do not wear loose fitting clothing, dangling operations or gas cutting operations with a
jewelry or long hair that can catch on controls or welding torch, wear specific safety goggles
in other moving parts of the machine. suitable for the task being performed. Consult
your welding equipment dealer for more
information.
 17
October 12, 2019 Safety Information
CLG856H General Hazard Information

Pay attention when opening fluid compartments

to prevent foreign materials from entering the
system. Always remove loose materials from
near caps and plugs.

When working under high noise conditions, wear

appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high Know the appropriate worksite hand signals and
noise on your hearing. who gives them. Accept signals from one person
only.
No smoking and keep open flames away when
maintaining air conditioner or if there is
refrigerant gas, the flames contact the refrigerant
and the cigarette smoke will cause personal
injury or death.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
Make sure all protective guards and covers are
other materials.
secured in place on the machine. Always replace
protective guards and covers removed for Use all cleaning solutions with care. Do not use
servicing or maintenance. Repair damaged any flammable material to wash components, for
guards and covers before operation. example, diesel oil or gasoline. They may easily
catch fire.
Keep the machine, especially the panels,
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.

Report all required repairs in time.

18
Safety Information October 12, 2019
General Hazard Information CLG856H

Do not allow unauthorized personnel on or Wear safety glasses and leather gloves. Never
around the machine. check for high-pressure leaks with your
unprotected hand. Use a board or cardboard
Guangxi Liugong bears no responsibility for
when checking for leaks.
failures caused by modifications to machine
structure without Liugong’s permission.

Compressed Air

Compressed air can cause personal injury. When

using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. Never
aim compressed air at yourself or others.
Compressed air could penetrate your skin and Even a pin-hole size leak can cause serious
cause serious injury or death. The maximum air injury, If you are hit by spraying high-pressure oil,
pressure used should not exceed 25psi see a doctor for treatment at once.
(0.2Mpa).

High-pressure Fluid

Avoid injury from high-pressure oil. When

repairing hydraulic lines, ensure that
system pressure is completely released
before beginning the repair. Hydraulic oil
under pressure contacting the skin could Disposal of Waste Fluids
cause serious injury or damage.
Improper handling of the waste fluid will cause
Use caution before disconnecting hydraulic lines pollution of the environment. Obey all local
or connectors. High pressure oil that is released regulations for disposal of waste fluids.
can cause a hose to whip. Collect all waste fluids when performing
Always support attachments and release inspections, maintenance, testing, adjusting and
residual pressure before attempting to repairs to the machine.
disconnect hydraulic lines. Pressure applied by Prepare to collect fluids with suitable containers
loads on attachments could cause hydraulic oil to before opening any compartment or
spray when lines are removed. disassembling any component that contains
fluids.
 19
October 12, 2019 Safety Information
CLG856H General Hazard Information

Use suitable containers to collect waste fluids. Always release pressure in the accumulator
Do not use food containers or beverage bottles before disposing of it.
as they could mislead people to drink the
contents. Asbestos Danger

Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
● Never use compressed air to clean up
asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.
Cautions about Accumulators ● A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
High-pressure nitrogen is contained in the can also be used.
accumulators making them dangerous articles.
Read the following requirements and pay ● Do not grind materials that contain asbestos.
attention to the proper use of accumulators. ● Operate the machine on the windward side of
Check accumulators before charging with the asbestos as far as possible.
nitrogen. Safe use cannot be guaranteed if there ● Obey environmental regulations for the
is not a nameplate attached to the accumulator. disposal of asbestos.
Never charge accumulators that have an
incomplete nameplate or that are of an ● Shower after contact with asbestos.
unidentified type. ● Wear an approved respirator if there is no
Accumulators are charged with nitrogen. The other way to control the dust.
use of oxygen, compressed air or other
flammable air in the accumulator could cause an
explosion and possible injury, death and damage
to the machine.
When charging accumulators with nitrogen, care
should be taken not to damage the diaphragm.
The accumulator's valve should be installed
facing vertically upward. Do not attempt to fix
accumulators by welding them.
Do not drill any hole in the accumulator or close
a hole by welding.
Do not weld a boss on the accumulator.
Accumulators are high-pressure vessels and
should be repaired only by trained specialized
personnel.
20
Safety Information October 12, 2019
Crushing and Cutting Prevention CLG856H

Crushing and Cutting If the machine must be repaired with engine

running, make sure that a qualified operator is
Prevention available in the cab to shut down the engine if
required.
Don't put hands, arms, or any other parts of the Do not use a kinked or frayed wire cable. Wear
body in the way of removable parts. gloves when handling wire cables.
Support equipment and attachments properly Retainer pins, when struck with force, can fly out
when working beneath them. Do not depend on and injure nearby persons. Make sure the area is
hydraulic cylinders to hold up the implement/ clear of people when driving retainer pins. Wear
attachment. The implement/attachment can fall if protective glasses when striking a retainer pin to
a control lever is accidentally moved, or if a avoid injury to your eyes.
hydraulic line breaks.
Chips or other debris can fly off objects when
struck. Make sure no one can be injured by flying
debris before striking any object.

Burn Prevention

Some parts of the machine become hot during

normal operation. Use caution when maintaining
the engine and hydraulics. Allow the machine to
For those parts fitted with shields, if it is cool after it has been operating for a long period
necessary to remove shields in order to perform of time.
maintenance, always install the shields after the
maintenance is performed. Coolant
Rotating or moving parts have cutting or crush
hazard. Keep clear or stop engine before At operating temperature, the engine coolant is
servicing. hot and under pressure. The radiator and all
lines to heaters and the engine contain hot water
or steam. Any contact can cause severe burns.

Keep hands and objects away from moving fan

blades. They can throw or cut any object that
contacts the moving blades.
Check the coolant level only after the engine has
Never attempt adjustments while the machine is been stopped and the coolant filler cap is cool
moving or the engine is running unless otherwise enough to remove with your bare hand.
specified.
Remove the cooling system filler cap slowly to
relieve pressure.
 21
October 12, 2019 Safety Information
CLG856H Fire & Explosion Prevention

Coolant contains alkali that can cause personal Always wear protective glasses and gloves when
injury. Avoid contact with the skin, eyes and checking batteries.
mouth.

Oil

Hot oil and components can cause personal

injury. Do not allow hot oil or components to
contact the skin.

Fire & Explosion Prevention

All fuels, most lubrication and some coolant

At operating temperature the hydraulic oil tank is mixtures are flammable.
hot and can be under pressure.
Fuel leaked or spilt onto hot surfaces or electrical
Remove the hydraulic oil tank cap only after the components can cause a fire.
engine has been stopped and the cap is cool
enough to remove with your bare hand. Do not smoke while refueling or in a refueling
area, or where flammable materials are stored.
Remove the hydraulic oil tank oil filling cap
slowly to relieve pressure.
Relieve all residual pressure in air, oil, fuel or
cooling systems before any lines, connectors or
related items are disconnected or removed.

Batteries
Clean and tighten all electrical connections.
Batteries give off flammable fumes which can Check daily for loose or frayed electrical wires.
explode. Have all loose or frayed electrical wires
Batteries and battery terminals may contain lead; tightened, repaired or replaced before operating
do not touch batteries with your bare hands. the machine.
Always wash your hands right after maintaining a Check the electric circuit periodically to avoid fire
battery. caused by overload or short circuit.
Do not smoke when observing the battery Keep all fuels and lubrications stored in properly
electrolyte levels. marked containers and away from all
Electrolyte is an acid and causes personal injury unauthorized persons.
if it contacts skin or eyes. If contact occurs flush Store all oily rags or other flammable materials in
with water and seek medical attention right away. a protective container away from naked flames
or other sources of ignition.
Do not weld or flame cut pipes that contain
flammable fluids. Clean the flammable fluids
before welding or flame cutting on them.
22
Safety Information October 12, 2019
Fire Extinguishers and First-aid Kit CLG856H

Remove all flammable materials such as fuel, Make sure that all clamps, guards and heat
lubrication and other debris before they shields are properly installed. During operation
accumulate on the machine. this will prevent vibration, abrasion, friction with
other parts and guard from excessive heat.
Do not operate the machine near an open flame.
Before removing or servicing any lines of the air
Keep all open flames or sparks away from the
conditioning system, always ensure there is not
battery. Do not smoke in battery charging areas.
an open fire nearby; any escaping gas coming
Do not charge a frozen battery. This may cause into contact with fire could result in poisonous
an explosion. fumes. Never smoke when servicing or repairing
the air conditioning system, any escaping gas
Ether that burns and inhaled can cause bodily harm or
death.
Starting the machine by use of ether could result
in serious damage to the engine or personal
injury or death. Fire Extinguishers and First-
aid Kit

A fire extinguisher that meets with all local fire

extinguisher laws and regulations should be
available on the machine.
Maintain the fire extinguisher in accordance with
all local laws and regulations. Contact your local
fire department for further information.
Know how to use the fire extinguisher and first-
Cautions Concerning Lines, Tubes and
aid kit.
Hoses
A first-aid kit should be available at the work site.
Do not bend or strike high-pressure lines. Do not Periodically check the contents of the kit and
install bent or damaged tubes or hoses. replace used medical supplies as necessary.
Tighten any loose fuel or oil pipes, hydraulic Keep telephone numbers of doctors, first-aid
system tubes or hoses. Repair any damaged fuel centers or fire stations etc with you so you can
or oil lines, tubes or hoses. Leaks can cause contact them in case of an emergency. Post the
fires. Contact Liugong or your Liugong Dealer for contact telephone numbers in regulated places.
factory authorized replacement parts. Ensure that all persons know where the
telephone numbers are located and know the
If you see evidence of any of the following
correct contact method.
situations, replace the part before using:
● Connectors damaged or leaking.
● Outer covering frayed or cut and reinforcing
wire exposed.
● Outer covering ballooning.
● Evidence of kinking or crushing.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
 23
October 12, 2019 Safety Information
CLG856H Electrical Storm Injury Prevention

Inspect and service the fire extinguisher Explosions of tires have resulted from gas heat-
regularly. Obey the recommendations on the induced and combustion inside the tires.
instruction plate and all local laws and Explosions can be caused by heat that is
regulations relating to fire extinguishers. generated by welding, by heating rim
components, by external fire, or by excessive
use of brakes.
Electrical Storm Injury
A tire explosion is much more violent than a
Prevention blowout. The explosion can propel the tire, the
rim components, and the drive train components
When lightning is striking in the vicinity of the as far as 500 m (1500 ft) or more from the
machine, the operator should never attempt to machine. Both the force of the explosion and the
mount and dismount the machine. flying debris can cause property damage,
personal injury, or death.
If you are in the cab during an electrical storm,
stay in the cab. If you are on the ground during Do not approach a warm tire. Maintain a
an electrical storm, stay away from the machine. minimum distance, as shown. Stay outside the
shadow area.
AT LEAST 15m(50ft) AT LEAST 500m(1500ft)

Tire Explosion Prevention

Maintenance, removal, repair and installation of

Dry nitrogen is recommended for inflation of
the tires and wheel rims must be performed with
tires. If the tires were originally inflated with air,
special equipment and a trained repairer.
nitrogen is still preferred for adjusting the
Therefore, it is better to repair and maintain the
pressure. Nitrogen mixes properly with air.
tires in a tire service shop.
Nitrogen inflated tires reduce the potential of a
tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation
of the rubber, deterioration of rubber, and
corrosion of rim components.
Avoid over inflation. Use proper inflation
equipment, and training for using the equipment
is necessary. Improper equipment or using will
result in tire break or rim damage.
Inproper tire and rim maintenance may cause tire
explosion, and such explosion can lead to
serious personal injury or death. Only trained
personnel with proper tools and correct
procedure can maintain the tires and wheel rims.
24
Safety Information October 12, 2019
ROPS/FOPS CLG856H

ROPS/FOPS Steering Frame Lock

ROPS/FOPS of Guangxi LiuGong Machinery Connect steering frame lock when the machine
Co., Ltd are located above the operator's is being lifted and shipped. Also connect the
compartment and secured to the machine. steering frame lock when performing repairs
near the articulation joint.
The strength of the structure will be reduced if it
is damaged due to a rollover. ROPS are certified Disassemble the steering frame lock before
structures and cannot be repaired. Any damage operating the machine.
to the ROPS structure will require replacement of
More information refers to Steering Frame Lock
the structure to retain the certification.
in Operation Manual.
Always fasten your seat belt when you operate
the machine.
Attachment Cautions
It is forbidden to drill holes or weld inside or
outside or change anything of the cab. This will
damage the integrity of the ROPS structure. Attachments should only be installed by
authorized people who have been trained to
If the cab is to be modified in any way, contact operate and maintain the attachment according
your local LiuGong dealer to avoid damaging the to the operator’s manual.
ROPS structure.
Refer to the instructions in the operation manual
and any other related information when installing
and using attachments.
Incorrect installation of attachments or optional
parts not only will result in safety problems, but
also will negatively influence the operation and
service life of the machine and the attatchments.
It is forbidden to modify the machine or any
attachments without permission from your
LiuGong dealer.
LiuGong bears no responsibility for injuries,
accidents or machine damage resulting from the
Operator Station use of unauthorized attachments.

This machine is equipped with a cab that meets

with industry standard: ISO 3411. Cautions about Machine
Any modifications or aditional equipment added Operation
to the inside of the operator station should not
project into the operator space. The addition of a Mounting and Dismounting
radio, fire extinguisher and other equipment must
be installed so that the defined operator space is Before mounting or dismounting the machine,
maintained. Any item that is brought into the cab check the condition of handrails, ladders and
should not project into the defined operator steps. Clean them of grease, lubricants and dirt
space. A lunch box or other loose items must be before use. Repair any damaged parts and
secured. Objects must not pose an impact tighten loose bolts.
hazard during travel over rough terrain or in the
event of the machine tipping.
 25
October 12, 2019 Safety Information
CLG856H Cautions about Machine Operation

Mount and dismount the machine only where Understand Your Working Area
there are handrails, steps or ladders.
Before starting, inspect the area where you will
Face the machine when getting on or off, grab
be working. You should check: adequate
the handrails with both hands and step onto the
ventilation, the position of any slopes, visible
steps or ladders. Touch three points
ditches, falling or hanging objects, conditions of
simultaneously (two feet and one hand or two
soils (soft or hard), accumulated water and
hands and one foot) to ensure stability of the
swamp areas, rocks or stumps, hidden
body.
groundwork, posts or the outer limits of walls, the
outer limits of the areas where garbage is buried
or that are filled in with earth, holes or openings,
obstacles, mud or ice, traffic, heavy dust, heavy
smoke, heavy fog, the exact locations of cables
or pipes for power supply, gas supply, phone
service, water supply, sewage disposal and other
utilities that are hidden or hung. If necessary
before starting work you should ask the utility
companies to mark out, close or move out these
utilities.
Never jump off the machine.
Never get on or off a moving machine. Before Starting the Engine
Be careful not to touch any control levers when
Inspect the machine carefully before starting the
getting on or off the machine.
engine, ensure all systems are in good
Do not try to climb on or off the machine when operational condition. Make sure nobody is on or
carrying tools or supplies. Use a rope to pull around the machine before starting the engine.
equipment up onto the platform or have an
Keep the steps and handrail clean. Clear any dirt
assistant pass them to you.
and sand from your shoes before mounting the
machine.
Understand Your Machine
Check all structural members, covers and
Be able to operate all the equipment on your fenders for deformation or damage.
machine.
Check the condition of safety items such as
Understand the purpose of all control systems, doors, guards and covers. Repair any damage
instruments and indicators. as necessary.
Understand the rated load, speed range, the Check the hydraulic system for oil leakage.
characteristics of braking and steering, turning Check the condition of hoses and pipes.
radius and the space clearance for operation.
Check all fasteners for security.
Remember that rain, snow, ice, gravel and soft
Check the condtion of the electrical wiring
earth may change the performance of the
harness and fuses, replace or repair as
machine.
neccessary. Also check the connectors for good
Understand the safety signs on the machine connection.
(Danger, Warning, Caution) and any other signs.
Check the fuel level and fuel system for normal
condition, drain any water or sediment in the
water/fuel separator. Dispose of fluids in
accordance with local regulations.
26
Safety Information October 12, 2019
Cautions about Machine Operation CLG856H

Replace all damaged or lost parts and carry out Do not start the engine until seated in the
lubrication according to the maintenance interval operators seat and the seat belt is firmly
schedule. fastened.
Remove all loose objects from the cab. Loose
objects may affect the operation and cause
accidents.
Make sure that all the windows, if fitted, are clean
and the screenwiper works normally.
Adjust the operators seat to a position that is
most comfortable and provides for easiest
operation of the machine. Check the seat belt
and the condition of mounting hardware. Repair
or replace any items that are damaged. Replace Ensure the hydraulic control levers are all in the
the seat belt after three years of use or any time NEUTRAL position and the shift control lever is
the belt shows signs of wear or damage. in the NEUTRAL position before starting the
engine.
Adjust the seat to ensure that you can depress
the pedals fully when your back is against the Sound the horn to alert personnel before starting
seat. the engine.

Check all the illumination equipment before

operation in low light, and ensure that the Beep
illumination system is in good condition.
Check to make sure the steering frame lock is in
the RELEASED position.

Engine Starting

Do not start the engine if there is a DO NOT

OPERATE or similar tag attached to the start Only start the engine from the operators seat in
switch or control levers. the cab. The transmission should be in
NEUTRAL position before engine starting. Never
start the engine by short-circuiting the starter
motor terminals. Starting the engine by short-
circuiting could result in damage of the electrical
G
IN

system, personal injury or death.

N
AR
W

er ot
!

op o n

After the engine is started, you should observe,

e
at
d

instruments and warning lights, and make sure

that they work and every reading is within
r:
te
ra
pe
O

:
ate

working range.
D
 27
October 12, 2019 Safety Information
CLG856H Cautions about Machine Operation

Observe machine movements and listen Machine Operation

carefully for unusual noises. If there is any fault
or abnormality, you should stop the engine Before operating the machine on roads, check
immediately. Locate the source of the problem whether the machine meets the requirements of
and repair before further operation. the local laws and regulations for road operation.
Make sure that you get the road operating
permission from relevant road administration
offices. Observe the local traffic regulations when
driving the machine on roads.
Before driving the machine, you should carefully
observe the surroundings, and find out the
relations between the direction that you want to
go in and the pedal/operating lever.
Do not allow another person to sit on the
Never run the engine in a closed or poorly machine unless equipped with an additional
ventilated environment. If working inside a seat, seat belt and Rollover Protective Structure
building, open the doors and windows to ensure (ROPS).
enough ventilation and try to prevent exhaust
gas poisoning. Use a power exhaust system
when working in an enclosed area.

Before working the machine, you should operate

the machine slowly to an open area, check for
proper operation of all control levers and all
protective devices.
Before Operating the Machine
Note any needed repairs during machine
operation such as an abnormal noise, vibration,
Make sure the machine is clear of personnel and
smell, wrong reading of gauges, gas or oil
fasten the seat belt before operation.
leakage, etc., stop what you are doing and report
Keep all the windows, lightshades and rearview any needed repairs.
mirrors clean. Secure doors and windows in
Dust, heavy rain, and heavy fog will blur your
either the open or close position.
vision. You should keep windows, mirrors and
Adjust the rearview mirrors for best vision, lights clean and in good condition. When the
especially close to the machine. visibility decreases, you should decrease the
Clear all obstacles from where the machine will speed and apply the proper lights.
be working. Be aware of hazards such as high
voltage wires, ditches, etc.
Make sure the horn, backup alarm (if equipped)
and all other alert devices are working properly.
28
Safety Information October 12, 2019
Cautions about Machine Operation CLG856H

If driving or operating the machine with a bad

view or in a crowded area, you should work with
a signalman, keep the signalman within the field
of your vision, and coordinate your hand signal.
When traveling with a load in the bucket, set the
load height at 17" ~20" (450~500mm) from the
ground level to below the boom articulation joint.

Consider filled or unstable ground. Be certain the

condition of the work site is stable and capable of
supporting the machine during operation. Do
operate the machine close to an unstable drop
off. Operation of the machine on shoulders, drop
H off's, or filled areas could cause the machine to
become unstable, presenting a work hazard.
Avoid bumping the obstacles on top of the
machine when operating it.
Never undercut a high bank. The bank edges
could collapse causing severe injury or death.
Avoid working at the base of a bank or under
overhanging structures. Overhanging ground
and structures could collapse. Extreme caution
should be used when working in such areas.
Stay away from overhanging banks and
structures. When driving the machine on a slope, make it
straight up and down and neither make turn on
the slope nor drive it transversely on the slope to
prevent tipping. The distance between bucket
and ground should be 200-300mm (7-12in).
If the engine stops accidentally when operating
the machine across the slope, depress the
service brake pedal immediately and lower the
bucket to the ground, then pull up the parking
brake button (or parking brake handle) to stop
the machine from moving.
If the machine begins to sideslip on a slope,
immediately remove the load and turn the
machine downhill.
When going down a slope, use the brake power
of the engine and drive in low speed. At the
same time, use the service brake to control the
travel speed if necessary. Do not shut down the
engine or push the lever to NEUTRAL position
when machine goes down the slope, so as to
prevent serious accident or personal injury.
 29
October 12, 2019 Safety Information
CLG856H Cautions about Machine Operation

Avoid operating the machine across the slope. If Never use the loader to lift people. Do not use
possible, drive the machine in reverse when the bucket as a work platform for people. Never
going down the slope with a load, and drive allow people to ride in the bucket.
forward when going up the slope. The machine
Be careful when working beside high voltage
may turn over if do not drive the machine in
wire. If it is possible to contact the electrical wire
reverse when going down the slope with a load.
while working, consult the Electricity Company
before working.
The contact with electrical wire may cause
accidents, such as injury or death, do not allow
any part of the machine to come close to or
contact an electrical wire. Check the area above
the machine, and learn about the exact distance
between electrical wire, machine and ground. If
possible, you’d better cut off the power supply. If
it is impossible to cut off the power supply, you
should ask a signalman to guide you.

To prevent the machine from tipping over or

damaging the attachment due to overloading,
If the machine has contacted the high voltage
never exceed the machines rated capacity.
wire:
● Alert all personnel to keep away from the
machine.
● If you can, drive the machine away to
disconnect the contact point and separate
the high voltage wire from the machine and
leave.
● If you can not disconnect the contact point,
stay inside the cab until the Electricity
Do not use the bucket or boom for lifting. The Company cuts off the power and you are
machine can only be used within its capability. informed to go out.
Any operation beyond its capability will bring ● If a fire occurs, hold your feet as close as
damage to the machine. Refer to the possible and jump off the machine without
Applications and Specifications section for the touching ground with your hands. Try to jump
specific capacities. into a safe place.
Never hoist heavy articles by directly hanging
slings on the bucket teeth.
30
Safety Information October 12, 2019
Cautions about Machine Operation CLG856H

Transportation If it is necessary to park the machine on a slope

or incline, lower the implement to the ground,
When transporting, make sure that the hooks engage the parking brake and shut off the
and the towing devices are adequate. Connect engine. Place chocks under the wheels at the
tie down equipment to a drawbar or hook only. downhill side on both sides to prevent the
Never straddle a wire rope cable or similar machine from moving.
device, nor allow others to do so.
Before transporting, ensure that no personnel
stays between the machine and tie down
equipment. The towing bracket or drawbar pin of
the tie down equipment should be centering
connected with the drawbar or hook of the
machine.

Parking the Machine

When possible choose flat level ground to park

the machine, apply the parking brake, always Understand and obey all regulations relating to
lower any attachment to the ground and ensure public roads, if the machine is parked on a public
the machine will not move, possibly causing road. Additional signal or flasher may be
damage or injury. required.

Consider any overhead hazards such as the Always lower attachments or other equipment
posibility of falling rocks, any powerlines or any before leaving the machine, apply the parking
other overhead hazards that may exist. brake.

Consider the ground conditions. Do not park the If the machine is equipped with a pilot cut-off
machine near the edge of a cliff, close to an open lever, turn it to OFF position. If the machine is
excavation or pit. equipped with a hydraulic lock switch, press it to
LOCK position. Put the work implement control
Consider environmental conditions such as the levers and shift control lever to the NEUTRAL
posibility of flooding, heavy snow fall, electrical position.
storms and exposure to wind and cold. Any of
these conditions may cause damage to the Engage the parking brake.
machine. Keep the engine running at idle speed for five
Do not cause an obstruction, consider the site minutes to let the engine cool down gradually.
access and other emergency conditions the Stop the engine, and take out the key from the
machine may obstruct. switch.
Turn the battery disconnect switch to OFF
position to avoid battery discharge.
 31
October 12, 2019 Safety Information
CLG856H Cautions about Machine Maintenance

When leaving the machine lock all equipment Store Accessories Safely
covers and doors with the key. Remove the key
and keep it with you. Store accessories and tools safely so as to
prevent them from falling and causing serious
injury or death. Keep playful children and
bystanders away from the storage area or any
area accessories are being stored while in use.

Lowering the Attachment/ Implement with

Engine Stopped

For a machine controlled by electro-

hydraulically control lever, in order to lower
the implement, the engine start switch must Cautions about Machine
be on ON position. Turn the engine start
switch to OFF position after lowering the Maintenance
implement.
Prepare the Working Area
In order to lower the implement to the ground or
trailer, move all control levers to DOWN position. Please choose a clean and flat area with
When release them, they will return to HOLD adequate space, enough light, and good
position. ventilation to carry out any repair work. Clean the
ground surface, wipe up fuel, lubricating oil and
water, and spread sand or other absorptive
materials on the slippery ground. Keep the work
area clean and dry.

Support the Machine Correctly

Lower to the ground or support any attachments

with stands or other methods. Ensure that any
attachment can not move during maintenance or
repair work, use wheel chocks or other devices
to prevent machine movement.
Do not work under any part of the machine or
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use
stands or other measures that are secure and
can support the weight being applied to them.
32
Safety Information October 12, 2019
Cautions about Machine Maintenance CLG856H

Transportation Information Before lifting, secure the front and rear frame
with the steering frame lock so that the machine
Obey the appropriate laws that govern the can not move.
parameters of the load (weight, length, width,
Use proper rated cables and lifting device, keep
and height).
levelling in lifting.
Understand the correct procedures for loading
Lifting device should be big enough to prevent
and unloading.
the machine from being damaged in lifting.
Carry out the loading and unloading operations
on flat ground.
Chock the wheel of the trailer to make it unable
to move.

Welding Operation

Any personnel engaging in welding operations

1. Wedge must have occupational certificates and carry out
2. Block the operation at a place with appropriate devices
3. Angle (Max. angle is 15°) equipped, When carrying out the welding
4. Distance between the ramps operation, the personnel must follow the
5. Ramp
instructions below:
Use loading ramps appropriate for the machine
being moved. Consider: size, strength, departure Before carrying out the welding operation, turn
angle and proper height. Make sure that the off the battery isolator switch, disconnect the
loading ramp is anti-slip and free of mud and battery, disconnect the controllers, GPS and
snow. other electrical parts.

Use chains and blocks to secure the machine to Remove all paint from the place to be welded, so
the trailer. as to prevent harmful gas from being produced.

Keep the bystanders away. Do not inhale smoke produced by burning paint.

Place all the working equipment in the Never weld pipes, close to rubber hose and
transportation position, secure all the equipment electrical wires.
and attachments or additional equipment with Always remove residual pressure from the
chains or other secure methods to prevent machine. Never weld pipes that are fitted to the
accidental movement. machine.

Lifting the Machine Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
Refer to the machine nameplate for the machine of the operation being performed.
mass. Ensure good ventilation.
 33
October 12, 2019 Safety Information
CLG856H Sound and Vibration

Remove all the flammable materials, supply the Sound and Vibration
work area with a fire extinguisher.

Sound

The machine provides noise level that meet the

requirements of Chinese "GB 16710-2010"
standards.
A-Weighted emission sound pressure level, L at
the operator's position measured according to
work cycle procedures specified in "GB/T 25615"
is less than or equal to 83dB(A), for the cab
offered by Liugong.
A weighted sound power level of the cab
Clean the Equipment Periodically
measured according to work cycle procedures
specified in "GB/T 25614" is less than or equal
To avoid possible injury or damage to the
to113 B(A).
machine, all the oil and scraps accumulated
should be removed. The engine, radiator,
Vibration Level
storage battery, hydraulic hose, fuel tank and cab
should be kept clean.
When carrying out the cleaning operation, wear
suitable PPE. Consider exposure to: chemicals,
slippery surfaces, high pressure water spray and Whole body vibrations generated by
material splash. construction machines, are to a high
degree, influenced by different factors, e.g.
working methods, ground conditions and
traveling speed selected by the operator.

This machine is equipped with an operator's

seat, which meets the criterion in standard ISO
7096. This seat is tested with the input spectral
class EM6 and has a Seat Amplitude
Transmissibility factor SEAT=0.95.
The hands and arms are exposed to a weighted
root mean square acceleration that is less than
Do not spray the water directly onto sensors, 2.5 m/s2.
connectors or instruments of the electrical The whole body is exposed to a weighted root
system. If water enters the electrical system mean square acceleration that is less than
malfunction may occur. 0.5 m/s2.
Measurements are obtained on a representative
machine using the procedures in the following
standards:
''ISO 2631-1"
"ISO 5349-1"
"ISO 5349-2"
34
Safety Information October 12, 2019
Key Spare Parts to be Periodically Changed CLG856H

Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically

No. Q'ty Change Intervals
Changed
Replace at first 500h, later every year or
1 Hydraulic oil tank filter element 1 every 1500h (To see which one comes
earlier)
2 Fuel hose (fuel pre-filter--fuel lift pump) 1
3 Fuel hose (fuel lift pump-- fuel filter) 1
4 Fuel hose (fuel filter--high pressure pump) 1
5 Fuel hose (fuel return hose) 1
6 Hose assembly (pump--flow amplifying valve) 1
Hose assembly (flow amplifying valve--metering
7 4
pump)
Hose assembly (flow amplifying valve--steering
8 2
cylinder)
9 Steering cylinder seals 2 Every two year or every 4000h (To see which
one comes earlier)
10 Hose (air compressor--combined valve) 1
11 Hose (combined valve--air reservoir) 1
12 Hose (air reservoir--foot brake valve) 1
13 Hose (foot brake valve--booster) 2
14 Nylon hose (foot brake valve--shut-off valve) 1
15 Nylon hose (foot brake valve--parking brake valve) 1
16 Nylon hose (parking brake valve--shut-off valve) 1
17 High pressure hose (booster--front axle steel tube) 1
18 High pressure hose (booster--rear axle steel tube) 1
Every three year or every 6000h (To see
19 Air reservoir 1
which one comes earlier)

1. To ensure the safety of this machine during usage, the user must adhere to replace the parts listed in the above table
regularly due to the importance of these parts in the security and fire prevention.
2. The materials of these parts will degenerate along with the passage of time, corrode, or more easy to wear. Moreover,
it is very difficult to determine the state of these parts simply according to the regular maintenance. Therefore, no
matter what usage state they are, it is necessary to change these parts regularly in order to ensure safety and their
performance.
3. If the parts fail to work even though not within the time schedule for replacement, they should be repaired or replaced
immediately.
4. If the pipe folder of the fixed hose has any damage, such as distortion or cracks, it should be replaced together with the
hose.
5. Replace the O-ring, seals and other parts like these at the same time when replacing the hose.
6. Contact the designated dealer of LiuGong Machinery Co., Ltd. to replace the safety key parts.
 35
October 12, 2019 Application and Specification
CLG856H Applications

Application and
Specification

Applications

This loader is a kind of engineering machinery

mainly used for loading & unloading loose
materials. It is mainly used for loading &
unloading, bulldozing and traction operation etc.
at mine areas, ports and docks, capital
construction, road repair and steel & iron
enterprises etc. It is a kind of multi-purpose and
high efficiency engineering machinery.
This loader is a kind of general-purpose
engineering machinery and is not suitable for the
flammable, explosive, dusty and air poisonous
environments.
Do not operate machine in conditions with
rollover or falling object risk.

Requirements of Work Environments

1. Altitude:≤3000 m
2. Environmental temperature: -15°C~40°C
(The cold starting Aid device is not available)
3. Water Depth: ≤ 630 m

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.
36
Application and Specification October 12, 2019
Main Specifications CLG856H

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
 37
October 12, 2019 Application and Specification
CLG856H Main Specifications

Machine Specifications

GCIC T2 engine/
NO. Item Unit 4BPZF210 gearbox/
AP3000 wet axle
1 Rated load weight kg 5500
2 Rated power KW 162
3 Operating mass kg 17300
4 Rated bucket capacity m3 3.5
5 Dumping height mm 3013
6 Max. breakout force (bucket tilting) kN 172
7 Tipping load (aligning) Kg 13750
8 Tipping load (full steering) Kg 12140
9 Boom lifting time (full load) s 5.7
10 Total time s 10
11 Max. traveling speed km/h 38
12 Max. gradeability ° 28
13 Min. turning radius (outside of front wheel) mm 6200
Overall Dimensions
Parameters below are for Z-bar or 8-bar machine Z-bar
1 A: Height to hinge pin, fully raised mm 4156
2 B: Dumping height, fully raised mm 3013
3 C: Dumping reach, fully raised mm 1195
4 D: Max. digging depth mm 50
5 E: Min. ground clearance (at articulation joint) mm 431
6 F: Distance from centre of rotation to the centre of the front wheels mm 1660
7 G: Wheel base mm 3320
8 H: Overall height (top of cab) mm 3450
9 J: Tread width mm 2150
10 K: Overall width (outside of wheel) mm 2750
11 L: Over length (bucket on ground) mm 8350
12 M: Max. steering angle ° 38
13 W: Overall width (outside of bucket) mm 2976
14 R1: Turning radius (outside of bucket) mm 6860
15 R2: Turning radius (center of rear wheel) mm 5905
16 P: Departure angle ° 28
17 S1: Bucket tilt back angle (on ground) ° 44
18 S2: Bucket tilt back angle (in transport position) ° 49
19 S3: Bucket tilt back angle (in highest position) ° 57
20 S4: Dumping angle (in highest position) ° 45
21 T: Bucket articulation height (in transport position) mm 500
38
Application and Specification October 12, 2019
Main Specifications CLG856H

Main Components Specifications

Engine
1 Manufacturer / GCIC
2 Model / 6LTAA9.3
3 Type / Mechanical
4 Displacement L 9.3
5 Rated power KW 162
6 Emission level / T2
Number of cylinders and
7 / Straight-six cylinders
arrangement
8 Intake type / Turbocharged & inter-cooling
9 Rated speed r/min 2200
10 Max. rotating speed (no-load) r/min 2360
11 Min. rotating speed (no-load) r/min 800
12 Rotating speed at max. torque r/min 1400
13 Max. torque N.m 940
14 Start motor V-Kw 24V-7.8 KW
15 Alternator V-A 28V- 70A
Power train system
1 Torque converter Type Single turbine, four members
2 Manufacturer ZF
3 Model ZF4BP210
4 Type Electro-hydraulic shift
Transmission Four forward speeds and three reverse
5 Number of gears
speed
Operating pressure of shift oil pump
6 2.0~2.2MPa
(gear pump)
7 Manufacturer ZF
8 Model AP3000
9 Type Wet-type alxe
Drive axle
10 Max. traction force 172kN
11 Front & rear axle reduction ratio 23.333
12 Rear axle swing angle ±10
13 Wheels Tire model 23.5-25PR18
14 F1/ R1 7/7.5km/h
15 F2 13.5/13.5km/h
Traveling speed
16 F3/ R3 25/25
17 F4/R4 38
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October 12, 2019 Application and Specification
CLG856H Main Specifications

Main Components Specifications

Work hydraulic system

1 Work pump Type Gear pump
2 Work pump displacement ml/r 100
3 System pressure MPa 20.7
4 Control valve / Two spools
5 System flow L/min 331(confluence flow)
6 Lifting time (full load) s 5.7
7 Dumping time s 1.3
8 Float lowering time s 3
9 Total time s 10
Steering hydraulic system
1 Steering angle ° 38
2 Steering pump Type Gear pump
3 Steering pump displacement ml/r 83.9
4 System pressure MPa 16.5
5 System flow L/min 147
Brake hydraulic system
1 Service brake Type Full hydraulic brake
2 Brake pump Type Gear hydraulic pump
3 Brake pressure MPa 13-16
Nitrogen Pre-charge pressure of
4 MPa 5.5
Accumulator
5 Parking brake Type Drum type parking brake
6 Parking brake control mode / Electrohydraulic control
Nitrogen Pre-charge pressure of
7 MPa 9.2
Accumulator
Air conditioner system
1 Type / Cooling & heating A/C
2 Heating capacity W 5800
3 Cooling capacity W 5000
4 Refrigerant Model R134a
40
Application and Specification October 12, 2019
Main Specifications CLG856H

Main Components Specifications

Electrical system
1 System voltage / DC 24V

Refill capacities
1 Fuel tank L 260
2 Engine oil L 22
3 Cooling system L 42
4 Transmission oil L 35
Front: 44
5 Drive axle oil L
Rear: 44
6 Hydraulic oil L 225
7 Brake oil L /
Note:
1. Continuous regeneration and improvement are made to LiuGong products. All the specifications are the latest product
information obtainable at the time of publication. LiuGong will reserve the right to make change without notice.
2. The above parameters are the theoretical values, the tolerance ranges during testing are provided by LiuGong
standard.
 41
October 12, 2019 Operation Manual
CLG856H Before Operation

Operation Manual Daily Inspection

For a maximum service life of the machine,

complete a through walk-around inspection
Before Operation before you mount the machine and before you
start the engine.

Mounting and Dismounting Inspect the area around the machine and under
the machine. Look for loose bolts, trash buildup,
Before mounting or dismounting the machine, hydraulic oil, coolant leakage, broken parts, or
check the condition of handrails, ladders and worn parts.
steps. Clean them of grease, lubricants and dirt Inspect the condition of the implement and the
before use. Repair any damaged parts and hydraulic components.
tighten loose bolts.
Check all of the oil levels, the coolant level and
Mount and dismount the machine only where the fuel level.
there are handrails, steps or ladders.
For additional information, refer to section
Face the machine when getting on or off, grab “Maintenance Interval Schedule”.
the handrails with both hands and step onto the
steps or ladders. Touch three points
simultaneously (two feet and one hand or two Operator Controls and
hands and one foot) to ensure stability of the Instrument Panels
body.

Battery Disconnect Switch

The battery disconnect switch is located in the

left counterweight box. Open the upper cover of
counterweight box to get access to it.

Never jump off the machine.

Never get on or off a moving machine.
Be careful not to touch any control levers when
getting on or off the machine.
Do not try to climb on or off the machine when
carrying tools or supplies. Use a rope to pull
equipment up onto the platform or have an
assistant pass them to you.
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

Disconnect switch--ON Engine Start Switch

Turn the battery disconnect switch key clockwise
to 90° before you start the engine. In this The start switch (also called ignition switch) is
position, the battery disconnect switch key will located inside the cab and it has four positions in
point to the ON position. clockwise direction.

关
OFF ON
开

Disconnect switch--OFF
AUX——The first position when insert the start
switch and turn it counterclockwise. The start
To shut down the electrical system, turn the
switch key will reset to OFF position
battery disconnect switch key counterclockwise
automatically after being released. This position
to 90° . In this position, the battery disconnect
is not available at present.
switch key will point to the OFF position.
OFF——The oil passage of the engine is cut off
关 at this position. The power of the machine is
turned off. All of the other electrical appliances
can not be turned on except the turn signal lights,
开

rotating beacon and dome light.

关
OFF ON
开

The start switch key can only be inserted or

taken out in OFF position.

ON——The first position when insert the start

The battery disconnect switch and the engine switch key and turn it clockwise. The electrical
start switch perform different functions. To system of the machine can turn on and work
disable the entire electrical system, turn the normally.
battery disconnect switch to the OFF position.
The battery remains connected to the electrical START——The second position when insert the
system when you just turn off the engine start start switch key and turn it clockwise. The engine
switch key. will be turned on and work. Release the start
switch key after starting the engine. This position
can not hold on automatically and the key will
reset to the ON position automatically after being
released.
Do not turn off the battery disconnect switch
while the engine is running, otherwise it may
damage the electrical system.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

The battery disconnect switch must be at I

position and the shift control lever must be
in NEUTRAL before starting the engine.

If the engine fails to start, turn the start

switch to the OFF position before restart or
the start switch could be damaged.
Do not engage the start switch for more
than 15 seconds at one time. Wait at least 30
seconds before restarting. Do not exceed
three consecutive attempts before allowing
the starter motor and choke solenoid to cool
down. Failure to comply could result in a
reduction of the service life of the battery as
well as damage to the starter motor and
choke solenoid.
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

Instrument Panels

Most of the gauges, alarms and steering indicators are integrated in the instrument panel under the
steering wheel. Brake air pressure gauge and service hour meter are installed on the console on the
right side of the seat. There are fourteen items showed on the instrument, namely, transmission oil
temperature, coolant temperature, transmission oil pressure, fuel level, engine oil pressure, power
voltage, hydraulic oil alert, parking brake low pressure alert, service brake low pressure alert, centralized
lubrication system alert, hydraulic oil temperature alert, service hour meter and left and right turn
indicator.

G
F
E
D
A
C
B
H

A: Central Instrument Panel E: A/C Panel

B: Front left instrument panel F: Sound control panel
C: Front right instrument panel G: Top switch panel
D: Front upright column instrument panel-RH H: Right instrument panel
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Central Instrument Panel Engine coolant temperature gauge

Central instrument panel consists of five pointer This gauge shows the coolant
gauges, one LCD screen,service hour meter, temperature of the engine. The green
status indicators and warning indicators, etc. zone shows normal work temperature; the yellow
zone shows low temperature and the red zone
5 1 2 1 3 4 shows high temperature.

Stop the engine and park the machine on a

convenient place to check when the gauge
points to red zone. Check the engine fan,
belts and the radiator coolant level. Never go
on working until the trouble is eliminated.

6 7
When checking the engine fan, belt and water
1. Turn indicators
2. Engine tachometer tank level, be extremely careful to avoid
3. Engine coolant temperature gauge injury. Keep away from the moving parts to
4. Torque converter oil temperature gauge avoid being injured and keep away from hot
5. Fuel level gauge
6. LCD screen
parts to avoid being burnt.
7. Service hour meter
Torque converter oil temperature
Turn indicators gauge

The left indicator flashes when the This gauge is used to indicate the oil
machine turns left, the front & rear left temperature of the torque converter. The green
turn signal light will also flash zone shows normal work temperature; the yellow
simultaneously. zone shows low temperature and the red zone
The right indicator flashes when the shows high temperature.
machine turns right, the front & rear
right turn signal light will also flash
simultaneously.
When the pointer of the torque converter oil
Engine tachometer temperature gauge points to the red zone,
park the machine on a safe and convenient
The tachometer shows the engine place for repair. Check the transmission and
rotating speed. After starting the transmission oil level. Never go on working
engine, multiply the tachometer pointer reading or operate the machine before eliminating
by 100 to produce the actual rotating speed of the problem.
the engine. The normal work range is
750~2200rpm, and the speed at maximum
torque is 1400rpm.
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

Fuel level gauge 3. Transimission fault code

“TRAN.FAULT. CODE” will illuminate
This gauge indicates the fuel level of
immediately if there is a fault when the
the machine. “1” indicates the high fuel
transimission is running. The transimission fault
level. “0” indicates the low fuel level. Add fuel in
code will display on the LCD screen, e.g: 32.
time when the fuel level is lower than “0.2”.

LCD screen

This LCD can display the travel speed, system

voltage, ZF fault code and so on, the unit of the
display can be switched between metric unit and
English unit.
1. Driving speed For more information about transmission fault
code, refer "Fault Code Index of ZF4BP210
“Km/h”or “MPH”will illuminate when machine is Gearbox " on page 166
travelling. Driving speed will display on the LCD
screen, e.g: 28.5 Km/h. Travel speed, system voltage on the screen can
be switched by the screen switch on the steering
column.

2. System voltage
System voltage will display on the LCD screen
when “Volts” illuminates, e.g: 24V.

The screen switch can return to the original

position automatically.

Service hour meter

Service hour meter indicates the total

work hours of the machine, unit in
hour. The time range of the hour meter is 0 to
9999.99 hours. When turning on the start switch,
the power of the panel is turned on and the
service hour meter starts to time. The LCD
display shows the accumulated work hours of the
machine. The recording value by the service
hour meter can be used to determine the
machine maintenance intervals.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Brake low pressure alert indicator

The illumination of this red alert

8
indicator indicates the hydraulic oil
pressure of the service / parking brake is too low.
Stop the machine to check.

Main fault alert indicator

When illuminates any one of the

following alert indicators: parking
brake, brake low pressure, engine oil pressure,
engine air filter blocked, lubrication system fault,
8. Voltage indicator transmission oil pressure, transmission fault,
hydraulic oil temperature and steering system
Voltage indicator alert indicator, the status indicator flashes; When
illuminates any one of the parking brake, brake
When the yellow indicator lights, it low pressure, engine oil pressure and steering
indicates the voltage of the machine is system fault alert indicator, at the same time, the
out of the range of 24.8-29.5V. If the voltage of engine is running, the buzzer will sound once.
the machine exceeds 31.5V, the voltage indicator
and status indicator will light, the buzzer will
sound at the same time.

12-16
9-11

12. Engine oil pressure alert indicator

13. Engine intake air filter alert indicator
14. Generator charge indicator
15. Lubrication system fault alert indicator
9. Parking brake indicator 16. Transmission oil pressure alert indicator
10. Brake low pressure alert indicator
11. Main fault alert indicator
Engine oil pressure alert indicator
Parking brake indicator
Engine oil pressure alert indicator will
flash to alert when the engine oil
When engaging parking brake, the red pressure is too low, and the buzzer will
indicator turns on. It indicates the sound at the same time. Stop the engine to
parking brake is working. check.
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

Engine intake air filter alert indicator

When the air filter is blocked, this

indicator will light. Stop the engine and
maintain the air filter.

Generator charge indicator

The indicator indicates if the generator 17

is generating electric power. When the
engine start switch is turned to the ON position,
this indicator illuminates. When the engine start
switch is turned to the START position, the
17. Sreering system fault indicator
generator reached the electric power generation
state, this indicator goes out. Steering system fault indicator

Centralized lubrication fault alert This red indicator is controlled by the

indicator (Unapplicable) instrument system. The indicator will
light and the secondary steering motor will start
When the red indicator flashes, it when the instrument detects a fault in the
indicates fault of the centralized lubrication
system. steering system.

Transmission oil pressure alert

indicator
18
The red indicator will flash when
19-20
transmission oil pressure is too low. Stop the
engine to check.

Park the machine on a safe and convenient

place for repair when the transmission oil
pressure alert indicator is flashing. Check the 18. Ride control indicator
transmission and transmission oil level. 19. Front floodlight high beam indicator
Never go on working or driving the machine 20. Centralized lubrication indicator
before correcting the fault.
Ride control indicator

When the green indicator flashes, it

indicates ride control function is running.

Front floodlight high beam indicator

The blue indicator indicates the front

floodlight is at high beam.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Centralized lubrication indicator Clutch cut-off indicator

The green indicator illuminates when The machine is at clutch cut-off state
the centralized lubrication system is when the yellow indicator lights. The
working. machine is out of clutch cut-off state when the
indicator goes out. .

The clutch cut-off function can be used only

when the machine is in gear F1, F2 or R1, R2.
21-24

FNR working indicator

25 When the yellow indicator illuminates,

it indicates that an operator is using the
FNR control lever or control button to control the
21. Wait to start indicator
22. Heater working indicator
travelling of the machine.
23. Secondar steering indicator
24. Clutch cut-off indicator Front Left Instrument Panel
25. FNR working indicator

Wait to start indicator

When the operating temperature inside

the machine tested by the system is 1
below -18°C, the machine automatically starts
the cold starting aid device to help the engine to
preheat quickly, then the wait to start indicator 2
will be on. When the indicator goes out, the
temperature has reached the preset requirement 3
and the engine can be started.

Heater working indicator 1. Position light and front floodlight switch

2. Hazard flasher switch
The yellow indicator illuminates when 3. Front work light switch
the heater is working.
Position light and front floodlight
Secondary steering indicator switch

When the secondary steering button is This switch controls the on and off of the
at ON position or the diesel engine position lights and front floodlights.
stops accidentally, the secondary steering motor It has three positions. When it is at the front
starts and the yellow secondary steering position, the position lights and the front
indicator lights. floodlights are off.
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

When it is at the middle position, the position Front Right Instrument Panel
light switch turns on. Then the four position lights
of the machine will turn on, the indicator on the
central instrument panel will turn on at the same
time. Press the switch to the middle position also
means that the work lights, rear floodlights and
front floodlights can be turned on through the
relevant switches, too.
When it is at the rear position, the front floodlight 1
3
switch turns on and the front floodlights are on.
Use the combination switch to choose high beam 2
or low beam.

Hazard flasher switch

1. Rear work light switch
After turning on the hazard flasher 2. Lighter
3. Grid heater switch
switch, all the turn signal lights (four
lights) will flash simultaneously. They function as Rear work light switch
warning lights when the machine stops in case of
danger and emergency. The rear work light switch controls on
or off of two rear work lights on the top
of the cab and two work lights on the rear hood (if
equipped) simultaneously.
The left and right turn lights switch will not
work after turning on the hazard flasher Lighter
switch. Therefore, turn off the hazard flasher
switch before starting the machine. Push down the lighter, the lighter will
be turned on and begins to heat. The
lighter will spring out when it is hot enough. Pull
Front work light switch
out the lighter for smoking. Return the lighter to
socket after use.
The front work light switch controls on
or off of the front work lights on the top
of the cab simultaneously.

The lighter will automatically spring out in 10-

18 seconds. If the lighter does not spring out
in this time, the lighter will heat continuously
and the lighter wiring terminal or jacket may
be burnt; Immediately drawout the lighter if it
does not automatically spring out exceed 25
seconds.

The socket of the lighter can be used as a power

supply interface of 24 volts DC, the maximum
power supply current is 10 Amp.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Grid heater switch Screen select switch

When press this switch, the preheat This switch is used for the switching of
indicator will light and the engine intake gear, engine rotating speed, drive
system will be in preheating state. The time for speed, system voltage, engine fault codes and
preheat is 45s. The grid heater switch will other items displayed on the LCD screen on the
automatically cut off after finishing preheat. central instrument panel.

Defroster switch

The defroster switch controls ON or

When the environment temperature lower to
OFF of the defrost device.
0 °C to -25 °C, use the grid heater function to
aid the engine to start.
Rear windshield wiper switch

Front Right Upright Column Instrument There are three positions of the rear
Panel windshield wiper: OFF, LOW and HIGH.
The wiper can reset automatically at OFF
The instrument panel is installed on the right position.
column.
Rear washer switch
2
The washer will work and spray water
from the reservoir to the windshield by
pressing the switch. The washer will stop
1
4 spraying when the switch resets automatically
after being released.

3 The washer reservoir is located on the rear right

5 side of the seat.

1. Screen select switch

2. Defroster switch
3. Rear windshield wiper switch
4. Rear washer switch
5. Clutch cut-off switch
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

When the clutch cut-off switch is turned to

CLUTCH CUT-OFF, the power cut-off function
will be cancelled, the power output of the
Frequently check the washer reservoir to find transmission will not be cut off even the service
whether the water has been used up, brake pedal is depressed.
otherwise the normal viewing may be
affected.
The washer reservoir should be emptied or
filled with antifreeze when the ambient The clutch cut-off function can be used in
temperature is below 0°C, otherwise the F1, F2 or R1, R2. When the machine is at
washer will not work or even be damaged by high speed, to ensure safety operation, even
being frozen. if clutch cut-off switch is turned to ON, the
As the washer with additive may be harmful shift control electronic box will not cut off
to human body, dispose of it according to power output of the transmission when
local laws and regulations. braking.

Clutch cut-off switch

A lock buckle is provided on the switch; When operating the machine on flat ground,
unlock this buckle by turning it the operator should turn the clutch cut-off
downward before pressing the switch. switch to ON. Otherwise the performance of
Otherwise the switch will be damaged. the brakes, service life of the brake system
and the transmission will be affected.
When the clutch cut-off switch is turned to
CLUTCH CUT-ON (see following picture), the For safe operation of the machine, when the
shift control valve will cut off the power output of machine is working on slopes or steep
the transmission when the driver depresses the inclines, do not turn the clutch cut-off
service brake pedal. switch to ON.

CLUTCH CUT-OFF

CLUTCH CUT-ON
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

A/C Panel Select this position, warm air indicator

6 will turn on. The air conditioning
The A/C panel is located on the upper right side system is defrosting (heating).
of the cab.

Fan
4 5 6
When reset the air change switch to
middle position, only the fan blower
works. Natural air will come out.

Temperature control switch

Turn the temperature control switch clockwise for

1 2 3 cool air. Turn it counterclockwise for warm air.

Starting explanation of air conditioner

1. Fan speed switch
2. Selector switch After the engine is started, turn the fan speed
3. Temperature control switch
4. Air change indicator switch to either H, M or L with engine starting to
5. Defroster switch turn on the air conditioner.
6. Cool air indicator
Turn the fan speed switch to O or OFF position to
Fan speed switch turn off the air conditioner.

Three positions are available: high(H),

medium(M), low(L). Turning the switch to O or
OFF position will turn off the fan. During winter, turn on the air conditioner for
Fan speed switch is also the power switch of the 20 minutes to run the compressor to avoid
air conditioner. Turn this switch to either H, M or leakage of coolant. This keeps the
L with engine starting to turn on the air compressor in best condition.
conditioner.
Cooling
Turn the fan speed switch to O or OFF position to
turn off the air conditioner.
1. Check if the warm water valve of engine
coolant inlet and outlet is at CLOSE position.
Selector switch
If it is at ON position, put it to CLOSE
position.
There are three positions available for selector
switch: cool air, defrost (warm air) and natural air. 2. After starting the air conditioning, adjust the
fan speed switch to the desired position.
Cool air
3. Turn the selector switch clockwise to cool air
Select this position, cool air indicator 7
position (the cool air indicator is on), the
will turn on, The air conditioning
cooling system is starting to work and the
system is cooling.
cooling air comes out from the air vent.
Defrosting (Warm air)
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

4. Adjust the temperature control switch to Fan

adjust the cool air temperature.
1. Turn on the fan speed switch to desired
position after the engine is started.
2. Turn the selector switch to fan position, then
It is recommended not to set temperature the natural air will come out.
control switch to COOL position and fan
3. Adjust the fan speed switch to adjust the fan
speed switch to Low position at the same
speed.
time, otherwise the evaporator will frost and
cooling effect could be affected.
Warm water valve

Heating The heating function of the air conditioning

system can be realized by the coolant flows
1. Before starting the engine, set the warm through the evaporator of the air conditioning
water valve at engine coolant inlet and outlet system to release heat.
to ON position (warm water valve direction is
the same with the hoses). A manual warm water valve is provided
respectively for the water inlet and water outlet of
3 the engine.(Note: some machine only has one
2
for the water inlet of the engine). A water
solenoid is fitted between the water intake and
the evaporator and is controlled by the selector
switch (This machine only has warm water
valve).
1
3 2

1. Warm water valve

2. Warm water valve ON
3. Warm water valve CLOSE
2. After the engine is started, turn the fan speed
switch to the desired position. 1

3. Turn the selector switch counterclockwise to

defrost (warm air) position, the defrost (warm 1. Warm water valve
air) indicator will turn on. The air conditioning 2. Warm water valve ON
system starts working, and the warm air 3. Warm water valve CLOSE
comes out from the air vent continuously.

At the beginning when the engine is started,

the air temperature is low due to the low
coolant temperature, but the air temperature
will raise after coolant temperature is
getting high.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

During heating operation, the manual warm Top Switch Panel

water valve should be at ON position (the warm
water valve direction is the same with the hoses).
1 2

If it is necessary to repair the air

conditioning system due to fault, first close
the manual warm water valve (the warm
water valve direction is vertical to hoses) to
prevent coolant loss.
When replacing the engine coolant, open
the warm water valve and set the selector 1. Shift mode switch
switch to defrost (warm air) position to 2. FNR enable switch
replace the coolant inside the evaporator
together. Make sure the engine coolant level Shift mode switch
is correct.
AUTO and MANUAL are available on this switch,
which is used to select the travel speed
automatically and manually.

The water radiator should be emptied or filled

MANUAL
with antifreeze and the selector switch
should be set to defrost (warm air) position
when the ambient temperature is below 0°C
and the engine stop running , otherwise the
radiator lines will be damaged by being
frozen.
AUTO

When AUTO is selected, the control box can shift

the travel speed automatically by judging the
engine speed and the current travel speed.
When MANUAL is selected, the travel speed can
only be shifted manually through the shift control
lever.

Do not change the switch mode when the

machine is travelling.
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

FNR enable switch

This switch is an automatic reset

switch, press this switch ,the FNR
indicator lights up, and the FNR
function of the machine is activated;
then press this siwtch again, the FNR indicator
lights out , and the FNR function of the machine
does not work.

Right Instrument Panel

1. Nine needles data diagnosis connector

Nine needles data diagnosis connector

This is the datalink connector that connects

computer. Use of the special software can test
the engine parameters and fault codes of the
engine and machine controller.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Control Devices

4
1 2

3 8
7

1. Steering Wheel 5. Service Brake Pedal

2. Horn Switches 6. Accelerator Pedal
3. Shift Control Lever 7. Parking Brake Button
4. Combination Switch 8. The Work Implement Control Lever
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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

Steering Wheel Horn Switches

There are three horn switches, one is located in

the centre of the steering wheel, the other one is
located at the end of the steering combination
handle, and the third one is located on the pilot
handle. The functions of these two switches are
the same, the horn will sound by pressing any
one of the switches. The operators can use the
switches according to their own operation habits.

Articulate full-hydraulic power steering is

provided on this machine, the steering wheel is
in the cab and it is connected to the full-hydraulic
metering pump through steering column. In
normal operation, turn the steering wheel
clockwise, the machine will turn right; turn the
steering wheel counterclockwise, the machine
will turn left.
The characteristics of the full-hydraulic power
steering are as follows:
1. The steering angle of the steering wheel is
not the same with the turning angle of the
machine, turn the steering wheel
continuously to increase the turning angle of
the machine until the desired position is
obtained.
2. The faster the steering wheel turns, the faster
the machine turns.
3. The steering wheel can not reset
automatically after being released, and the
machine steering angle will not change.
Therefore, turn the steering wheel
counterclockwise to let the machine travel in
straight direction after finishing turning.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Shift Control Lever Reverse: push the shift control lever to

REVERSE position, the machine will move
The shift control lever is located on the left side backward.
of the steering column, which is used to choose
travel direction and travel speed. Speed selection

Rotate the shift control lever. The number in the

arrow direction as illustrated in the picture is the
speed position. This machine has four forward
speeds and three reverse speeds. When the shift
control lever is in the R4, actually it is in R3.

When the shift control system has a fault,

never remove the transmission system
without authorization. Consult LiuGong
dealer or Service Company if the fault can not 1. ''1'' for first speed
be eliminated. 2. ''2'' for second speed
3. ''3'' for third speed
4. ''4/D'' for fourth speed
Direction selection
The shift control lever of the F5 gearbox is in the
seme position as the F4 gerabox. When the lever
is in the F4 gear, it will automatically upgraded
from F4 to F5 after satisfying certain confitions,
and will automatically reduced from F5 to F4
gear when it is not satisfied. Specific gear can be
viewed through the LCD screen on the central
function panel.
1

1 2
F: Forward
N: Neutral
R: Reverse
1. Shift control lever
Forward: push the shift control lever to
FORWARD position, the machine will move 3
forward.
1. Gear
Neutral: push the shift control lever to NEUTRAL 2. Shift control level
position, the machine should not move. Only 3. Gear direction
when the shift control lever is in NEUTRAL
position can the engine starts.
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The specific travel speed of the machine will 3. Forced down shift function (Kick down
display on the speedometer on the central key)
instrument panel.
Two KD keys are available. One is at the end of
Except for the direction and speed change
the shift control lever. The other one is on the
function, the shift control system also has other
pilot control lever.
special functions.

Special functions of the shift control system: KD

1. Neutral/start interlock protection

functions

The electrical system of the machine has neutral/

start interlock protection function, start the
engine only after the shift control lever is at
NEUTRAL position so as to prevent unexpected
accidents due to sudden actions.

2. Direct forward/reverse change function

The shift control lever of the machine has no

turning interlock function, the driver can directly
change directions according to the driving speed:
At F1or F2gear, directly engage the
corresponding reverse (F1 <=> R1 and F2 <=>
R2) any time.
At F3 and F4, The driver should operate the shift
control lever according to the driving speed as
the following rules:
When the machine exceeds the preset speed
(normally 2nd gear is set as the maximum driving
speed), the system first automatically reduces to
2nd position at the present driving direction and
engages the 2nd position after a while, and
finally changes speed to the preset position.
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The KD key function and the direct forward/ 5. System self-protection function
reverse change function have supplied a
convenience for gear shifting when loading When abnormal information occurs (such as
materials. For example, when the machine disconnected wiring, ground short-circuit of the
moves close to the material stack at F2, push electronic control box and odd signal) or power
down the KD key, the gear can shift into F1 supply exceeds the specified limit or there is an
automatically; after loading, press down the key open circuit, the electronic control box changes
↓, the gear will shift to R2 automatically. The to NEUTRAL to lock all output signals so that
machine will leave the material stack at R2 misoperation can be greatly prevented to ensure
speed, so a high working efficiency can be the driving safety.
achieved.
6. Clutch cut off function

Depress the brake pedal after the clutch cut off

switch is turned to ON (see the follwing picture),
then the shift control valve will cut off the
transmission power output.

CLUTCH CUT-OFF

CLUTCH CUT-ON
The KD key function will stop automatically when
other position is selected, cancel the KD key
function through the following ways:
● Pressing KD key again. When the clutch cut off switch is turned to OFF,
● Reversing. the power cut off function will be cancelled. That
is, the transmission power output will not be cut
● Operate the shift control lever to change the off when the brake is engaged.
driving speed.
The lever is at NEUTRAL position.

4. Start speed limit function The clutch cut off function only can be used
in F 1, F 2 or R 1, R 2. To ensure safe
To ensure the driving safety, the position is operation, when the machine is at high
limited at F1, F2 or R1, R2 by the electronic speed, even if the clutch cut off switch is
control box when the machine starts. Only after turned to ON, the electronic control box will
the speed exceeds the setting value can F3, F4 not shut off power output of the
be shifted. If the speed doesn’ t reach this value, transmission.
the machine only can move in F2 (the road
condition determines the running speed) even
shift the gear to F3, F4. Therefore, after the
machine starts, it can move at high speed only
after the driving speed exceeds the setting value.
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Operation Manual October 12, 2019
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High beam/ low beam shift

A lock buckle is provided on the clutch cut

off switch. Unlock the buckle before turning
off the switch, otherwise the switch could be
damaged.
When operating the machine on flat ground,
the operator should turn the clutch cut off
switch to ON. Otherwise the performance of
the brakes, service life of the brake system
and the transmission will be affected. The high beam/ low beam can be achieved by
For safe operation of the machine, when the the up and down movement as per the arrow
machine is working on a slope, do not turn direction.
the clutch cut off switch to ON. If the front floodlight is at low beam state, push
the combination switch up and down to change
Combination Switch the light to high beam and the blue front
floodlight high beam indicator on the central
The combination switch located on the right of instrument panel turns on. Push the combination
the steering wheel is an integrated type switch. It switch up and down again, the front floodlight
has the following functions: steering indication, high beam will change to low beam.
front floodlight high beam / low beam shift, horn
control, windshield wiper control, windshield Horn control
washer control etc.

Steering indication

The horn will sound by pressing the horn button

Push the combination switch forward when at the end of combination switch.
turning left, the left turn indicator will flash, and
the front & rear left turn signal lights will also turn
on simultaneously. Pull it backward when turning
right, the right turn indicator will flash, and the
front & rear right turn signal lights will also turn
on simultaneously. When the hazard flasher
switch is on, the turn signal lights will not work.
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October 12, 2019 Operation Manual
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Front windshiled wiper control Service Brake Pedal

Front windshield wiper switch is located on the

combination switch. There are four positions: The service brake pedal is located at the front left
OFF (O), intermittent (J), low velocity (I), high side of the driver's seat.
velocity (II). The position J is not available at
present. Rotate the switch to I position, the The service brake system has single brake pedal
windshield wiper works at low velocity, rotate it to and double circuits. The other circuit will not be
II position, it works at high velocity. affected if one of the circuits has fault so as to let
the machine keep enough brake capability to
Front washer control ensure the operation security. Repair the brake
system in time if it has fault to ensure the
machine has enough brake power.
Depress the service brake pedal, the front and
rear axle will brake and the brake light will turn
on. Release the brake pedal to disengage the
serviced brake.

The washer will work by pressing the washer

control switch inwards. The water from reservoir
will be sprayed to windshield window glass.
The washer will reset to natural position and stop
spraying after being released.
Refer to section “Window Washer Reservoir--Fill”
for the location and maintenance of the washer
reservoir.
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Operation Manual October 12, 2019
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Accelerator Pedal Parking Brake Button

The accelerator pedal is located at the front right

side of the driver's seat. Naturally, the engine is
Do not use the parking brake when the
at idle state. The diesel engine oil supply and the
machine is traveling unless the service brake
engine speed will increase by depressing down
failed. Use the parking brake as the service
the pedal while the supply declines and the
brake in the regular operation will damage
engine speed slows down by releasing it.
the brake system seriously.
Stop the engine through the start switch “OFF”
position. When the engine is running, turn the The parking brake button is located on the right
start switch key to “OFF” position, the engine side of the driver’s seat. Pull it up to engage the
stops. parking brake, press it to disengage the parking
brake.
The parking brake is also used as emergency
brake. If an emergency occurs when the
machine is working, pull up the parking brake
button to engage the emergency brake. If the
machine is at the 1st or 2nd speed, the
transmission will automatically shift to NEUTRAL
simultaneously.
When the service brake system has faults and
the accumulator pressure in the service brake
circuit is below 0.3 Mpa, the parking brake will
cut off power and the parking brake system will
actuate brake automatically. The machine
engages the emergency brake to ensure driving
safety.
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October 12, 2019 Operation Manual
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Work Implement Control Lever Lower

The work implement control lever are located on Push the control lever forward, the
the right side of the driver's seat. They are used boom will lower. The control lever will
to control the boom and bucket. Push the boom return to NEUTRAL position after being
control lever forward and pull it backward to released.
control the boom lowering and raising; push the
bucket control lever leftward and pull it rightward Float
to control the bucket rotation. The control levers
are naturally at the NEUTRAL position when the Push the control lever forward until it
engine stops. reaches the limit position, then it will
stay at that position (the control lever will not
A KD key is provided in the middle of the pilot reset after being released) and the boom is at
control lever. It has the same function with the FLOAT state.
KD key on the shift control lever. The operator
can use any one of them according to operation When scraping or loading, push the control lever
habit. to the FLOAT position, then the bucket will raise
or lower along with the ground condition to avoid
damaging the road surface.
1 2
When lowering the boom, push the control lever
to FLOAT position, and then the boom will lower
slowly due to its dead weight.
Pull the control lever to NEUTRAL position to
cancel FLOAT state.
3
4

Do not use FLOAT when lowering the boom

1. FNR switch with a loaded bucket. The quick lowering
2. Horn switch speed of the boom will damage the
3. KD key
4. Work implement control lever machine.

Boom control Hold

Raise The control lever will return to the

NEUTRAL position after being
Pull the control lever backward, the released from RAISE or LOWER position, the
boom will raise. boom will stay at the position that is selected.
Boom lift kickout: pull the control lever backward
until it reaches to the limit position, then the Bucket control
control lever will stay at this position (it will not
reset after being released); when the boom Dump
reaches its maximum height, the boom lift
kickout switch works and the control lever will Push the control lever rightward
return to the NEUTRAL position, the boom will (forward), the bucket will dump
not raise any more. forward.
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Hold

The control lever will return to the

NEUTRAL position after being Before lowering the work implement, make
released from DUMP or TILT BACK position, the sure that no obstacles or personnel is around
bucket will stay at the position that is selected. the machine to avoid machine damage or
personnel injury or death.
Tilt back

Pull the control lever leftward Other Devices

(backward), the bucket will tilt back.
The control lever will hold at the maximum tilting Steering Column
position till the bucket reaches the positioning
position. Then the control lever will return to the The tilt angle of steering column can be adjusted
NEUTRAL position. within a certain range to adapt to the driver’s
operation habit.
Bucket positioning
There is a pedal on the lower lrft side of the
steering column, it is connected with a air spring.
When the bucket is at DUMP condition, pull the
control lever leftward to the limit position, then
the control lever will hold at that limit position. It
will not return to NEUTRAL position after being
released. The bucket keeps tilting backward until
it reaches the positioning position. Then the
control lever will automatically return to the 3
NEUTRAL position and the bucket will hold at
the bucket positioning position.
Pull the control lever leftward to the limit position
again, the control lever will not hold, it will return
to the NEUTRAL position after being released.
2
Only when pushing the control lever rightward
and the bucket dumping angle exceeds the 1
bucket positioning position, the bucket positioner
switch will reset and the bucket positioning
function will recover. Push the control lever
leftward to the limit position again, the control
lever will hold at the limit position.
1. Pedal
When the bucket is dumping, the control lever 2. Air spring
does not have HOLD function. Keep pushing the 3. Adjusting handle
control lever rightward and it will reset to the Adjust the steering column forward or backward
NEUTRAL position after being released. as follows:
1. Depress the pedal, the air spring will be
released.
Push the control lever to LOWER position to 2. Keep the pedal unmoved, move the steering
lower the work implement onto ground or column forward or backward to desired
trailer if the engine flames out. position.
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

3. Release the pedal, the steering column will Seat

be fixed at this position.
Adjust the steering column(if equipped) upward The seat provided for this machine can be
or downward as follows: adjusted in the aspects of fore-and-aft direction,
height, backrest angle, armrest angle, headrest
1. Rotate the adjusting handle counterclockwise height and weight to meet the needs of different
for one quarter turn, the steering wheel will drivers in various working conditions.
be unlocked and can be adjusted upward or
downward to desired position. 1. Fore-and-aft adjustment.

Hole the linkage under the seat, move the seat

forward or backward to the desired position.
Release the linkage, the seat will be fixed on the
locking position. The seat can be moved forward
or backward for 210mm.

2. Rotate the adjusting handle clockwise for one

quarter turn, the steering wheel will be
locked, and it is unable to adjust the steering
wheel upward or downward at this time.

2. Armrest angle adjustment

Adjust height and angle of the armrest through

roller. The adjustment range of armrest angle is
40°and height is 40mm.

The maximum supporting capacity of the

armrest is 50KG.
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Operation Manual October 12, 2019
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3. 3-step height adjustment by lifting the 5. Backrest angle adjustment

seat top
Backrest angle adjustment min.90°. It can be
adjusted to meet the need of different operators.

Three increment are available. When lifted to the

max. height, the seat will get back to the min.
6. Weight adjustment and suspension
height automatically.
function

Two stroke options are available for this weight

adjustment: 60mm and 80mm. Adjust according
Do not adjust the seat while the machine is to the operator's weight. Weight adjustment is
running, otherwise a serious accident could infinite from 50 kg to130 kg.
result!

4. Headrest adjustment

Headrest height adjustment 157mm.

Before taking off the headrest, raise the

headrest and remove the spring under the
bush cover first.
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October 12, 2019 Operation Manual
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7. Nonretractable seat belt (optional) 1. Up and down adjustment

Press and hold the plate on the right side of the

armrest box and pull up hardly to adjust the
armrest upward. Similarly, press and hold the
plate and press down hardly to adjust the
armrest downward.

8. Document box

The document box is located at the back of the

backrest.

2. Fore-and-aft adjustment.

Press and hold the hand cushion and move the

hand cushion forward or backward to adjust the
front and rear direaction.

Right Armrest Box

The armrest box is located on the right side of

the driver’s seat. Above the armrest box is a
hand cushion. When the driver is working, he
can put his right forearm on the han cushion to
reduce fatigue.
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Seat Belt (Optional) A red button is provided by side of the buckle.

Press the button, the catch will spring up from
the buckle.

The machine is equipped with a seat belt by

Liugong before transporting it to the
destination. Its quality and installation
instruction has met the standard of
ISO6683.

The seat belt used in this machine can not retract

automatically.
Fasten the seat belt before operating the
machine. Before using the seat belt, check the
Before using the seat belt, check whether the
seat belt for wear and fastness, replace if
buckle of the seat belt can lock and release
necessary. Contact your LiuGong dealer for the
normally.
seat belt replacement.
Adjust length of the seat belt before use in order Sound System (Optional)
to ensure safety and comfortability. Length of the
seat belt can be adjusted by moving position of The sound system is located inside the cab and
catch on the safety belt. consists of the main unit, loudspeaker and
The buckle of the seat belt is located at the right antenna.
rear side of the seat. Insert catch of the safety 1 2 13 14 15
belt into the buckle to latch it.

3 4 5 6 7 8 9 10 11 12

1. Source/mute key
2. SRC/SOUND
3. Volume key
4. Menu key
5. Preset key 2
6. Preset key3
7. Preset key4/last menu
8. Preset key 5/next menu
9. SCAN key
10. Search station forward/last song/hour
11. Auto store station/exit
12. Search station backward/next song/minute
13. Audible signal input
14. USB
15. Waveband key
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October 12, 2019 Operation Manual
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1. Press SRC/SOUND key for 2 seconds to

enter BASS-TRE.

Connect the battery negative terminal only

when the sound system has been installed to
avoid a short circuit.
Make sure you can still hear traffic (horns, 2. Press VOLUME+/- key shortly to select your
sirens and so on) when adjusting the volume. own sound style.

Source/mute key

Press to switch on the power. Press

this key for more than 2 seconds to ● BASS-TRE——Your own settings of bass
switch off the power. Press this key shortly to and treble.
mute or cancel the mute (silence) .
● FLAT——Original
Time set key ● JAZZ——Jazz music
● VOCAL——Speech
● POP——Pop music
● Press SET key for 2 seconds to enter or
escape SETUP menu. ● CLASSIC——Classical music

● Press SET key shortly to enter hour or ● ROCK-Rock music mode

minutes selection of TIME. 3. The LED display will show the sound type
● Select or  to adjust hour or minute and that has been selected.
the digital will flash. The new time setting will
be memorized.
● Press SET key at least 2 seconds to escape
SETUP menu. No sound mode will be shown on the display
if no sound mode is selected.
Sound adjustment
Volume balance adjustment
Volume Key
1. Press the SOUND key continuously to select
Press the VOLUME+/- key to adjust the balance modes:
the volume up or down.
BASS—TREBLE—BAL—FADER—LOUD
Sound BASS--low volume control, -7, +7.
TREBLE--high volume control, -7, +7
BAL--left and right balance control. -7-- -0- --7
FADER--horn control, -7- -0- 7
LOUD--undertone volume control. Four choices
are available: OFF LOW MID HI.
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Operation Manual October 12, 2019
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2. Press VOLUME+/- shortly to adjust the Store stations

selection mode.
Press any keys from 1 to 6 to store
desired stations.
● Manual store
Press the desired preset key (1 to 6) for more
than 2 seconds to store the current tuned station.
If no other sound mode is selected, BASS/
TREBLE will show on the display. ● Automatic store (AUTO STORE)
You can automatically store the 6 strongest FM
stations on the FM AST band or 6 strongest MW
(AM) stations on the MW(AM) AST band. When
The sound system will escape from the you use Auto Store, the new stations replace any
sound mode and memorize the last setting if stations previously stored in the FM AST band or
no further changes within 5 seconds. the MW (AM) AST band.
Press ''AST''key to activate auto-store.
Radio

Waveband
USB
Press BAND to select the desired
band. USB interface is provided on this machine.
Features:
● Support MP3 format only.
● Support 32Mbyte~4G memory disc.
● Support MPEG Audio 1, 2 and 2.5.
Automatic search
● Support Layer 3.
● Support FAT16 and FAT 32 partition
memorizing.
● Press '''' to tune to a station of a lower
● Sampling frequency range: 8k,16k, 32k,
frequency or '''' to a higher frequency. To
11.025k, 22.05k, 44.1k, 1k, 12k, 24k and
search for another station, press the key
48kHz.
again.
● Bit rate: 8k ~ 320kbps and VBR(MP3 PRO).
Manual search
Do as follows:
● Press '''' or '''' for two seconds to change
to manual search. 1. Insert the memory disc, USB PLUG will show
on the display.
● Press '''' to turn to a station of a lower
frequency or '''' to a higher frequency or a
desired frequency.
● The radio will search the station
automatically when you release '''' or ''''
for five seconds.
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October 12, 2019 Operation Manual
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Initialization is needed when inserting the It is recommended not to extend the USB
memory disc. It will last for a few seconds by cable because USB connection has a high
different memories. Do not take out the requirement on the length, resistance and
memory disc within the initialization process. signal delaying of the cable, other cables may
not meet the requirement, which could result
2. Press SRC key shortly under radio state to
in a reading failure of the memory disc.
change to USB mode, then the following
interface will be shown:
Audible signal input

A 3.5 mm audible signal input interface

is provided on the sound system,
which can be used to connect other music
players. Press SRC key and select AUX IN
3. The display will show the album number mode. The volume can be adjusted under AUX
before playing the songs. IN mode.
4. When playing, the display will show the
song's name and playing time. After finishing,
it will continue to play the next one.
5. Press or to select the last song or the
next song to play.
6. Press SCAN key during playing, each song in
the same album will play for 10 seconds in
sequence, press SCAN key again to make it
return to normal playing state.
7. During playing, press MENU key to show the
the song sequence in the album, after 2
seconds, it will return to normal playing state.
8. In playing state, press 3||, playing will
pause, press this key again to continue
playing.

Do not take out the memory disc when

playing, otherwise the file could be damaged.
It is better to take out the memory disc after
turning off the sound system.
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Lights The front combination lights consist of front high/

low beam, front position lights, front turn signal
Lights of the machine consist of front work lights lights.
(left & right each), front combination lights (left &
right each), rear work lights (left & right each), 55
rear combination lights (left & right each) and
dome light.
6

77
1

8
6

5. Front left turn signal light

4 6. Front high/low beam
7. Front position light
8. Front right turn signal light

1. Front work light

2. Front combination light
3. Rear work light
4. Rear combination light
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

The rear combination lights consist of rear Door Lock

position lights, brake lights, backup signal lights
and rear turn signal lights .The turn signal lights The machine is equipped with one-sided door.
are controlled by the combination switch. The door is on the left side and the windown is
on the right side. The door lock is installed on the
left door. Insert the key and rotate it clockwise for
12
180 degrees then take it out. Hold the door lock
with your hand, push the lock pin down with your
thumb, then open the door by pulling the door
outwards.

11 10 9

12

Before locking the door, first close it. Insert the

key and rotate it counterclockwise for 180
degrees, then take it out. After the door is locked,
9 10 13 the lock pin can't be pressed.

9. Brake light
10. Reflex reflector
11. Rear left turn signal light
12. Backup light (optional)
13. Rear right turn signal light

14

14. Dome light

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Operation Manual October 12, 2019
Operator Controls and Instrument Panels CLG856H

Latch Extract the fixed pin to unlock the latch and then
open the right window completely.
The right window of the cab can be a spare exit. Fixed pin
If the left door can not be opened at the
emergent situation, leave the machine from the
right window of the cab.
Open the right window from the driver’s cab. Pull
the latch handle and then push it outward to
open the right window partly.
Latch handle

When open the window, the pressurization

in the cab will disappear.

When open the right window completely, the

position latch on the right window is locked by
the buckle behind. Then the right window is
locked in this position.
Buckle
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October 12, 2019 Operation Manual
CLG856H Operator Controls and Instrument Panels

Rear View Mirrors Engine Hood

Left and right rear view mirrors are separately Open engine hood
located at the top of the cab. Before operating
The unlock device of engine hood is located
the machine, adjust the rear view mirrors and
under the handle of the rear engine hood
make sure the driver has a good rear view when
handle. Open the unlock mechanism shield by
sitting on the seat.
hand, and then pull the lock lever outward and
hold the handle and open the engine hood by
pulling it upward.

Adjustment of Rear View Mirrors 2

1. Loosen the connecting bolts between the 1. Protection shield

rear view mirror brackets and the cab, turn 2. Lock lever
the brackets to adjust the rear view mirrors to 3. Handle
proper position.
2. Loosen the connecting bolts between rear
view mirrors and the brackets, adjust the rear
view mirrors to desired angles.
3. After completing the above-mentioned
adjustment, tighten the bolts.
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Open and close the engine hood in steps The steering frame lock is located at the left or
through the cable on the engine hood. right side of the machine.

2
1

1. Pin
2. Steering frame lock
Connect the steering frame lock when the
Close engine hood machine is being lifted and transported. Also
connect the steering frame lock if you are
Pull the cable downwards to grab the engine performing service work near the articulation
hood handle, then press the engine hood to the joint.
button, and push the lock lever and close the
shiled of the lock mechanism. Separate the steering frame lock before
operating the machine. Move the steering frame
Steering Frame Lock lock to the rear frame and install the pin.

Backup Alarm System (Optional)

The backup alarm is located at the back of the

No clearance for person in this area when machine. When the machine is reversing with
machine turns. Injury or death from crushing shift control lever turned to REVERSE position,
could result. the backup alarm will sound automatically.

To connect the steering frame lock, the

machine must be in the straight ahead
direction.
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October 12, 2019 Operation Manual
CLG856H Engine Starting

Engine Starting 2. Mount and dismount the machine according

to the safety regulations.

Check Before Starting the Engine

Check the engine coolant level.

Check the engine oil level.
Check the hydraulic oil level.
Check each oil pipe, water pipe and fuel pipe for
airtight condition.
3. Close the left and right doors of the cab.
Make sure air pressure of the tires is normal.
Check the seat belt for normal condition and
Check batteries for damaged wiring and loose fasten it.
connectors.
4. Adjust the rear view mirrors close to the
machine as much as possible in order to get
good rear view.
5. Make sure the shift control lever and work
Before starting the engine, Clear personnel
implement control lever are at NEUTRAL
around the machine. Clear away any
position, if not, turn them to NEUTRAL
obstacles. Make sure the machine is under
position.
control by the operator.

Engine Starting
The engine can start only when the shift
1. Turn on the battery disconnect switch. After control lever is at NEUTRAL position. This
the battery disconnect switch is turned on, can avoid the accident that produced when
the key will point to ON position. the machine is started suddenly.

关
6. Insert the key to the start switch and turn
clockwise to turn on the power. Sound the
开 horn to warn that the machine is going to
start, keep away from it.

关
OFF ON
开
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Operation Manual October 12, 2019
Operation Techniques CLG856H

7. Check if the selector switch of A/C system is 12. During severely cold weather, preheat the
at natural position, if not, turn it to hydraulic oil. Pull the control lever backward
corresponding position. and hold for about 4-5 minutes, depress the
accelerator pedal and let the bucket
positioner stop on the boom to make the
hydraulic oil flow out, which can increase the
hydraulic oil temperature rapidly.
13. Check the service brake and parking brake
systems for normal condition.
14. If there are no obstacles around the machine,
slowly turn the steering wheel and observe
for left and right turning.
8. Slightly depress the accelerator pedal, and
turn the start switch key clockwise to START
position to start the start motor of the engine. Operation Techniques
In normal case, the engine will start within 10
seconds. Release the start switch at once to
Operation Information
let it reset.

Follow these basic instructions when you are

operating the machine.
Start motor operation should not exceed 15 1. To prevent injury, make sure that no one
seconds. If the engine doesn't start after 15 works on the machine or near the machine.
seconds, release the start switch at once. Always keep control of the machine.
Wait 30 seconds before trying to start again, 2. Raise the bucket or the implement high
If the engine can not be started for three
enough to go over any obstacle.
times, wait for at least three minutes before
trying again to prevent damage to the start 3. Before disengaging the parking brake,
motor. depress the service brake pedal in order to
prevent the machine from moving.
9. Warm up the engine at idle speed of (750 ±
50r/min) after the engine is started. Check 4. Drive the machine forward for best visibility
the coolant temperature gauge. Run the and the best stability.
engine with full speed only after the coolant 5. Reduce the engine speed when turning and
temperature of the engine reaches green go over a hill.
zone.
10. The warning indicators on the central
instrument panel will turn off in sequence.
Disengage the parking brake button, the Personal injury or death can result from
parking brake low oil pressure indicator will falling material. Remove any suspensions
turn off. and watch out sliding material.
11. Check the readings of all the gauges to make
sure they are in the normal range. Check that
all the lights, indicators, horn, windshield
wiper and brake lights work normally. Never allow the bucket in the float position
to avoid bucket damage.
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CLG856H Operation Techniques

Driving Operation of the Machine 3. Turn the shift control lever to get forward or
reverse gear, and depress the accelerator
pedal properly at the same time, the machine
will travel forward or backward.

Before driving the machine on road, check

whether the machine meets the
requirements of the local road laws and
regulations, and obtain the road travel
permission from the related administration
office. Observe the local laws when driving. 1

1. Shift control lever

1. Turn the pilot control lever to tilt the bucket F: Forward
backward to limit position. Raise the boom to N: Neutral
the transportation position. Keep a clearance R: Reverse
of approximately H=500~600mm between
the lower articulation point of the boom and
the ground.
The machine can start only when the F1, F2
or R1, R2 is selected.
4. Drive the machine to open and flat ground;
turn the steering wheel to check whether the
machine has spot right and left turn ability.
5. Check the brake performance of the
H machine. Drive the machine at F1 or F2,
release the accelerator pedal, smooth58ly
2. Depress the service brake pedal and press depress the service brake pedal, the
the parking brake button to disengage the machine should obviously reduce speed and
parking brake. Slowly release the service stop.
brake pedal and observe the machine for
movement.

After depressing the service brake pedal, if

you can not feel the machine obviously
Depress brake pedal and pull up the parking reduce speed, to ensure safety, pull up the
brake button if the machine moves. Then parking brake button (or parking brake
check the shift control system for failure. If handle) at once to engage the emergency
the machine stops on slope, chock the brake to force the machine to stop.
wheel to prevent movement before checking 6. Check engagement of all the gears.
the machine.
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Operation Techniques CLG856H

Steering Operation of the Machine Shift Operation of the Machine

1. Release the accelerator pedal to slow down It is no need to stop the machine or depress the
the engine running speed. service brake pedal when you shift the travel
speed from F1 to F2 during driving.
2. Depress the service brake pedal to slow
down the driving speed. When shifting from low speed to high speed,
decrease the accelerator and operate the shift
3. Push the combination switch forward when
control lever at the same time, then increase the
turning left; pull the combination switch
accelerator. When shifting from high speed to
backward when turning right. Then the turn
low speed, increase the accelerator before
signal lights on both the front and rear of the
slowing down to make the rotating speed of the
machine and the turn indicators on the
transmission output shaft the same with the drive
central instrument panel will light to warn the
shaft.
neighboring vehicles and passerby that the
machine is going to turn. Stop the machine before changing the driving
direction.
A

1 Brake Operation of the Machine

B When performing brake, first release the

accelerator pedal, then smoothly depress the
brake pedal to perform the service brake
operation.

1. Combination switch
A: Left steer
When the machine runs at high speed, do not
B: Right steer rapidly depress the brake pedal unless an
emergency occurs, so as to avoid accidents
4. Turn the steering wheel for turning. Turn the
and damage to the machine.
steering wheel oppositely for straight driving
after steering operation is finished. When the machine is traveling or working on
a slope, do not cut off the transmission
5. After the steering is finished, turn the
power output when performing the service
combination switch to NATURAL position. brake to ensure safety.
The turn signal lights and the turn indicators
will go out.
6. Depress the accelerator pedal to get a
desired running speed of the engine.

Never turn the machine on a slope. Drive the

machine to flat ground before turning.
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CLG856H Operation Techniques

Downhill Operation 4. Thoroughly clear sludge, water or frozen

snow from the machine to avoid them
entering into the seams and damaging
Select a proper speed before going down a hill. sealing performance.
Do not change gears during the downhill
process. Most of time, the speed for downhill 5. Park the machine on dry and hard ground. If
operation is the same. impossible, park the machine on wooden
boards. The wooden boards can prevent the
Maintain a proper speed that is slow enough for machine from being frozen.
the conditions. Use the service brake to control
the travel speed. Using service brake when the 6. After the weather turns warm, change fuel,
machine runs at a high speed may result an hydraulic oil and lubricant with half viscosity.
overheating of the brakes and driving axle oil. Refer to section “Oil Specifications” for
These will bring serious abrasion or damage to particular oil brands.
the brakes.
Drive the machine reversely when going down a Machine Operation
hill with a load. Drive forward when going up the
hill.
Preparation before Operation

Operation during Cold Weather Before operation, first level the work site with this
machine. Remove ballooning, fill-in the pits and
shovel away the wet and slide ground surface.
Clear the area of large, sharp rocks to avoid
damaging the machine's tyres or the machine
itself.
If the ambient temperature is too low, the
engine can't be started easily, and the If this machine is used to load or unload a truck
radiator will be frozen. or hopper, adjust the limit height of the boom lift
kickout according to the height of the truck or the
hopper to allow the bucket to go in and out of the
1. Use fuel, hydraulic oil and lubrication with low truck or hopper safely.
viscosity. Refer to section “Oil Specifications”
for particular oil brands. For information about how to use the work
implement control lever, refer to section “Wok
2. Add anti-freeze in coolant. Implement Control Lever”.

Shoveling

Keep antifreeze away from an open fire. Do 1. Common Shoveling

not smoke when adding antifreeze.
Common shoveling is suitable for loading loose
3. In severe cold areas, use anti-cold batteries. materials.
As the ambient temperature drops, the
electrolyte may be frozen. In order to prevent 1. Drive the machine at F2 speed to approach
battery capacity loss, cover the battery or materials. Align the bucket middle with the
move it to a warm place and install it the next materials, lower the boom to transportation
day, then the engine can be started easily at position.
the next day.
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Operation Manual October 12, 2019
Operation Techniques CLG856H

2. At the distance of about 3' (one meter) from 3. Repeat cutting in material and tilting the
the material, lower the boom, let the bucket bucket until the bucket is completely filled.
contact the ground and keep the bucket
bottom parallel with the gound. Push the shift
control lever to I position to change the speed
of the machine from F2 speed to F1 speed.
3. Depress the accelerator pedal to force the
bucket to cut into the material with full power.
When the machine can't advance any more,
push the control lever for a while to tilt the
bucket backward, then release the work
implement control lever back to the 3. Retreating from the material
NEUTRAL position. The machine will
advance and continuously cut in the material. 1. After the bucket is filled fully, tilt the bucket
Repeat cut in material and tilting the bucket backward until the bucket block contacts the
until the bucket is completely filled. boom.
2. Raise the boom to a certain height to keep
the machine away from the material when
reversing. Then operate the machine
backward.
3. After the machine retreats from the material,
lower the boom to the transportation position.

Excavating With Bucket

2. Combination Shoveling 1. Lower the bucket to the ground and position

for a slight digging angle.
Combination shoveling is mainly used for hard
and viscous materials.
1. The operation of the cutting in the material
pile is the same as the common shoveling.
2. When the bucket can't advance after cuting
in the material, tilt the bucket upward, then
the bucket cuts in forward for some
distances. Then tilt the bucket backward so
as the bucket can continue to cut in the
material.
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October 12, 2019 Operation Manual
CLG856H Operation Techniques

2. Apply down pressure to the bucket as the ● When transporting distance is less than 500
loader starts forward. Return the lift control to meters, using trucks for transportation is not
HOLD when sufficient penetration is economical.
obtained.
When transporting, make sure that the lower
articulated joint of the boom is at transporting
position (about 500mm above the ground). Tilt
the bucket back to its limit position (the bucket
block contacts the boom) in order to ensure
safety and stability when transporting.

Never raise the bucket to a higher position

3. Maintain level cuts while moving forward, by for transporting, otherwise the machine
raising and lowering the bucket. could tip over.

Dumping Operation

1. Dumping materials into a truck or hopper

1. Release the accelerator pedal to let the

machine approach the truck or hopper at a
low speed when the machine is at a distance
of 15 meters from the truck or hopper with a
full load.
4. When the bucket is loaded, tilt it back against
the stops. Carry the loaded bucket 2. Let the boom raise to its limit position, the
approximately 40 cm (15 inches) above the boom will not raise up any more once it
ground when moving to the dump area. reaches its limitation.
3. When the bucket is on the top of the truck or
hopper, depress the brake pedal to stop the
machine. Then tilt the bucket forward and
dump the materials.
4. If the body length of the truck is over two
times than the bucket width, dump the
materials from the front part to the rear part.

Transportation of Materials

The machine can be used for transporting

material under the following conditions:
● When the ground is too soft or the ground is
not leveled, a truck can not be used.
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Operation Manual October 12, 2019
Operation Techniques CLG856H

To ensure shoving safety, operate the work

implement control lever slowly and smoothly
when lifting or lowering the boom.
When dumping, it is advisable not to bump
the bucket block with the boom repeatedly
so as to avoid damaging the machine.

Do not lower the boom when the bucket is at

high dumping position with full load,
otherwise the machine may tip over.
5. After dumping, tilt the bucket backward until it Scraping Operation
reaches the positioning position.
6. Then push the shift control lever to the Lift the boom, tilt the bucket forward until the
REVERSE position so that the machine can blade contacts the ground. The angle between
leave the truck or hopper reversely. the blade and ground should be kept at about
60°.
7. After the machine leaves the truck or hopper,
the driver could drive the machine with The work implement control lever should be set
lowering the boom for next operation. to the float position for hard road surface, and it
should be pushed to the NEUTRAL position for
2. Dumping at low position soft surfaces.
Pull the shift control lever to REVERSE speed
When carrying materials among the work sites, and depress the accelerator pedal to operate the
sometimes you may need to dump at a lower machine backward. Scrape the ground evenly by
position, that is, the machine dumps materials the bucket blade.
near the ground. After dumping, first tilt the
bucket to the level position, then lift the boom.

Shoving Operation

Place the bucket on the ground, push the shift

control lever to the F1 or F2 and depress the
accelerator pedal to drive the machine forward.
During the shoving operation, slightly lift the
boom and continue the shoving operation if the
machine meets an obstacle.
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October 12, 2019 Operation Manual
CLG856H Operation Techniques

Operation Method 2. Shuttle operation method

1. V Type operation method The shuttle operation is mainly used for the
combination operation of the machine with a
truck team.
1. As shown below, after loading, the machine
returns to a distance of 2~3 times the truck
width. Then the truck runs to the front of the
machine from one side and stops. The
machine moves forwards and lifts the boom.
After dumping, the machine returns to the
original position.

1. As shown in the above figure , maintain 60°

angle between the machine and the truck.
Stop the machine at 12~15m away from the
truck.
2. After the machine is loaded fully, drive the
machine to 12~15m from the material, then 2. If the truck is not completely filled with
run the machine towards to the truck with materials, drive the truck forward for one
bucket lifted while it is turning. After position. After the machine performs the
dumping, return the machine to the original second loading, it will return to the original
position for next loading. position. Then the truck returns to the front of
the machine for dumping.
3. Repeat the operation until the truck is filled
with material. The machine then goes on
loading the next truck.
4. This operation requires skillful cooperation
between the machine and the truck drivers.
They communicate with each other by using
the horn, lights, or hand signals.
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Operation Manual October 12, 2019
Operation Techniques CLG856H

Parking Lowering the Work Implement with

Engine Stopped
Stopping the Machine Make sure that no pesonnel is around the
machine before lowering the implement.
1. Park the machine on flat ground. If it is
needed to park the machine on a slope, 1. Turn the engine start switch to ON position.
place a wedge under the wheels to stop it 2. Push the boom control lever to LOWER
from moving. position to lower the implement. This lever
can return to HOLD position automatically
after being released.
3. Turn the engine start switch to OFF position.

Leaving the Machine

1. Close the left and right doors and lock them.

2. Use the ladder and the handrail when you get
off the machine. Face the machine and use
both hands. Make sure that the steps are
2. Use the service brake to stop the machine. clear of debris before you dismounting.
3. Turn the shift control lever to NEUTRAL 3. Inspect the engine compartment for debris.
position. Clean out any debris and paper in order to
4. Pull up the parking brake button (or parking avoid a fire.
brake handle). 4. Remove all flammable debris in order to
5. Lowering all the implements to the ground reduce a fire hazard. Dispose all debris
and press the bucket downwards slightly. properly.
5. Turn the battery disconnect switch to the “O”
Turning off the Engine position.
6. If the machine is not filled with anti-freeze,
after the machine parks in winter, open all
water drain valves of the engine in time to
Do not turn off the engine when the machine discharge coolant in the cooling system and
is working with a load. Otherwise, the air conditioner system so as to prevent the
engine parts will be worn quickly due to machine from being cracked by frost. If the
overheating. machine has been filled with anti-freeze at
ex-factory, refer to the instructions of the anti-
freeze labels.
1. Let the engine run at idle speed for 5min to
cool down the parts. 7. Fix all covers, lock all equipment and remove
the key.
2. Turn the start switch of the engine to OFF
position and take out the key.
3. Turn all the switches to NEUTRAL or OFF
position.
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October 12, 2019 Operation Manual
CLG856H Transportation Information

Storage 2. Lubricate all moving pins and shafts.

3. Before starting the machine, wipe off grease
Before Storage from the hydraulic oil cylinder piston rod.

1. Clean and dry every part of the machine and

store it in a dry warehouse. If the machine
has to be stored in the open air, park the If the machine is not coated with antirust
machine on concrete ground and cover with additive per month during storage, consult
canvas. your LiuGong dealer.
2. Before storage, refill the oil tank, lubricate
every moving pin & shaft and change Transportation Information
hydraulic oil.
3. Paint a thin layer of grease on the exposed
parts of the hydraulic oil cylinder piston rod. Transportation of the Machine
4. Remove batteries from the machine and
store in a separate place.
5. If the air temperature is below 0°C, add anti-
freeze in cooling water of the engine until it Obey the correlative laws govern
reaches the engine body and evaporator of characteristics of the load (weight, width, and
the air conditioner. Drain out water in the length).
cooling system, also drain out water in the
evaporator of the air conditioner.
Investigate the travel route for overpass
During Storage clearances, Make sure that there will be
adequate clearance for the machine.
1. Start the machine once every month and run Clean ice, snow, or other slippery material from
every system, and lubricate every parts of the the loading dock and from the truck bed before
moving pins and shafts. Meanwhile, charge you load the machine onto the transport
the batteries. machine. This will prevent the machine from
2. Before starting the machine, wipe off grease slipping in transit. This will also prevent the
from the hydraulic oil cylinder piston rod. machine from moving during transportation.
After operation, paint a layer of grease on it.
3. Paint antirust additive on rusted parts.

To avoid personal injury or death, when

working with anti-freeze inside the room,
open the windows for ventilation.

Before Reuse

1. Change lubricant of the engine, transmission,

axles lubrication and hydraulic oil, brake oil
and anti-freeze of the engine.
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Operation Manual October 12, 2019
Transportation Information CLG856H

Perform loading according to the following 10. Turn the battery disconnect switch to the
steps: OFF position.
11. Chock the wheels of the machine and fasten
1. Chock the trailer wheels or the truck wheels
it with steel wires or chains to avoid
before you load the machine.
movement during transportation.

2. When the machine is loading on the trailer or

12. Cover the exhaust outlet to prevent the
truck, it is forbidden to turn.
turbocharger from rotating during
3. After the machine being parked, use the transportation. Damage to the turbocharger
steering frame lock to lock the front frame can result.
and the rear frame.
Driving the Machine

1. Before operating the machine, consult your

tire dealer for recommended tire pressure
and speed limitations.
2. Stop for 30 minutes after every 40km or after
every hour when driving the machine for a
long distance in order to cool down the tires.
3. Inflate the tires to the correct pressure. Refer
to the maintenance section for tire inflation
4. Lower the bucket to the floor of the trailer. information.
Turn the shift control lever to the NEUTRAL
position. 4. Travel at a moderate speed. Observe all
speed limitations when you drive the
5. Turn the pilot shutoff lever to OFF position (if machine.
equipped).
6. Push the pilot cut-off lever to the OFF
position (If equipped).
7. Engage the parking brake.
8. Stop the engine, turn every switch to
NEUTRAL or OFF position and remove the
key.
9. Lock the door and remove the key.
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October 12, 2019 Operation Manual
CLG856H Transportation Information

Lifting the Machine 6. The lifting decal can be seen on the front and
rear frame of the machine.

Improper lifting or securing could cause the

machine to move accidentally and cause
personnel injury or death. Install the steering
frame lock before lifting.

1. Lift the machine by professional personnel.

2. Calculate the maximum lift weight of the
crane and loading capacity of the lifting 7. Before lifting, secure the front and rear frame
device to ensure the lift safety. with the steering frame lock so that the
machine can not move.
3. Lift the machine by the lifting device with
frame to avoid damaging the machine. The
length and width of the frame are 2.5-4m and
1.8-2.2m. The 6.3t D type or bow shackle will
2
be preferred (reference standard: JB8112- 1
1999).

1. Pin
2. Steering frame lock
8. The lifting device should be fixed on the lift
eyes with lift decals on the machine.

4. The length of the four ropes on the lifting

device must be the same to ensure the four
lifting eyes share the same pressure.
5. Turn the battery disconnect switch to OFF
position.
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Operation Manual October 12, 2019
Transportation Information CLG856H

Towing Information

Towing the Machine

Before releasing the parking brake, chock the
wheel to prevent movement. Remove the
wedge before starting the machine.
Personal injury or death could result when 2. The towing machine should be equipped with
towing a disabled machine incorrectly. Chock protective guard to protect the towing
the wheels before disengage the brake to operator once the towing ropes or towing bar
prevent the machine from moving. cracks accidentally.
3. Do not allow riders on the machine that is
Do not tow the machine unless the loader has a being towed unless the operator can control
severe trouble. The machine can only be towed the steering wheel or the brake.
for a short distance for repair. Never tow the
machine for a long distance. The towing distance 4. Before you towing the machine, make sure
should not exceed 10Km and towing speed that the towing ropes or the towing bar are
should not exceed 10km/h; otherwise, the gear strong enough for towing the machine. The
box will be damaged due to insufficient towing ropes or towing bar must have a
lubrication. If the machine needs to be strength that is 1.5 times of the gross weight
transported for a long distance, a truck and trailer of the machine that is being towed.
should be used. 5. Do not use a chain for pulling. A chain link
may break. This can cause personal injury.
Do the following steps: Use a wire rope that has cable loops or end
rings. Position an observer at a safe location.
1. If the machine doesn’t move due to machine The observer should stop the pulling
brakes caused by an engine fault or a brake procedure if the cable starts to break or the
system fault. Remove the connecting shaft cable starts to loose. If the towing machine
between the parking brake flexible shaft and moves without the pulled machine, stop the
the parking brake rod to disengage the pulling procedure.
parking brake by force.
6. The minimum angle between the towing
ropes and straight direction should not
1 exceed 30°.
7. Quick machine movement could cause the
towing ropes or the towing bar overload. This
could cause the towing ropes or the towing
bar to break. A smooth machine movement
helps towing operation easier.
2 8. Normally, the towing machine should be as
large as the disabled machine. The towing
machine must have enough brake capacity,
weight, and power for the grade and distance
1. Parking brake handle that is involved.
2. Parking braker
9. During towing, all personnel should keep
away from the both sides of the towing ropes
so as to avoid injury caused by break.
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October 12, 2019 Operation Manual
CLG856H Transportation Information

10. It may be necessary to connect a large

machine or additional machine to the
disabled machine in order to provide
sufficient control and brake ability. This will
prevent the disabled machine from rolling
away on a downgrade.
11. When towing the disabled machine downhill,
to get enough control and brake ability, it is
necessary to connect a larger truck or
additional machine on the back to avoid a
rolling accident.
It is impossible to list all the requirements for all
different situations. Refer to liugong dealer for
more information of towing the disabled
machine.

Towing with a Running Engine

If the engine is running, the machine can be

towed for a short distance under certain
conditions. The power train and the steering
system must be operable. Tow the machine for a
short distance only. For example, pull the
machine out of mud or to the side of the road.
The operator on the towed machine must turn
the machine in the direction of the towing ropes.
Turn the shift control lever to NEUTRAL position,
lift all implements and strictly observe all the
instructions that are outlined in this topic.
94
Maintenance Manual October 12, 2019
Maintenance Guidance CLG856H

Maintenance Manual Maintenance Suggestions

1. Use only recommended fuels and lubricants.

2. Don't adjust the engine speed setting and/or
the hydraulic safety valve.
3. Protect electronic units from water and vapor.
Perform the maintenance procedures at the
intervals according to this manual. Proper 4. Do not disassemble electronic units such as
maintenance will extend the service life of the sensors etc.
machine and provide safer operation. 5. Use only recommended Liugong parts.

Cleanser of Windshield
Maintenance Guidance Clean the windshield with special windshield
cleanser and ensure no foreign matter mixes
Correct Maintenance Procedures with cleanser.

Learn how to maintain your machine correctly. Clean Engine Oil

Follow the instructions of this manual, if your
machine has troubles, you must maintain or Use clean engine oil and keep the engine oil
contact your dealer before operating. clean. Ensure no foreign matter mixes with the
engine oil.
Daily Checks
Check Discharged Oil or Used Filter Element
1. Check the gauges.
After replacing the oil or filter element, check the
2. Check the coolant, fuel and oil level.
discharged oil or filter element for iron particles
3. Check hoses and tubes for leakage, wear and foreign matter. If any iron particles or foreign
conditions and damage. matter is found, report this immediately and take
preventive measures.
4. Perform a walk-around inspection of the
machine.
Welding Cautions
5. Check for loose or missing parts.
1. Turn off the engine.
Check Service Hour Meter
2. Do not keep using voltage above 200V.
1. The service hour meter determines when 3. Keep the welding area and earth cables
your machine needs to be maintained. The within 1m. If the earth cable is close to
time in the maintenance table is basically gauges or connectors, failure could result.
given for normal operation. If the machine is
4. Protect the seals and bearings located
operated in severe conditions, you must
between the welding area and earth cables.
maintain the machine more frequently.
5. Never use the surrounding area of the work
Maintain Machine on Schedule implement pin or cylinder as an earthing
point.
Follow the maintenance methods listed in this
maintenance manual.
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October 12, 2019 Maintenance Manual
CLG856H Maintenance Guidance

Prevent Dropping Things into Machine 2. When installing hoses, do not twist or bend
Interior them. This will damage and shorten the
service life of the hoses.
1. When checking through an open window or
tank filler, be careful not to drop nuts, bolts or Proper Fuel and Lurbicant
tools into the machine interior. If anything is
dropped carelessly, take them out at once. Use proper fuel and lubricant that adapts to the
ambient temperature.
2. It is suggested not to take unnecessary items
with you in your pockets, take necessary
Check Electrical Wiring
tools only.

Dusty Environment

Pay attention to the following instructions when If a fuse is burnt out frequently or short-
working in dusty environments: circuited, find out the reason and repair or
1. Check the air filter indicator regularly to see contact your Liugong dealer for assistance.
whether it is blocked. Service the air filter
prior to the normal schedule. Keep the battery surface clean.
2. Wash the radiator core frequently. Clean and
replace the fuel filter periodically. 1. Check the fuse for damage. Check the circuit
for broken or shorted wires. Check the
3. Clean the electrical units, especially the terminals for loose connections and tighten
starter motor and alternator, to remove any loose parts.
accumulated dust.
2. Check the circuits of the battery, starter motor
Avoid Mixing Oil and alternator.
3. Contact your Liugong dealer for more
Do not use oils of different brands. If it is really information about the solutions.
needed, change the old oil prior to using the new
oil of another brand. Check Air Conditioner

Lock the covers Check the fan speed switch of the air
conditioning system to see if it is at NEUTRAL
If it is needed to service the machine with the position and the work mode switch is at the OFF
covers opened, lock the covers with the lock position. If not, turn them to the correct position.
lever.
Check Gauges
Purge Hydraulic System
Check the gauges, lighting, indicators, horn and
Purge the air from the hydraulic lines if the wipers for good condition. Contact your Liugong
hydraulic lines or components have been dealer if any problem is found.
repaired, replaced or removed.

Install Hydraulic Hoses

1. If components equipped with O-rings or Before starting the engine, make sure
gaskests need to be removed, clean the nobody is on or near the machine. Keep the
mounting surfaces. Do not forget to install machine controlled by the operator.
new O-rings and gaskets.
96
Maintenance Manual October 12, 2019
Run-in CLG856H

Preparation before Maintenance Run-in

Park the machine as follows before
maintenance: The run-in of new machine is an important
procedure for prolonging the service life of the
1. Park the machine on flat ground. machine, eliminating fault and avoiding
2. Lower the bucket to the ground. accidents. The user must read these guidelines
for run-in of a new machine and how to operate
3. Set the engine speed to idling speed and run
and maintain the machine after purchase.
it for 5 minutes.
4. Turn the start switch to OFF position and take Run-in-Requirements for a New Machine
out the key (If the machine needs to be
maintained with the engine running, make 1. Run-in of a new machine is 100 hours.
sure the machine is under control of the 2. Run the engine at idle speed for five minutes
operator). after starting the engine. Start the machine at
5. Push the pilot control lever to LOCK position. low speed. Slowly increase speed.
6. Attach a ''DO NOT OPERATE'' tag to right 3. Run-in should be done averagely in each
hand control lever if the machine is not forward or reverse gear.
operated.
4. Start the machine at low speed. Slowly
increase speed. Always avoid starting,
speeding up, turning and braking suddenly
except for emergency cases.
G
IN
N

5. It is better to load with loose material during

AR
W

er not
!

run-in period. Do not operate rushly and

e
at
do

exceed its rating load capacity and travel

op

speed by 70%.
r:
te
ra
pe
O

:
ate
D

6. Check the lubricant periodically. Replace or

add lubricant according to the recommended
period.
7. Always pay attention to the temperature of
the transmission, torque converter, front and
rear axles, wheel hub, parking brake, middle
shafts, hydraulic oil, engine coolant and
engine oil, if there is overheating, find out the
reason and eliminate it.
8. Check the tightness of all the bolts and nuts.

The following must be done after the first 8

hours of operation during the run-in period.

1. Check the tightness of all the bolts and nuts

especially the bolts of the engine cylinder
cover, exhaust pipe, front and rear axles,
drive shaft, diesel engine, transmission, front
and rear frames joint, and wheel rim nuts etc.
 97
October 12, 2019 Maintenance Manual
CLG856H Maintenance Interval Schedule

2. Check the tightness of the fan belt, engine Maintenance Interval

belt and air conditioner compressor belt.
Schedule
3. Check the oil level of the transmission, drive
axle and diesel engine.
4. Check the hydraulic system and brake
system for oil leakage.
5. Check the connections of all control levers, Read and understand all the safety
throttle linkage (if equipped) and flexible instructions, warnings and indications before
shaft. any operations or maintenance.
6. Check temperatures and connections of the
electrical system, power supply of the The maintenance intervals stated in this manual
alternator, lights and the turn signal lights. are determined according to the service hour
meter or calendar intervals shown (daily, weekly,
monthly, etc). Liugong recommends that
maintenance should be performed according to
Check oil level according to the relevant whichever of the above-mentioned intervals
operation regulations. occurs first.
Under extremely severe, dusty or wet operating
Work should be done after the finish of run-in conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart
1. Check the tightness of all the bolts and nuts may be necessary.
especially the bolts of the cylinder head, Perform service on items at multiples of the
exhaust pipe, front and rear axles, drive original requirement. For example, at every 500
shaft, diesel engine, transmission, front and service hours or 3 months, also service those
rear frames joint, and wheel rim nuts etc.. items listed under every 250 service hours or
2. Check the tightness of the fan belt, engine monthly, every 50 service hours or weekly and
belt and air conditioner compressor belt. every 10 service hours or daily.
3. Check the hydraulic system and brake Every 10 Service Hours or Every Day
system for oil leakage.
4. Replace the transmission oil and axle ● Check engine oil level.
lubricant. ● Check coolant level.
5. Replace the secondary filter and clean the ● Check hydraulic oil level.
primary filter of the transmission.
● Check fuel level.
6. Clean the return oil filter element of the
hydraulic oil tank. ● Drain any water and impurity from the fuel
pre-filter and filter of the engine.
● Daily inspection.
● Check the engine fan and belt.
Replace transmission oil, axle lubricant and
secondary filter of the transmission ● Check working condition of lights and
according to operation instructions. gauges.
● Check tire inflation pressure and look for tire
damage.
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Maintenance Manual October 12, 2019
Maintenance Interval Schedule CLG856H

● Check the working condition of the backup ● Check the lubrication condition of the
alarm (if equipped). lubricating points and lubricate every
lubricating point according to lubrication
● Lubricate every drive shaft according to
diagram on the machine. If the machine is
lubrication diagram on the machine.
equipped with central lubrication system, for
● Pull outward the manual water drain valve those manual lubricating points, pump
draw ring at the bottom of the air reservoir to grease by hand according to the lubrication
drain water of the air reservoir. If lots of diagram on the machine.
accumulated water occurrs in the air
● Check the oil level of the booster cup
reservoir, it indicates that the drying agent of
(suitable for the machine with air reservoir).
the air dryer installed in the front of the fuel
tank fails to work, replace the air dryer body ● Check nitrogen precharge pressure of the
timely (suitable for the machine with the air accumulators at the first 50 service hours
dryer). (suitable for the machine with accumulators).
● Push upward or pull outward the manual
water drain valve draw ring at the bottom of Every 100 Service Hours or Two Weeks
the air reservoir to drain water of the air
reservoir (suitable for the machine with group In addition to all previous service checks:
valve). ● Tighten all connecting bolts on drive shafts at
the first 100 service hours, tighten them
Every 50 Service Hours or Every Week every 2000 service hours later on.

In addition to all previous service checks: ● Replace transmission oil, the filter strainer
and seal ring of transmission oil filter (if
● Check the transmission oil level. equipped with ZF gearbox, replace the filter
● At the first 50 service hours, check the element and seal ring), and clean the primary
clearance between the parking brake shoe filter in the transmission oil sump at the first
and brake drum, adjust it if necessary; check 100 service hours, and doing once every
the wear condition of the friction disc, replace 1000 service hours later on. If the operating
it if it has been worn away, and exhaust air in hours are less than 1000 hours a year,
the clamp. Check once every 250 service replace the transmission oil at least once
hours later on (suitable for the machine with every year.
clamp). ● Replace gear oil of the axles after the first
● Check the oil level of the booster cup, the oil 100 service hours, replace once every 1000
level should align with the inner screen. service hours later on. If the operating hours
are less than 1000 hours a year, replace the
● For the machine equipped with air gear oil of the axles at least once every year.
conditioner, clean the dust and sundries from
the cab recirculating air strainer and fresh air ● Clean the engine cylinder head.
strainer. Wash them if it is necessary. Check ● Clean the radiator groups.
the compressor belt for tightness and check
the condenser for grease, dirt and sundries. ● Clean the filter strainer of the fuel tank.
● Check the oil level of the front and rear axles.
● Check nitrogen precharge pressure of the
accumulators at the first 100 service hours
(suitable for the machine with accumulators).
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October 12, 2019 Maintenance Manual
CLG856H Maintenance Interval Schedule

● At the first 50 service hours, replace engine Every 500 Service Hours or Three Months
oil and engine oil filter. Replace once every
500 service hours later on. In addition to all previous service checks:
● Check the density of anti-freeze and coolant
Every 250 Service Hours or Every Month
additives.
In addition to all previous service checks: ● Tighten connecting bolts of the front & rear
axles and front & rear frames.
● Check battery voltage.
● Check bolts on the articulation joint of the
● Check the tightening torque of the rim set
frame for loose condition.
bolts.
● Check the tightening torque of the ● Check nitrogen precharge pressure of the
transmission and engine mounting bolts. accumulators at the first 500 service hours
(suitable for the machine with accumulators).
● Check the work implement, and each stress
weld and mounting bolt of the front & rear ● Replace the return oil filter element of the
frames for cracks and looseness. hydraulic system at the first 500 service
hours. Replace the return oil filter element of
● Check the engine air intake system, air filter the hydraulic system once every 1500
service indicator or air filter alert indicator (if service hours later on.
equipped). If the yellow piston of the service
indicator rises to red area or the alert ● Replace the pilot oil filter element of the
indicator blinks, clean or replace the air filter hydraulic system at the first 500 service
element. hours. Replace the pilot oil filter element of
the hydraulic system once every 1500
● Check tension and wear conditions of the service hours later on (suitable for the
engine belt and air conditioner compressor machine with pilot oil filter element).
belts.
● Replace the oil suction filter element of the
● For the machine equipped with air hydraulic system at the first 500 service
conditioner, check the refrigerant in the hours. Replace the oil suction filter element
refrigerant receiver. of the hydraulic system once every 1500
● For the machine equipped with air service hours later on (suitable for the
conditioner, clean the fresh air strainer and machine with oil suction filter).
the recirculating air strainer of the cab. ● Replace the engine oil and engine oil filter.
● Check the service brake ability and parking Use high grade engine oil can prolong the
brake ability. engine oil replacement time. For details,
please contact LiuGong or engine
● Check the clearance between the parking manufacturer.
brake shoe and brake drum, adjust it if
necessary; check the wear condition of the ● Replace the fuel pre-filter of the engine.
friction disc, replace it if it has been worn ● Replace the fuel filter of the engine.
away, and exhaust air in the clamp (suitable
for the machine with clamp). ● Exhaust air in the clamp if the machine is
equipped with clamp.
● Check nitrogen precharge pressure of the
accumulators at the first 250 service hours Every 1000 Service Hours or Six Months
(suitable for the machine with accumulators).
In addition to all previous service checks:
● Adjust the engine valve lash.
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Maintenance Manual October 12, 2019
Maintenance Interval Schedule CLG856H

● Check the engine tensioner bearing and fan ● For the machine equipped with air
shaft housing. conditioner, check the refrigerant pipe and
water hose of the air conditioner for cracks,
● Replace transmission oil, the filter strainer
wear or foaming by oil. Check the connectors
and seal ring of transmission oil filter (if
and clamps for loose condition.
equipped with ZF gearbox, replace the filter
element and seal ring) and clean the primary ● For the machine equipped with air
filter in the transmission oil sump. conditioner, replace the recirculating air
strainer of the cab.
● Change gear oil of the drive axles.
● Check flexibility of the steering system.
● Clean the fuel tank.
● Tighten all connecting bolts on drive shafts.
● Tighten all mounting bolts of the battery and
clean the battery surface. ● Check the tightening torque of the
transmission mounting bolts.
● Check nitrogen precharge pressure of the
accumulators at the first 1000 service hours ● Check nitrogen precharge pressure of the
(suitable for the machine with accumulators). accumulators at the first 2000 service hours,
check the pressure every 2000 hours later on
● For the machine equipped with air
(suitable for the machine with accumulators).
conditioner, replace the fresh air strainer of
the cab.

Every 1500 Service Hours or Nine Months

In addition to all previous service checks:

● Replace the return oil filter element of the
hydraulic system.
● Replace the pilot oil filter element of the
hydraulic system (suitable for the machine
with pilot oil filter element).

Every 2000 Service Hours or Every Year

In addition to all previous service checks:

● Replace coolant, coolant filter (unsuitable to
the machine equipped with GCIC engine)
and clean the cooling system. If the operating
hours are less than specified, replace the
coolant at least every two years.
● Replace hydraulic oil, clean the hydraulic oil
tank and check the oil suction hose.
● Check the service brake system and parking
brake system. Remove and check the friction
disc for wear condition and replace if
necessary.
● Check airtight condition of the control valve
and work cylinder by measuring natural
sediment of the cylinder.
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October 12, 2019 Maintenance Manual
CLG856H General Torque Specifications

General Torque Specifications

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

Standard Torque lb.ft (N·m)

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

British System

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

1/4 9±3 (12±4)
5/16 18±5 (25±7)
3/8 33±5 (45±7)
7/16 52±11 (70±15)
1/2 74±11 (100±15)
9/16 110±15 (150±20)
5/8 148±18 (200±25)
3/4 266±37 (360±50)
7/8 420±59 (570±80)
1 645±74 (875±100)
102
Maintenance Manual October 12, 2019
Tire Inflation Information CLG856H

Tire Inflation Information Ply rating Front wheel Rear wheel

or inflation inflation
Tire size
strength pressure pressure
Liugong recommends the use of dry nitrogen for index kPa kPa
tire inflation and tire pressure adjustments. It
26.5-25 PR28 475~495 455~475
includes all machines with rubber tires. Nitrogen
is an inert gas that will not aid combustion inside 26.5R25 ★ 475~495 455~475
the tire. 29.5-25 PR28 425~445 405~425

The use of nitrogen for tire inflation can not only

29.5R25 ★★ 600~620 580~600

reduce the risk of explosion, but also help to 35/65-33 PR30 425~445 405~425
prevent oxidation, aging of the rubber, and The tire pressure will significantly change when
corrosion of the wheel rim parts. you drive the machine into freezing temperature
from a normal environment with a temperature of
18°C to 21°C (65 °F to 70 °F). If you inflate the
tire to the correct pressure under normal
Training for using the equipment is temperature, the tire will be under inflated in
necessary to avoid over inflation. A tire freezing temperature. Low pressure will shorten
blowout or a rim failure can cause personal the service life of the tires. Consult your Liugong
injury. Do not set the tire inflation equipment dealer when you are not sure about the tire
regulator higher than 140 kPa (20 psi) over inflation pressure.
the recommended tire pressure.

Check and adjust the tire inflation pressure after

the tire cools down completely. Ask all other
If the machine travels for a long distance at
persons to leave the danger area (around the
high speed, stop the machine for 30 minutes
rim).
each time when it has travelled for 45km so
The inflation pressure for nitrogen and air are the as to let the tires cool down.
same when charging the tires. Consult your tire
dealer for operating pressures.
See the following table for the tire inflation
pressure under normal temperatures.
Ply rating Front wheel Rear wheel
or inflation inflation
Tire size
strength pressure pressure
index kPa kPa
17.5-25 PR12 350~370 330~350
17.5-25 PR16 475~495 455~475
17.5R25 ★ 475~495 455~475
20.5-25 PR16 350~370 330~350
20.5-25 PR20 470~490 450~470
20.5R25 ★ 475~495 455~475
23.5-25 PR16 300~320 280~300
23.5-25 PR20 375~395 355~375
23.5-25 PR24 475~495 455~475
23.5R25 ★ 475~495 455~475
 103
October 12, 2019 Maintenance Manual
CLG856H Lubrication Specifications

Lubrication Specifications
Oil Change Interval and Refill Capacities

Care must be taken in order to ensure that fluids are contained during performance of
inspection, maintenance, testing, adjusting and repair of the equipment. Collect the fluid with
suitable containers before opening any compartment or disassembling any component. Obey
all local regulation for the disposal of liquids.
Approximate
Item Interval (service hours)
quantity(L)
Torque converter oil,
2000 35
transmission oil
Hydraulic oil 2000 225
Front axle oil 1000 44
Rear axle oil 1000 44
Engine oil 500 22
Cooling system 2000 42
Fuel / 260

Oil Specifications

Temperature
Type of oil Name of oil Position of use
(°C)
-35~10°C 0W-20 (API CH-4)
-35~30°C 0W-30 (API CH-4)
-35~40°C 0W-40 (API CH-4)
-30~30°C 5W-30 (API CH-4)
Engine oil For diesel engine
-30~50°C 5W-40 (API CH-4)
-20~40°C 10W-30 (API CH-4)
-20~50°C 10W-40 (API CH-4)
-10~50°C 15W-40 (API CH-4) ★
Above 4°C 0# ★
Above -5°C -10#
Fuel Above -14°C -20# For diesel engine
Above -29°C -35#
Above -44°C -50#
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Maintenance Manual October 12, 2019
Lubrication Specifications CLG856H

Temperature
Type of oil Name of oil Position of use
(°C)
-10~45°C ★ HM-46 anti-wear hydraulic oil
HV32 low temperature anti-wear For implement hydraulic
-20~35°C
Hydraulic oil hydraulic oil system & steering
HS32 extreme low temperature hydraulic system
-24~35°C antiwear
hydraulic oil
SAE 15W-40 Mobil 1300 (other oil
-15°C~50°C specifiacation refer to ZF List of
Transmisson lubricants TE-ML 05) For torque converter and
oil S4 TXM 10W-30 (other oil transmission
-30°C~50°C specifiacation refer to ZF List of
lubricants TE-ML 05)
★ ZF-POWERFLUID CPLUS、
MOBILFLUID 424 (other oil
specifiacation refer to ZF List of
Normal
lubricants TE-ML 05, which product
temperature,
application type is loader and the
extreme cold and
Gear oil product series is the oil grade allowed For bevel gear of axles and final drives
extreme hot
by AP3000. The oil recommeded in
working
the TE-ML 05 are suitable for all
conditions.
working conditions. Details please
refer to “Authorized Drive Axle Oil
Suppliers”. )
Refrigerant ★ R134a For A/C
Manual For roller bearings,
lubrication ★ 2# MOS2 lithium based grease bushings, pins, frame
pins, swing frame of rear
Grease
Centralized axle, drive shaft spline,
2# compound lithium based grease universal joint and water
lubrication
pump shaft etc.
Coolant Anti-freeze Recovery tank
 105
October 12, 2019 Maintenance Manual
CLG856H Lubrication Specifications

Do not mix oils of different brands even if they have the same specifications. Clean the system
before refilling the different oil.
If the machine is used at low temperature in severe cold areas for a long time, 46# low
temperature anti-wear hydraulic oil should be used, and ATF220 or DEXRON-III or Donax TC
transmission oil should be used.
Replace the lubricant periodically even though the lubricant is very clean because the lubricant
might go bad after a long time use.
Choose the fuel according to the lowest air temperature in the local area where the machine is
used.
Only the engine oil that meets the requirement of engine oil grade and engine oil viscidity grade
at the same time can be used on the engine.
106
Maintenance Manual October 12, 2019
Important Maintenance Procedures CLG856H

Important Maintenance Check all the lighting equipment and replace

cracked bulbs and glass if necessary.
Procedures
Check the cab and keep the cab tidy.
Check the instrument panels and indicators for
Daily Inspection damage. Replace damaged parts if necessary.
Check the seat belt, buckle and tighten the bolts.
Replace the worn or damaged parts if necessary.
Adjust the rearview mirrors and check the
Watch carefully for leakage. If you find window to ensure good vision for the driver.
leakage, service it. If you suspect leakage or Clean the windows if necessary.
observe leakage, check the fluid level more Turn on the start switch and check the instrument
frequently. if it alerts anomaly.

Check the engine compartment and clean the

accumulated sundries from it and the radiator.
Check the engine for damaged parts.
Check the axles, differential, wheel rim brakes
and transmission for leakage. Repair the leakage
point.

It is a normal phenomenon if there is a little

oil stain around the breather of the
transmission during machine operation.

Check the hydraulic oil tank, all of the tubes and

hoses, plugs, seals, connectors and grease
fittings for leakage. Repair the leakage and
replace the hose if necessary.
Check all of the implements and linkage for
cracks and damage.
Ensure that all doors, covers and shields are
securely attached. Check them for damage.
Check the ladder, walkway and handrail. Clear
away all the trash and repair or replace any
damaged part.
Check the air inlet and outlet of the evaporator in
the air conditioner. Clear away the cotton, paper,
plastic and film that can block the air inlet.
Check the ROPS for visible damage. Consult
your Liugong dealer for repair information if there
is damage.
 107
October 12, 2019 Maintenance Manual
CLG856H Important Maintenance Procedures

Engine System

Maintenance Table

Interval (Hours)
250hr
Item As 10hr or 50hr or 100hr 500hr 1000hr 2000hr
or
require every every or 2 or three or half or one
every
d day week weeks months a year year
month
Coolant level--Check
Coolant--Add
Coolant--Replace
Air filter service indicator--
check
Air filter main element--Clean/
Replace
Air filter safety element--
Replace
Fuel level--Check
Fuel--Add
Fuel tank--Clean
Fuel tank strainer--Clean
Water and impurity--Remove
Fuel pre-filter--Replace
Fuel filter--Replace
Engine oil level--Check
Engine oil--Replace ★★★
Enigne oil filter--Replace ★★★
Radiator group--Clean
Engine valve lash--Adjust
Air intake system--Check
Tensioner bearing and fan
hub--Check
Engine belt--Check
Belt tension--Check/Adjust

Note: ★ ★ ★ indicates the first service interval.

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Maintenance Manual October 12, 2019
Important Maintenance Procedures CLG856H

Coolant Level--Check

Check the cooling system of the engine for

Hot coolant can cause serious burns. To leakage if it needs to add coolant everyday.
open the cap, stop engine until the radiator If leakage is found, eliminate the leakage
cools down. Then loosen cap slowly to and add coolant until it reaches the proper
release the pressure. level.
Do not check coolant according to the
The coolant is in the radiator located at the rear recovery tank beside the water tank, check it
of the machine. only by the sight glass.
Anti-freeze density and coolant additive
density-check

Anti-freeze has been added into the

machine before leaving the factory which
can resist to - 30°C.

If the temperature is forecasted to drop below

Checking method for coolant level: 0°C (32° F), add anti-freeze suited to local
climatic conditions into coolant. If only anti-freeze
1. Open the engine hood, the coolant level sight concentrate is available, it is needed to mix it
glass is on the recovery tank. with soft water in a certain proportion. Refer to
the proportioning instruction for the mixing
proportion of anti-freeze concentrate.
Before adding anti-freeze, use refractometer to
measure the freezing point of the well mixed anti-
freeze accurately to ensure that the anti-freeze
adapt to the local lowest temperature. The mixed
anti-freeze by experience is just a general range,
the anti-freeze measured by refractometer is
accurate, which can effectively avoid frost
cracking and damage to the radiator and engine.
When replacing anti-freeze, use high quality anti-
2. Check the coolant sight glass on the freeze and follow the instructions for filling.
recovery tank. Add coolant if the coolant level
is lower than the centerline of the sight glass.

When adding anti-freeze, use the anti-freeze

of the same brand.
 109
October 12, 2019 Maintenance Manual
CLG856H Important Maintenance Procedures

Coolant must contain additive (DCA4 for GCIC Coolant--Add

engine, SCA for other engines) to prevent the
engine parts which contact with coolant from
rusting, scaling, pitting, and corrosion. Additive
(DCA4 for GCIC engine, SCA for other engines)
of low density doesn’t have effect, additive Hot coolant can cause serious burn. To open
(DCA4 for GCIC engine, SCA for other engines) cap, stop engine until radiator cools down.
of high density will have a negative impact on Then loosen cap slowly to release the
engine, it may result in water pump leakage and pressure.
corrosion of cooling system solder and aluminum
parts.
The density of coolant additive should be
maintained at about 3% (0.49-0.58 units/L for Anti-freeze is flammable. Never expose anti-
GCIC engine). Anti-freeze already contains freeze to an open fire. Never use water as
additive, but the additive will be consumed up the coolant otherwise it will cause corrosion
during running the engine. Therefore, check the damage to the cooling system.
coolant density every 500 work hours or six
months. Add additive by changing the coolant Water used in coolant must be soft water or
filter periodically. distilled water, because ordinary fresh water and
tap water contains a lot of calcium and
Refer to the Operation and Maintenance Manual
magnesium materials, which will cause scaling of
of Diesel Engine provided with the machine for
the cooling system radiator, engine and piping,
the additive density inspection method and
while excessive chlorine compounds and sulfate
detailed instructions.
will corrode the cooling system and engine
waterways. If there isn’t soft water or distilled
water, the quality of water used in coolant must
meet all of the requirements listed in the
following table, and the density level of each
element shall not exceed the permitted
maximum value in the following table.
Min. water quality requirement

Permitted max. content

Item
value
Calcium and
Max. content in (CaCO3 + MgCO3)
magnesium
is 170ppm
content (hardness)
Chlorine Max. content in (Cl) is 40ppm
Sulfur Max. content in (SO4) is 100ppm

If the temperature is forecasted to drop below

0°C (32° F), add anti-freeze suited to local
climatic conditions into coolant. If only anti-freeze
concentrate is available, it is needed to mix it
with soft water in a certain proportion. Refer to
the proportioning instruction for the mixing
proportion of anti-freeze concentrate.
110
Maintenance Manual October 12, 2019
Important Maintenance Procedures CLG856H

Since the heat absorption capacity of anti-freeze 5. Turn the manual valve on the water inlet hose
to the engine isn’t as good as water, add anti- of the engine to ON position. (The valve is at
freeze into the engine before thoroughly mixed ON as shown).
with water will cause overheat of the engine.
Before adding anti-freeze, use refractometer to
measure the freezing point of the well mixed anti-
freeze accurately to ensure that the anti-freeze
adapt to the local lowest temperature. The mixed
anti-freeze by experience is just a general range,
the anti-freeze measured by refractometer is
accurate, which can effectively avoid frost
cracking and damage to the radiator and engine.

Add coolant as follow:

6. Open the filler cap of the water radiator
1. Mix the water and coolant completely recovery tank, slowly add coolant until the
according to desired density level of the level reaches the filler cap of the recovery
coolant. As the endothermic performance of tank and keeps stable within 10 minutes.
the anti-freeze is worse than water, adding
antifreeze into the engine before completely
mixed with water will cause overheat of the
engine.
2. Turn on the battery disconnect switch.

关
OFF ON
开

When adding coolant, exhaust air from the

cooling system lines of the engine.
3. Insert the key into the start switch and turn
clockwise to the ON position to turn on the 7. Keep the radiator filler cap open, start the
power of the machine. engine and run at idle speed for 5-10
4. Turn the selector switch of the air conditioner minutes, and at high speed for 5-10 minutes.
to WARM position. 8. Run the engine at idle speed and check the
coolant level again. Add coolant if necessary.

Close the radiator filler cap before stopping

the engine, or coolant will spray out from
the filler.
 111
October 12, 2019 Maintenance Manual
CLG856H Important Maintenance Procedures

9. Check the radiator filler cap for good Completely replace the coolant every 2000
condition, replace it if damaged. service hours or one year (which ever comes
first) and clean the cooling system. Clean the
cooling system before that interval if the coolant
is polluted, the engine is running excessively hot
Do not add coolant when the engine or bubbles appear in the radiator.
temperature is high, otherwise this could When coolant is polluted, engine overheated or
cause damage to the engine. Add coolant bubbles appeared in radiator, test the freezing
only after the coolant temperature is below point of the additive and anti-freeze in the cooling
50°C. system to determine whether the coolant must
be replaced, replace the coolant if it exceeds any
Coolant--Replace permitted limit value in the coolant replacement
limit table.
Coolant replacement limit table

Pollutants Permitted limit value

Hot coolant can cause serious burn. To open
Sulfate (SO4) Max. 1500ppm
cap, stop engine until radiator cools down.
Then loosen cap slowly to release the Chloride (Cl) fluoride,
Max. 200ppm
bromide
pressure.
Engine oil or fuel Coolant shall not contain
Anti-freeze might hurt the skin, when pollution engine oil or fuel
replacing it, wear goggles and protective pH value Min. 6.5 (see Note ★ )
clothing to avoid personal injury.
Grease, solder ,
Coolant shall not contain these
silicone, corrosion or
pollutants.
scaling

Care must be taken in order to ensure that Note ★ : The replacement limit of the min. pH value may
fluids are contained during performance of change with the product changes. Consult the product
manufacturer for the pH value limit. The pH value less
inspection, maintenance, testing, adjusting than 6.5 is unacceptable generally.
and repair of the equipment. Prepare to
collect the fluid with suitable containers Steps for cleaning the cooling system
before disassembling any hydraulic oil lines.
Obey all local regulation for the disposal of 1. Turn on the disconnect switch.
liquids.
If the cooling system failed to be cleaned
关

thoroughly, the new coolant may be polluted 开

during adding, and result in the cooling

system and engine failure.
关
Do not mixed use multiple brands of coolant, OFF ON
开
otherwise the consequent cooling system
and engine failures are not covered by
warranty.

2. Insert the start switch key and turn clockwise

to the ON position to turn on the power of the
machine.
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3. Turn on the warm air switch of the air 7. Turn on the water drain valve on the left side
conditioner. of the engine to drain out coolant of the
engine and collect with a container.
4. Turn the manual valve on the water inlet hose
of the engine to ON position (The valve is at
ON as shown).

1. Water drain valve

8. After draining out coolant, turn off the water
5. Start and run the engine at idle speed for drain valve on the left of the engine.
5~10 minutes, then stop the engine. Turn the
start switch to the first position to turn on 9. Check all water lines and clamps of the
power of the machine. Open the water cooling system for damage, replace if
solenoid valve of the air conditioner. necessary. Check water radiator for leakage,
damage and piled-up trash, clean and repair
6. Slowly screw out the water radiator filler cap if necessary.
to release pressure after the coolant
temperature is below 50°C. 10. Add cleanser mixed with water and sodium
carbonate into the cooling system of the
engine, its proportion is 0.5 kilograms of
sodium carbonate against 23 liters of water.
The level should reach normal level of the
engine and keep stable within 10~15
minutes.

When adding cleanser into the cooling

system, exhaust air from cooling system
lines of the engine. During cleaning of the
cooling system, never cover the water
radiator filler cap of the recovery tank while
running the engine.
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11. Keep the water radiator filler cap open, start Air Filter Service Indicator--Check
the engine, when the coolant temperature
reaches over 80°C, run the engine for 5~10 The service indicator is located on the air filter.
minutes again. Service indicator

If the coolant temperature can not reach

80°C, use a hardboard to cover the water
radiator filler cap of the recovery tank.

12. Stop the engine, drain out cleanser.

13. Add clean water into cooling system of the
engine until it reaches normal level and
keeps stasble within 10 minutes. keep the
water radiator filler cap open, start the
engine, when the coolant temperature 1. Shut down the engine and open the engine
reaches over 80°C, run the engine for 5~10 hood to access the service indicator of the air
minutes again. filter.

14. Stop the engine, drain out water in the 2. Stop the manchine and service the air filter
cooling system. If the drained water is still exo-element if the intake resistance indicator
dirty, clean the system again until the drained (mechanical) alerts (rises to the red zone).
water gets clean. When equipped with electronic intake
resistance indicator, the engine intake air
15. Replace with a new coolant filter, close all filter alert indicator should be observed from
drain plugs, then add new coolant according the instrument panel of the cab. When the
to the operation rules previously described in indicator lamp is on, stop the the manchine
section “Coolant--Add”. and service the air filter exo-element.

The coolant of the engine is poisonous and

impotable. Dispose of it according to the
local laws and regulations.
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Main Filter Element of the Air Filter 5. Clean the inner wall of the air filter housing.
--Clean/ Replace

If the engine air filter alert indicator on the

instrument panel is on, then maintain the
engine air filter.
6. Clean the main filter element with
1. Stop the engine and open the engine hood. compressed air (below 300kPa) from inside
2. Remove outer cover of the air filter. to outside.

It is not allowed to clean the main element

from outside to inside with compressed air.
Do not use oil or water to clean the main
element.
Do not hit the main element when cleaning it.
Otherwise the engine could be damaged.

3. Take out the main filter element along with

the housing direction.

7. After cleaning the main filter element, check

with a bulb, if small holes and particles as
well as damage of the washer and seal are
found, replace with a new main filter element.
4. Check the main filter element.
a) Replace the main filter element if any
damage is found to pleats and gaskets.
b) Clean the main filter element if it is not
damaged.
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8. Install a clean main filter element into the air 2. Remove the outer cap of the air filter.
filter and ensure an even contact with the
housing.
9. Clean and install the cap of the air filter, make
sure that the inner cap gasket in the air filter
contacts evenly with the air filter housing.

The main element should be replaced after

being cleaned for 4-5 times. It is forbidden to
remove the safety element when servicing
the main element. 3. Remove the main filter element along with
the housing direction.
10. Close the engine hood.

Air Filter Safety Element--Replace

Replace the main filter element and safety

filter element at the same time. Always
replace the safety filter element with a new
one. Never use again after cleaning.

1. Stop the engine and open the engine hood, 4. Remove the safety filter element.
then can see the air filter.
5. Cover the air inlet. Clean the inside wall of
the air filter.

6. Check the gasket between the air inlet tube

and the air filter housing. Replace with a new
one if it is damaged.
7. Open the air inlet. Install a new safety filter
element, make sure the seal ring on the top
of the safety filter element contacts evenly.
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8. Install a new main filter element and install Fuel--Add

the outer cap of the air filter. Tighten the clip
to secure the cap of the air filter housing.
9. Close the engine hood.
It is forbidden to smoke when adding fuel.
Keep any flames or sparks away.
Fuel Level--Check
The fuel tank of the machine is located at the
The fuel level gauge is on the cab instrument rear end of the machine and under the radiator .
panel. It has two zones. “no.3” indicates the high Open the engine hood to access the fuel filler of
fuel level. “no.1” indicates the low fuel level. Add the fuel tank. .
fuel in time when the fuel level is lower than
“no.2”.
If the fuel level is lower than “no.2”, ensure
enough time for the operator to add fuel.

1. Stop the engine.

2. Pull up the lock plate of the cap. Rotate the
cap counterclockwise to next position and
move the cap outward to take off the oil filler
cap.

Don’t take out the strainer of the oil filler

when adding fuel.
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3. Add fuel. 2. Remove the flange cover in front of the fuel

tank. Wash the inner surface of the tank with
clean fuel.

1 2
Do not take out the strainer of the fuel filler
when adding fuel. 1. Flange cover
2. Drain plug
Fuel Tank--Clean 3. Remove the drain plug to drain out the
residual fuel.
4. Repeat washing until the drained fuel is
clean.
Care must be taken to ensure that fluids are
contained during performance of
inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
collect the fluid with suitable containers
before disassembling any component
containing fluids. Dispose of all fluids
according to local regulations.
No smoking and keep away from the flames
or spark area when cleaning the fuel tank.

1. Stop the engine.

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Fuel Strainer--Clean 5. After completing daily work, loosen the water

drain plugs of fuel pre-filter (fuel water
1. Stop the engine. separator) to drain out water and impurity.
2. Remove the fuel filler cap of the fuel tank.
Check the gaskets for damage. Replace the
gaskets if damaged.
3. Take out and check the fuel strainer. Replace
if damaged.
4. Wash the fuel filler and fuel strainer with
clean and nonflammable detergent. Dry them
in the air or by compressed air. 1 2
5. Install the fuel filler cap and strainer.

Water and Impurity--Remove 1. Fuel pre-filter (Fuel water separator)

2. Fuel filter
The fuel pump and fuel injection nozzle are
precision devices, if fuel is mixed with water or
impurity, the fuel pump and fuel injection nozzle
can't work properly and quickly worn. Measures
should be taken to remove water and impurity in Add the fuel in time. Any residual fuel at the
fuel. bottom of the fuel tank that contains water
and impurity will affect the normal running
1. If the condition is permitted, fuel should be of the engine. Drain and clean fuel tank
deposited for 24 hours before it is filled to the before adding.
tank.
2. Before filling, screw out the drain plug at the
bottom of the fuel tank to drain out water and
impurity deposited in the tank once every
week.
3. After completing daily work, add fuel and
remove the humid air in the fuel tank.
4. After replenishing the fuel tank every time,
wait for 5 ~ 10 minutes before starting the
engine so that water and impurity have sunk
to the bottom of the tank.
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Fuel Pre-filter--Replace 4. Check the gasket, replace if damaged.

5. Install a new fuel pre-filter to the support.
The fuel pre-filter is located on the right side of
the engine. Open the engine hood to get access
to it.

Do not fill with fuel before the fuel pre-filter

is installed. Fuel contamination will quicken
damage of the fuel system parts.

Fuel Filter--Replace

The fuel filter is located on the right side of the

engine.

1. First clean the fuel pre-filter surroundings and

the support.
2. Remove the fuel pre-filter from the support
with a wrench.

1. First clean the fuel filter surroundings and the

support.
2. Remove the fuel filter from the support with a
wrench.

3. Remove the gasket on the thread connector

of the support. Clean the seal surface of the
support with a non-fibrous cloth.

3. Clean the fuel filter surroundings and the

support. Make sure that all old gaskets are
removed.

1. Gasket
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4. Install a new gasket on the thread connector Engine Oil Level--Check

of the support of the fuel filter. Apply a coat of
engine oil on the seal surface of the filter. Fill
the fuel filter with clean fuel.

Too much or too little engine oil can result in

damage to the engine.

1. Drive the machine to flat ground, stop the

engine and engage the parking brake.
2. After stopping the engine, wait for 10 minutes
to let the engine oil in the crankcase return to
the engine oil pan.
3. Open the engine hood, the engine oil filler
and the engine oil dipstick are located on the
5. Install the filter to the support by hand. After right side of the engine.
the gasket of the filter contacts with the
support, continue to tighten 1/2 ~ 3/4 turns.
Do not over tighten the filter with the wrench
to avoid damaging the filter.
2

1. Engine oil filler

2. Engine oil dipstick
4. Take out the dipstick. Wipe it with a clean
cloth and completely reinsert the dipstick into
the end of the oil level of the engine. Take the
dipstick out again and check the oil level. The
Do not fill with fuel before the fuel filter is oil level on the dipstick should be between
installed. Fuel contamination will quicken the low (L) and high (H) graduation marks.
damage of the fuel system parts. 5. If the oil level is below L, add oil. If the oil
level is above the H, screw out the oil drain
plug at the bottom of the engine oil pan to
release some oil.
6. Reinsert the the oil dipstick and close the
engine hood.
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Engine Oil--Replace 4. Tighten the oil drain plug.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any component containing
fluids or dismounting any hydraulic lines.
Dispose of all fluids according to local
regulations. 5. Add clean engine oil to the oil filler of the
engine until the engine oil is at H on the oil
dipstick. Run the engine at idle speed to
check the engine oil filter and oil drain plug
High-temperature lubricant can cause for leakage.
personal injury. Replace the lubricant only 6. Stop the engine and wait for about 10
when the lubricant is warm and the impurity minutes, let the engine oil fully return to the
is floating. oil pan, check the engine oil level again, if
insufficient, add engine oil to the H on the
1. Park the machine on flat ground, start the dipstick.
engine and run until the water temperature
reaches 60°C.
2. Stop the engine and engage the parking
brake.
3. Loosen the engine oil drain plug at the
bottom of the oil pan to drain the oil into a
suitable container.

Within 15 seconds after the engine has been

started, check the reading of engine oil
pressure gauge. If no reading is found, shut
down the engine immediately to protect the
engine. Check to see if the engine oil level is
correct.
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Engine Oil Filter--Replace 5. Install a new O-ring, replenish the oil filter
with clean engine oil, and apply a coat of
The engine oil filter is located at the left side of clean engine oil on the gasket surface.
the engine.

1. Open the engine hood. Fill the filter with clean engine oil before the
2. Clean the area around the support of the engine oil filter is installed. If an empty
engine oil filter. engine oil filter is installed, the engine could
be damaged due to a lack of lubricant.
3. Remove the engine oil filter with a belt
spanner and check it. 6. Secure the engine oil filter on the support and
tighten the gasket of the engine oil filter until
4. Clean the surface of the gasket of the
it contacts with the support. Tighten engine
support with a clean cloth. If old O-ring
oil filter according to the specified
adheres to the support, remove it.
requirements with the spanner.
7. Close the engine hood.
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Radiator Group--Clean Engine Air Intake System--Check

1. Open the engine hood to get access to the Check the air intake system for cracked hoses,
radiator group. loose clamps or holes. Tighten or replace the
parts to ensure the sealability of the air intake
system.

Engine Tensioner Bearing and Fan Hub

--Check

Check the tensioner to ensure it can turn freely.

Check the fan hub, it should rotate without any
wobble or excessive clearance.

2. Remove the dust and debris on the radiator Engine Belt--Check

group by compressed air.
Check the belt of the engine by sight for cracked
surfaces.
If the belt cracks lengthways or if flaking material
falls off, replace it with a new belt. For more
information about the replacing procedure, refer
to the Operation and Maintenance Manual of the
Engine.

Fan Belt Tension--Check/Adjust

For more information on fan belt adjustment

procedures, refer to the Operator and
Maintenance Manual of the Engine.

Reduce the compressed air pressure when

cleaning. Keep any bystander away and use
protective devices to avoid being hurt. Loose fan belt could cause improper battery
charging, engine heating and rapid
Engine Valve Lash--Adjust abnormal belt wear problems. But an over
tightened fan belt will cause damage to both
bearings and the belt .

Adjustment of the engine valve lash must be

performed by trained personnel with special
tools.

For more information about the adjusting

procedure of the engine valve lash, refer to the
Operation and Maintenance Manual of the
Engine.
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Power Train System

Maintenance Table

Interval (Hours)

Item 10hr or 50hr or 100hr 250hr 500hr 1000hr 2000hr

As
every every or 2 or every or three or half or one
required
day week weeks month months a year year
Transmission oil level--Check
Transmission oil--Replace ★★★
Transmission secondary filter--
Replace ★★★

Transmission primary filter--

Clean ★★★

Drive axle gear oil level--Check

Drive axle gear oil--Replace ★★★
Transmission mounting thread
torque--Check ★★★

Drive shaft hitch bolt--Check ★★★

Note: ★ ★ ★ indicates the first service interval.
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Transmission Oil Level--Check Check transmission oil level:

1. Park the machine on flat ground.

2. Turn the shift control lever to NEUTRAL
position, engage the parking brake to avoid
Stop the machine on flat ground when movement of the machine.
checking the oil level. Turn the shift control
lever to NEUTRAL position, engage the 3. Check the transmission cold oil level when
parking brake and install the steering frame the engine runs at idle speed for 1~2 minutes
lock to avoid movement of the machine. and the transmission oil temperature reaches
25~40°C. The oil level should between "MIN"
and "MAX" of the sight glass (it is suggested
Check the transmission oil level every 50 service
that the oil level should be in the middle of
hours or once a week to ensure enough oil.
"MIN" and "MAX")(as show in the below
The transmission oil filler is located at the right figure).
side of the articulation joint.

Pay close attention to cleanliness when

2
checking the transmission oil level and
replacing transmission oil and filter. Do not
let impurity enter the transmission system
to avoid damage to the transmission.

The operating method to raise the

transmission oil temperature quickly when
checking the transmission hot oil level:
1. Transmission oil filler pipe
2. Oil dispick 1. Park the machine on flat ground.
2. Turn the shift control lever to NEUTRAL,
press the parking brake button to disengage
parking brake.
When checking the transmission oil level,
3. Depress the service brake pedal completely.
always separately check cold oil level and
hot oil level. Too high or too low oil level of 4. Turn the shift control lever to F4, then the
the transmission could result in damage to torque converter is under stall condition, the
the transmission, make sure the oil level of transmission oil temperature will raise fast.
the transmission is at proper level.
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5. After the transmission oil temperature 4. Loosen the oil drain plug under the torque
reaches 80°C~90°C, turn the shift control converter oil radiator and collect with a
lever to NEUTRAL again, engage the parking container. Loose the air release plug of the
brake. Then check the hot oil level of the torque converter oil radiator to quicken oil
transmission. release speed.

Transmission Oil--Replace

Care must be taken to ensure that fluids are

contained during performance of
inspection, maintenance, testing, adjusting
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any hydraulic lines or
component containing fluids. And dispose
all fluids according to local regulations.

Replace the transmission oil at the first 100

hours. Replace the transmission oil every 1000 Drain out the oil in transmission, torque
service hours or at least once a year later on. converter and radiator simultaneously.
1. Park the machine on flat ground and turn the 5. Clean any iron filings attached on the drain
shift control lever to NEUTRAL. Engage the plug by the magnet, and clean the iron filings
parking brake and attach the steering frame on the inner wall of the transmission.
lock to the front and rear frames to avoid
6. Secure the transmission oil drain plug and oil
movement of the machine.
drain plug under the torque converter oil
2. Start the engine and run at idle speed for 3~5 radiator and corresponding seals.
minutes. Stop the engine.
7. Loosen the oil filling plug above the torque
3. Loosen the oil drain plug at the bottom of the converter oil radiator. Add clean transmission
transmission to drain oil. Collect oil with an oil from the oil filler of the torque converter oil
appropriate container. radiator. After the radiator is fully filled with
transmission oil, tighten the air release plug
and oil filling plug.
8. Loosen the transmission oil filler cap, add
Because the transmission oil temperature is clean transmission oil from the oil filler. The
still high when draining, wear protective transmission oil level should be at the limited
clothing and be careful to prevent injury. top level of the oil level switch.
9. Start the engine and stop it after running for
about 5 minutes, and then turn on the oil
level switch. Check the oil level, the level
should be between the limited top level and
the lowest level of the oil level switch. If the
oil is insufficient, add oil. If the oil is
excessive, drain some excessive oil.
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10. Tighten the oil filler cap clockwise. 2. Clean any iron filings attached on the drain
plug by the magnet. Insert the magnet into
the transmission oil pan from the primary
filter mounting port. Clean the iron filings on
the inner wall of the primary filter.
Before replacing transmission oil, cover the
parking brake by cloth to prevent the friction 3. Secure the primary filter, oil suction pipe,
disc from touching with oil to ensure the drain plug and oil drain plug of the torque
parking brake performance. converter oil radiator and seals.

Transmission Oil Filter--Replace Replace secondary filter as follows:

The secondary filter of the transmission is

located in the box on the right side of the
machine. See the following picture.
Care must be taken to ensure that fluids are
contained during performance of
inspection, maintenance, testing, adjusting
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any hydraulic lines or
component containing fluids. And dispose
all fluids according to local regulations.

Replace the primary filter as follows:

1. Remove the oil suction pipe on the rear right

side of the transmission. Take the primary
filter out. Clean it with compressed air or fuel.
Install the primary filter after it is dried in the
sun.

3
1

1. Clean the surface around the transmission

secondary filter.
1. Oil drain plug 2. Remove the secondary filter from the support
2. Transmission primary filter
3. Oil suction pipe with a wrench.
3. Clean the seal surface of the support with a
clean cloth.
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4. Coat the gasket of the new secondary filter 4. Tighten the oil drain plug.
with transmission oil.
5. Install the secondary filter on the support until
the gasket contacts with the seal surface of
the support and then manually further tighten
it by 1/3 or 1/2 turn.

ispose of the transmission oil that drained

from the transmission oil sump properly to
avoid polluting the environment.
5. Check the oil level of another axle according
Axle Oil Level--Check (LiuGong Axle) to the previous operation steps.

Check the axle oil level at every 250 hours or Axle Oil--Replace (LiuGong Axle)
once a month in order to ensure enough oil.
Replace the axle oil after the first 100 service
hours. Replace the axle oil every 1000 service
hours at least once a year later on.
Be careful of the splashing hot oil when
adding, draining, or loosening the plug.

As the drain plug on the wheel end of the front

Care must be taken to ensure that fluids are
and rear axles could not be at the level position
contained during the performance of
at the same time, so check the oil level of the
inspection, maintenance, testing, adjusting
front and rear axles separately.
and repair of the product. Be prepared to
1. Park the machine on level ground, slowly collect the fluid with suitable containers
drive the machine at low speed to keep the before disassembling any hydraulic line or
drain plug on one wheel end of the axle at component containing fluids. Dispose of all
level position. fluids according to local regulations. Drain oil
after the machine runs for a period of time to
2. Turn the shift control lever to NEUTRAL
let the impurities deposited in the oil
position, engage the parking brake to prevent
suspend.
movement of the machine and stop the
engine. Because the oil drain plugs on both wheel ends
3. Remove the oil drain plug on this wheel end of the front and rear axles could not be at the
of the axle to check the oil level. The inner lowest position at the same time, therefore,
axle oil level should be at the lower edge of replace oil of the front and rear axles separately.
the oil drain outlet. If the oil level is lower than
the lower edge of the oil drain outlet, refill
with clean axle oil. Observe for about 5
minutes after adding until the oil keeps
stable.
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1. Drive the machine for a while to let the 4. Tighten the oil drain plug on the wheel end of
settling impurities in the axle suspend fully. front axle and the oil drain plug in the middle
Park the machine on level ground. Slowly of the axle.
operate the machine to locate the oil drain
5. Start the engine, disengage the parking
plug on one wheel end of the front axle at the
brake. Turn the shift control lever to the first
lowest position. Because the oil drain plugs
gear, and slowly operate the machine to
on both wheel ends could not be at the
locate the oil drain plug on the other wheel
lowest position at the same time, so drain oil
end of the front axle at the lowest position.
of the axle separately.
Then turn the shift control lever to NEUTRAL
position, engage the parking brake and stop
the engine.
6. Loosen the oil drain plug on the wheel end of
the front axle and the oil drain plug in the
middle of the axle to drain oil, and collect with
a container.
1 7. Tighten the oil drain plug on the wheel end of
front axle and the oil drain plug in the middle
of the axle.
2. Turn the shift control lever to NEUTRAL
position, engage the parking brake to prevent 8. Add clean axle oil from the oil filler in the
movement of the machine and stop the middle of the axle until the oil flows over the
engine. oil filler. Observe for about 5 minutes after
adding, the oil level should keep stable, and
3. Loosen the oil drain plug on the wheel end of then tighten the oil drain plug of the oil filler.
the front axle and the oil drain plug in the
middle of the axle to drain oil, and collect with 9. Start the engine, disengage the parking
a container. brake. Turn the shift control lever to the first
gear, and slowly drive the machine to keep
the oil level auxiliary line on one wheel end of
the front axle at level position, and the oil
drain plug should be above the oil level
auxiliary line at the same time. Then turn the
shift control lever to NEUTRAL position,
engage the parking brake and stop the
engine.

1 22

1. Oil filler
2. Oil drain outlet

Because the axle oil temperature is still hot 10. Add clean axle oil to the oil drain outlet on
when draining, wear protective clothing and this wheel end of the axle until the oil flows
be careful to prevent injury. over the oil filler. Observe for about 5 minutes
after refilling, the oil level should keep stable.
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11. Tighten the oil drain plug on this wheel end of

the axle.
12. Add axle oil to the oil drain outlet on the other
wheel end of the front axle according to the
above operation steps.
13. Refer to the section “Lubrication
Specifications” for axle oil refill capacity. But
in the actual operation, add axle oil until the
oil flows over the oil filler as mentioned in
above operation steps.
14. Replace the rear drive axle oil according to
the previous operation steps.

Drive Axle Oil Suppliers

The Great Wall Hydraulic Drive Brake Oil is

certified by ZF Company in China and provided
by Lubricatiing Oil Branch og China
Petrochemical Co. ltd.
Details of foreign lubricating oil suppliers certified
by ZF Company are given in the following
attached table.
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Authorized Drive Axle Oil Suppliers

Lubricant class 05C

Gear oil with limited-slip-additives

Viscosity grades: SAE 75W-90 / 75W-110 / 75W-140 / 80W-90 / 80W-110 / 80W-140 / 85W-90 / 85W-
110 /85W-140 / 90
ZF
Manufacturer （05C） Trade name （05C） approval
number
ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL GETRIEBEÖL GH 85W-90 LS ZF000629
ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL GETRIEBEÖL GH 80W-90 LS ZF000703
ARAL AG, BOCHUM/DE ARAL GETRIEBEÖL BS-LSX 75W-140 ZF000140
ARAL AG, BOCHUM/DE ARAL GETRIEBEÖL HYP LS 85W-90 ZF000465
AVISTA OIL REFINING & TRADING DEUTSCHLAN, PENNASOL LIMITED SLIP HYPOID GEAR
ZF000844
UETZE/DE OIL LS SAE 90
BAYWA AG MÜNCHEN, MÜNCHEN/DE TECTROL MULTIGEAR LS 90 ZF001167
BELGIN MADENI YAGLAR TIC. VE SAN. A.S.,
BELGEAR LS 85W90 ZF002257
KOCAELI/TR
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UNIVERSAL LS SAE 90 ZF000727
CASTROL SYNTRAX LIMITED SLIP 75W-
CASTROL LTD, LONDON/GB ZF000269
140
CASTROL LTD, LONDON/GB CASTROL AXLE Z LIMITED SLIP 90 ZF000307
CASTROL LTD, LONDON/GB CASTROL AXLE Z LIMITED SLIP 85W-90 ZF002044
CASTROL TRANSMAX LIMITED SLIP LL
CASTROL LTD, LONDON/GB ZF002141
75W-140
CASTROL TRANSMAX LIMITED SLIP Z
CASTROL LTD, LONDON/GB ZF002178
85W-90
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES CEPSA AURIGA LS PLUS 80W-90 ZF001050
CHEVRON LUBRICANTS, SAN RAMON, CA/US GEAR OIL ZF SAE 80W-90 ZF000787
CHEVRON LUBRICANTS, SAN RAMON, CA/US GEARTEX LS 80W-90 ZF000809
CHEVRON LUBRICANTS, SAN RAMON, CA/US GEARTEX LS 85W-90 ZF000810
CHEVRON LUBRICANTS, SAN RAMON, CA/US GEARTEX LS SAE 85W-140 ZF001686
CLASS KGAA MBH, HARSEWINKEL/DE CLAAS AGRISHIFT BLS 90 ZF001287
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBILUBE LS 85W-90 ZF000031
EXXONMOBIL CORPORATION, HOUSTON, TX/US GEARLUBE VS 500 ZF000851
FINKE MINERALÖLWERK GMBH, 27374
AVIATICON HYPOID LS 90 ZF002301
VISSELHÖVEDE/DE
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN GEAR LS SAE 90 ZF000651
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU G-TRUCK LS 80W-90 ZF000558
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU G-TRUCK LS 85W-140 ZF000561
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU G-TRUCK LS 85W-90 ZF000937
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GEORG OEST MINERALÖLWERK GMBH & CO.KG,

OEST GETRIEBEÖL HYPOID LS 90 ZF001479
FREUDENSTADT/DE
GRUPA LOTOS S.A., GDANSK/PL LOTOS TITANIS LS GL-5 80W-90 ZF000924
GRUPA LOTOS S.A., GDANSK/PL LOTOS TITANIS LS GL-5 SAE 85W-140 ZF001135
GS CALTEX CORPORATION, SEOUL/KR DOOSAN LS GEAR OIL 80W90 ZF001341
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR LS 90 ZF000891
HINDUSTAN PETROLEUM CORPORATION LTD.,
HP GEAR OIL ZFL 80W 90 LS ZF001578
MUMBAI/IN
INA MAZIVA LTD., ZAGREB/HR INA HIPENOL GTL LS 90 ZF000424
INDIAN OIL CORPORATION LTD, MUMBAI/IN SERVO GEAR SUPER LS 90 ZF001445
INDIAN OIL CORPORATION LTD, MUMBAI/IN SERVO GEAR SUPER LS 80W-90 ZF001450
JOHN DEERE GL-5 GEAR LUBRICANT W/
JOHN DEERE, MOLINE, ILLINOIS/US ZF001312
LS ADD 80W-90
JOHN DEERE GL-5 GEAR LUBRICANT W/
JOHN DEERE, MOLINE, ILLINOIS/US ZF001313
LS ADD 85W-140
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT,
Q8 T 45 LS SAE 90 ZF002109
ANTWERP/NL
LIEBHERR HYDRAULIKBAGGER GMBH,
LIEBHERR GEAR BASIC 90 LS ZF000845
KIRCHDORF/DE
LIQUI MOLY HYPOID-GETRIEBEÖL PLUS
LIQUI MOLY GMBH, ULM/DE ZF001367
GL 5 LS 85W-90
MEGOL HYPOID-GETRIEBEOEL AXLE LS
MEGUIN GMBH & CO. KG, SAARLOUIS/DE ZF001345
SAE 85W-90
MOL-LUB KFT, ALMASFUZITO/HU MOL HYKOMOL LS 85W140 ZF001075
MOL-LUB KFT, ALMASFUZITO/HU MOL HYKOMOL LS 85W90 ZF001114
MORRIS LUBRICANTS, SHREWSBURY/GB TERRAIN LS 80W-90 ZF001637
NORTHLAND PRODUCTS COMPANY, WATERLOO,
POSI-GRIP JDZF 80W90 ZF000049
IOWA/US
NORTHLAND PRODUCTS COMPANY, WATERLOO,
POSI-GRIP JDZF 85W140 ZF000051
IOWA/US
NOVA STILMOIL SPA, MODENA/IT GEARING WONDER LS SAE 85W90 ZF000918
OILFINO MINERALÖL GMBH, PRISDORF/DE OILFINO VARIUS G 400LS 85W-90 ZF000740
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION LS TM-5 80W-90 ZF001497
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION LS 85W-90 ZF001761
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR LS 80W-90 ZF000603
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM AGRO LS 80W-90 ZF001272
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR LS 85W-140 ZF001459
PAKELO MOTOR OIL, SAN BONIFACIO (VR)/IT UNIVERSAL GEAR EP LS SAE 85W/90 ZF000027
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY LS 90 ZF000396
PETROGAL S.A., LISBOA/PT GALP LS 90 ZF000775
PETROL OFISI A.S., ISTANBUL/TR MAXIGEAR EP-X 85W-90LS ZF001480
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA AXF 80W-90 (SAE 80W-90) ZF000546
KUALA LUMPUR/MY
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PETRONAS LUBRICANTS INTERNATIONAL SDN BH,

AKCELA AXLEPOWER (SAE 80W-90) ZF000781
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AKROS AXLEGEAR 80W-90 (SAE 80W-90) ZF000782
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, TUTELA TRANSMISSION W90/LS (SAE
ZF000901
KUALA LUMPUR/MY 80W-90)
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
ARBOR TTF (SAE 80W-90) ZF001373
KUALA LUMPUR/MY
PHI OIL GMBH, ST. GEORGEN/AT SUPERGEAR BRONZE 85W90 LS ZF001004
PTT PUBLIC COMPANY LIMITED, BANGKOK/TH PTT LIMITED SLIP (SAE 80W-90) ZF000013
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH,
RAVENOL SPERRDIFF.-GETR.-OEL LS 90 ZF001180
WERTHER/DE
REPSOL LUBRICANTES Y ESPECIALIDADES, S.A, REPSOL CARTAGO EP AUTOBLOCANTE
ZF000981
MADRID/ES SAE 80W90
RN-LUBRICANTS, LLC, MOSCOW/RU TNK TRANS GIPOID LS 80W-90 ZF000761
RN-LUBRICANTS, LLC, MOSCOW/RU TNK TRANS GIPOID LS 85W-90 ZF000791
SASOL DIFFERENTIAL OIL LIMITED SLIP
SASOL OIL, RANDBURG/ZA ZF000700
80W-90
SAVSOL AUTOGEAR 85W140 LIMITED
SAVITA OIL TECHNOLOGIES LIMITED, MUMBAI/IN ZF001857
SLIP GL5
SAVITA OIL TECHNOLOGIES LIMITED, MUMBAI/IN SAVSOL AUTOGEAR 90 LIMITED SLIP GL-5 ZF001898
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S3 ALS 80W-90 ZF001303
LONDON/GB
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL ZLS GL-5 85W/90 ZF000127
SK LUBRICANTS, SEOUL/KR SK ZIC G-5 LSD 80W-90 ZF003340
SRS SCHMIERSTOFF VERTRIEB GMBH,
SRS WIOLIN RSH ZF000442
SALZBERGEN/DE
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS DA 80W-90 ZF001255
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS DA 85W-140 ZF001512
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS LS 80W-90 ZF001545
TOTAL LUBRIFIANTS S.A., NANTERRE/FR ELF TRACTELF BLS 80W-90 ZF001546
TOTAL LUBRIFIANTS S.A., NANTERRE/FR GULF LS REAR AXLE 80W-90 ZF001548
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS DA 80W-90 ZF002309
UNIL OPAL, SAUMUR/FR GEAR AB-EP 85W90 ZF000526
VALVOLINE CUMMINS PVT LIMITED, GURGAON/IN GEAR DURA 80W90 LS ZF001465
VALVOLINE HEAVY DUTY AXLE OIL PRO
VALVOLINE EUROPE, DORDRECHT/NL ZF001996
80W-90 LS
YACCO SAS, ST PIERRE LES ELBEUF/FR BVX LS 200 80W-90 ZF001614
Lubricant class 05F

Universal axle and transmission oil

ZF
Manufacturer （05F） Trade name （05F） approval
number
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Important Maintenance Procedures CLG856H

ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL UTTO SAE 10W-30 ZF000509
ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL UTTO EXTRA (SAE 20W-40) ZF001845
ARAL AG, BOCHUM/DE ARAL FLUID HGS ZF000457
AVIA MINERALÖL-AG, MÜNCHEN/DE AVIA HYDROFLUID TD ZF001811
BAYWA AG MÜNCHEN, MÜNCHEN/DE TECTROL UTTO-ZF ZF001161
BAYWA AG MÜNCHEN, MÜNCHEN/DE TECTROL UTTO-HF ZF002193
BP VANELLUS AGRI SUPER
BP PLC., LONDON/GB ZF000210
TRANSMISSION 80W
BP PLC., LONDON/GB BP TRACTRAN TF-10 ZF000897
BP VANELLUS AGRI SUPER
BP PLC., LONDON/GB ZF002161
TRANSMISSION 80W
BUCHER AG LANGENTHAL, LANGENTHAL/CH FARMER POLY 304 ZF000590
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UTTO CF ZF001158
CASTROL LTD, LONDON/GB CASTROL AGRI TRANS PLUS CVT 80W ZF000302
CASTROL LTD, LONDON/GB CASTROL AGRI TRANS PLUS 80W ZF000759
CASTROL LTD, LONDON/GB CASTROL AGRI TRANS PLUS 10W-30 ZF000950
CASTROL TRANSMAX AGRI TRANS PLUS
CASTROL LTD, LONDON/GB ZF002188
80W
CATERPILLAR, INC., MOSSVILLE/US CAT MULTIPURPOSE TRACTOR OIL ZF000834
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES CEPSA AURIGA TE 55 10W-30 ZF001200
CHEVRON LUBRICANTS, SAN RAMON, CA/US CHEVRON 1000 THF ZF000100
CHEVRON LUBRICANTS, SAN RAMON, CA/US TEXTRAN TDH PREMIUM ZF000820
CLASS KGAA MBH, HARSEWINKEL/DE CLAAS AGRISHIFT GA 12 ZF001289
DEUTSCHE ÖLWERKE LUBMIN, LUBMIN/DE AVENO UTTO ZF001687
EUROL B.V., NJIVERDAL/NL EUROL HYKROL JD 68 ZF001971
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBILFLUID 424 ZF000040
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBILFLUID 426 ZF000061
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN UTTO ZF (SAE 20W-40) ZF000661
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN AGRIFARM UTTO MP ZF002183
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN AGRIFARM UTTO MP ZF002184
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU G-SPECIAL UTTO 10W-30 ZF002211
GB LUBRICANTS, GATESHEAD/GB GB UNITRANS(R) ZF ZF000870
GS CALTEX CORPORATION, SEOUL/KR DOOSAN AXLE OIL STANDARD ZF001995
GULF OIL INTERNATIONAL, MUMBAI/IN GULF MPTF 10W-30 ZF000921
GULF OIL INTERNATIONAL, MUMBAI/IN GULF MPTF 10W-30 ZF000922
HYUNDAI OILBANK CO., LTD., SEOUL/KR XTEER THF 75W-80 ZF002219
IGOL FRANCE, AMIENS/FR TICMA FLUID MU XTREM ZF001336
INA MAZIVA LTD., ZAGREB/HR INA TRANSHIDROL JD 50 ZF000400
INA MAZIVA LTD., ZAGREB/HR INA TRANSHIDROL ZF 20W-40 ZF000433
INA MAZIVA LTD., ZAGREB/HR INA TRANSHIDROL JD 50 ZF000613
JCB INDIA, BALLABGARH/IN JCB REAR AXLE OIL ZF001502
JOHN DEERE, MOLINE, ILLINOIS/US JOHN DEERE HY-GARD ZF001223
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KUWAIT PETROLEUM INTERNATIONAL LUBRICANT,

Q8 T 2000 ZF000177
ANTWERP/NL
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT,
JCB HP GEAR OIL PLUS ZF001636
ANTWERP/NL
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT,
Q8 T 2200 ZF002042
ANTWERP/NL
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT,
JCB HP GEAR OIL PLUS ZF002096
ANTWERP/NL
LIEBHERR HYDRAULIKBAGGER GMBH,
LIEBHERR GEAR MF 80W ZF001856
KIRCHDORF/DE
LIQUI MOLY GMBH, ULM/DE LIQUI MOLY SPECIAL UTTO ZF001368
MEGOL TRAKTORENOEL UTTO PREMIUM
MEGUIN GMBH & CO. KG, SAARLOUIS/DE ZF001344
SAE 10W-30
OBNINSKORGSINTEZ, OBNINSK/RU RW DRIVE FORCE UTTO SAE 10W-30 ZF003350
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL VERSO PLUS ZF002295
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL VERSO LVX ZF002303
OPET FUCHS MADENI YAG. SAN. VE TIC. A.S.,
OPET FULLGEAR FD 80W-140 ZF001866
IZMIR/TR
PAKELO MOTOR OIL, SAN BONIFACIO (VR)/IT UTTO FLUID 4 D SAE 10W/30 ZF001276
PANOLIN AG, MADETSWIL/CH PANOLIN JD 303 ZF000414
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE
LUBRAX UNITRACTOR SAE 10W-30 ZF001366
CAXIAS/BR
PETROGAL S.A., LISBOA/PT GALP TRALUB 807 S ZF000849
PETROL OFISI A.S., ISTANBUL/TR MAXITRAK TMS OIL 500 ZF001351
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA MULTI G (SAE 10W-30) ZF000544
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA MULTI G (SAE 10W-30) ZF000545
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA MULTI G (SAE 10W-30) ZF000551
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA TRX 20W-40 (SAE 20W-40) ZF000658
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA TRX 80W-140 (SAE 80W-140) ZF000660
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
ARBOR TRW 140 SPECIAL (SAE 80W-140) ZF000942
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, AKCELA TRANSAXLE FLUID 20W-40 (SAE
ZF000943
KUALA LUMPUR/MY 20W-40)
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, AKCELA TRANSAXLE FLUID 80W-140 (SAE
ZF000944
KUALA LUMPUR/MY 80W-140)
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, AKCELA TRANSAXLE FLUID 80W-140 (SAE
ZF001045
KUALA LUMPUR/MY 80W-140)
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AKCELA TRANSAXLE FLUID 20W-40 ZF001184
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA MULTI G (SAE 10W-30) ZF001409
KUALA LUMPUR/MY
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Important Maintenance Procedures CLG856H

PETRONAS LUBRICANTS INTERNATIONAL SDN BH,

ARBOR MTF (SAE 10W-30) ZF001461
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AKCELA NEXPLORE (SAE 10W-30) ZF001634
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AKCELA NEXPLORE (SAE 10W-30) ZF001838
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA MULTI G (SAE 10W-30) ZF002075
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AKCELA NEXPLORE (SAE 10W-30) ZF002092
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
ARBOR MTF (SAE 10W-30) ZF002093
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA TRX 80W-140 (SAE 80W-140) ZF002138
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, AKCELA TRANSAXLE FLUID 80W-140 (SAE
ZF002139
KUALA LUMPUR/MY 80W-140)
PETRONAS LUBRICANTS INTERNATIONAL SDN BH,
AMBRA TRX 20W-40 (SAE 20W-40) ZF002151
KUALA LUMPUR/MY
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, AKCELA TRANSAXLE FLUID 20W-40 (SAE
ZF002152
KUALA LUMPUR/MY 20W-40)
PHI OIL GMBH, ST. GEORGEN/AT GEAR OIL UTTO SILVER 10W-30 ZF000958
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH,
RAVENOL GETRIEBEOEL UTTO ZF001718
WERTHER/DE
SAME DEAUTZ FAHR, TREVIGLIO/IT SDF UTTO ZF002229
SAME DEAUTZ FAHR, TREVIGLIO/IT DF UTTO ZF002230
SASOL OIL, RANDBURG/ZA UNIVERSAL TRANSMISSION OIL 68 ZF000707
SASOL UNIVERSAL TRANSMISSION OIL
SASOL OIL, RANDBURG/ZA ZF001828
RS 68
SAVITA OIL TECHNOLOGIES LIMITED, MUMBAI/IN SAVSOL 315 HAT ZF001131
SEANON PETROCHEMICAL CO.,LTD., LIUZHOU, SEANON DEDICATED TRANSMISSION OIL
ZF001959
GUANGXI/CN 10W-30
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S4 TXM ZF000357
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S4 TXM ZF000358
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S4 TXM ZF000359
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S6 TXME ZF001295
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S4 TXM ZF001613
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP. LTD,
SHELL SPIRAX S4 TXM ZF003325
LONDON/GB
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL UTTO ZF000105
SRS SCHMIERSTOFF VERTRIEB GMBH,
SRS HYDROFLUID N ZF000827
SALZBERGEN/DE
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TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS MPV ZF000540

TOTAL LUBRIFIANTS S.A., NANTERRE/FR ELF TRACTELF BF 16 ZF001317
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS LS 20W-40 ZF001346
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS MPWB ZF001539
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL DYNATRANS MPX ZF002222
UNIL OPAL, SAUMUR/FR FLUID VO ZF000366
VALVOLINE CUMMINS PVT LIMITED, GURGAON/IN VALVOLINE UTF PREMIUM ZF002218
VALVOLINE EUROPE, DORDRECHT/NL UNITRAC 80W ZF002041
Lubricant class 05G

Premium universal axle and transmission oil

ZF
Manufacturer （05G） Trade name （05G） approval
number

SINOPEC LUBRICANT CO., LTD., BEIJING/ SINOPEC GREATWALL HD DRIVE ZF002162

CN AXLE OIL
ZF FRIEDRICHSHAFEN AG, ZF-POWERFLUID PLUS ZF001021
FRIEDRICHSHAFEN/DE
ZF FRIEDRICHSHAFEN AG, ZF-POWERFLUID C-PLUS ZF002087
FRIEDRICHSHAFEN/DE
Lubricant class 05H

Biodegradable lubricants

Viscosity grade: SAE 75W-80

Instructions on the use of biodegradable lubricants:

The oil manufacturer´s change-over directives included in the product description are to be
observed when changeover to biodegradable lubricants is effected.
ZF
Manufacturer （05H） Trade name （05H） approval
number

PANOLIN AG, MADETSWIL/CH PANOLIN BIOFLUID LS ZF001206

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Important Maintenance Procedures CLG856H

Hydraulic System

Maintenance Table

Interval (Hours)
Item As 10hr or 500hr or 1000hr or 1500hr or 2000hr or
required every day three months half a year nine months one year
Hydraulic oil level--Check
Hydraulic oil--Add
Hydraulic oil--Replace
Serious polluted hydraulic oil-
-Replace
Hydraulic oil tank breather
filter--Clean
Return oil filter element--
Replace ★★★

Hydraulic oil tank--Clean

Note: ★ ★ ★ indicates the first service interval.
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Hydraulic Oil Level--Check

Sight glass
1. Ensure that the hydraulic oil tank, hydraulic
lines, radiator and other hydraulic parts are
full of hydraulic oil before checking the
hydraulic oil level.
2. Park the machine on level ground. The front
and rear frames must be aligned in a straight
line.
3. Tilt the bucket backward to limit position,
raise the boom to the highest position by full
engine speed.
4. Let the engine run at idle speed, push the 6. Add hydraulic oil if the oil level is lower than
pilot control lever to lower the boom to the MIN line. And check the hydraulic oil level
lowest position at constant speed, and lower again according to the above method.
the bucket onto ground. Stop the engine and
take off the start switch key, push the pilot Hydraulic Oil--Add
control lever forward and backward, left and
right to release pressure. Hydraulic oil tank

5. Check the sight glass of the hydraulic oil tank 1. Unscrew the breather filter cap of the
when there aren’t bubbles. The hydraulic oil hydraulic oil tank to release the pressure.
level should be within green range of MAX Take off the oil filler cap.
line and MIN line of the sight glass.

2. Refill the hydraulic oil tank and check the

sight glass. The hydraulic oil level should be
within range of MAX line and MIN line of the
sight glass.
3. Install the oil filler cap.
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Hydraulic Oil--Replace 4. Push the bucket control lever forward to let

the bucket tilt forward by its deadweight, and
discharge the hydraulic oil in the tilting
cylinder. After the bucket tilts to the limit
position, push the boom control lever forward
Care must be taken to ensure that fluids are to let the boom lower by its deadweight, and
contained during performance of discharge the hydraulic oil in the boom
inspection, maintenance, testing, adjusting cylinder.
and repair of the product. Be prepared to 5. Clean the oil drain outlet below the hydraulic
collect the fluid with suitable containers oil tank, loosen the oil drain plug to drain out
before disassembling any hydraulic line or the hydraulic oil and collect with a container.
component containing fluids. Dispose of all
fluids according to local regulations. Oil drain plug

Pay close attention to the cleanliness when

replacing the hydraulic oil, do not allow dirt
enter the hydraulic system.

1. Park the machine on flat ground, push the

shift control lever to NEUTRAL position, pull
up the parking brake button (parking brake
handle) and install the steering frame lock.

6. Meanwhile, open the breather filter cap (oil

filler cap) of the hydraulic oil tank to quicken
the oil discharging speed.

Because the hydraulic oil temperature is still

high when draining, wear protective clothing
and be careful to prevent injury.
2. Start and run the engine at idle speed for 10
minutes. Operate the boom and tilt the 7. Remove the oil inlet hose of the hydraulic oil
bucket repeatedly to raise the hydraulic oil cooler and drain residual hydraulic oil from
temperature. the cooler.

3. Raise the boom to the highest position, tilt 8. Remove the end cap of the return oil filter
the bucket backward to the limit position, and from the hydraulic oil tank, take out the return
stop the engine. oil filter element and replace with a new one.
9. If the hydraulic oil tank is equipped with a
suction oil filter element, remove the element
and replace with a new one.
10. Open the breather filter cap (oil filler cap),
take out the strainer.
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11. Wash the breather filter cap (oil filler cap), Serious Polluted Hydraulic Oil--Replace
strainer and oil drain plug with nonflammable
detergent. Dry them in the air or with
compressed air.
12. Install the oil drain plug, return oil filter,
strainer, breather filter cap (oil filler cap), and Care must be taken to ensure that fluids are
oil inlet pipe of the hydraulic oil cooler. contained during performance of
inspection, maintenance, testing, adjusting
13. Refill the hydraulic oil tank from the hydraulic and repair of the product. Be prepared to
oil filler until the oil level reaches the upper collect the fluid with suitable containers
graduation of the sight glass. Tighten the before disassembling any component
breather filter cap(oil filler cap) after finishing. containing fluids or dismounting any
14. Remove the steering frame lock and start the hydraulic line. Dispose of all fluids
engine. Operate the work implement control according to local regulations.
lever to raise and lower the boom for 2~3 Pay close attention to the cleanliness when
times. Tilt the bucket forward and backward replacing the hydraulic oil, do not allow dirt
and turn from left to right to the maximum enter the hydraulic system.
angle to fill cylinders with hydraulic oil. Then
run the engine at idle speed for five minutes
1. Park the machine on flat ground, push the
to drain air in the system.
shift control lever to NEUTRAL position, pull
15. Stop the engine. Open the hydraulic oil filler up the parking brake button (parking brake
cap. Refill the hydraulic oil tank. handle) and install the steering frame lock.

2. Start and run the engine at idle speed for 10

minutes. Operate the boom and tilt the
bucket repeatedly to raise the hydraulic oil
temperature.
3. Raise the boom to the highest position, tilt
the bucket backward to the limit position, and
stop the engine.
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4. Push the bucket control lever forward to let Breather Filter of Hydraulic Oil Tank
the bucket tilt forward by its deadweight, and --Clean
discharge the hydraulic oil in the tilting
cylinder. After the bucket tilts to the limit The breather filter is located in the oil filler of the
position, push the boom control lever forward hydraulic oil tank.
to let the boom lower by its deadweight, and
discharge the hydraulic oil in the boom
cylinder.
5. Loosen the oil drain plug to drain out
hydraulic oil and collect with a container.
Meanwhile, open the breather filter cap(oil
filler cap) of the hydraulic oil tank to quicken
the oil discharging speed.
Oil drain plug

1. Pull up the lock plate of the breather filter

cap. Rotate the cap counterclockwise to next
position and move the cap outward to take off
the cap. Unscrew the mounting bolt then
take out the filter element.

Because the hydraulic oil temperature is still

high when draining, wear protective clothing
and be careful to prevent injury.

6. Disconnect one end of the oil inlet pipe to

drain the residual hydraulic oil from the 2. Wash the breather filter with clean and
steering cylinder, oil cooler and other pipes. nonflammable detergent. Dry it in the air or
7. After finish draining, install the oil drain plug with compressed air.
and all the disconnected pipes. 3. Install the breather filter element and the cap.
8. Open the breather filter cap (oil filler cap) of
the hydraulic oil tank and fill with clean oil to
proper level.
9. Replace the polluted hydraulic oil according
to the procedures described in section
"Hydraulic Oil--Replace". Replace the return
oil filter element, suction oil filter element (if
equipped), and wash the breather filter cap
(oil filler cap) and hydraulic oil tank.
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Return Oil Filter Element of Hydraulic Hydraulic Oil Tank--Clean

Oil Tank--Replace

Replace the return oil filter element at first 500

service hours, replace it every 1500 service
hours later on. Replace the return oil filter Care must be taken to ensure that fluids are
element in advance if the working condition is contained during performance of
very bad. inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
1. Loosen the oil drain plug to drain out
hydraulic oil and collect with a container. collect the fluid with suitable containers
before disassembling any component
Hydraulic oil drain plug containing fluids or dismounting any
hydraulic line. Dispose of all fluids
according to local regulations.

1. Stop the engine.

2. Unscrew the oil drain plug at the bottom of
the hydraulic oil tank to drain hydraulic oil.
Collect with a container.
Hydraulic oil drain plug

2. Remove return oil filter flange and O-ring,

take out the oil suction filter element.
Return oil filter flange

3. Remove the return oil filter cap, take out the

oil filter element and O-ring.

3. Replace with a new return oil filter element

and O-ring. Install the return oil filter flange
and oil drain plug. 1

1. Return oil filter cap

2. Oil tank opening cap
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4. Remove the oil tank opening cap and sealing

gasket.
5. Wash the bottom and four walls of the
hydraulic oil tank with fuel through the oil Check accumulator nitrogen precharge
suction filter and the oil tank opening cap and pressure according to the intervals
dry with a clean cloth. specified in maintenance interval schedule
section to ensure the proper working of the
6. Wash the bottom and four walls of the service brake system and parking brake
hydraulic oil tank with hydraulic oil again. system. Checking of the precharge pressure
7. Install the sesaling gasket and opening cap should only be done by trained personnel
of the oil tank. with special tools only.

8. Install the oil drain plug, a new return oil filter 1. Park the machine on flat and open ground,
element, a new O-ring and return oil filter and lower the bucket on the ground. Turn the
cap. shift control lever to NEUTRAL, stop the
engine.
Pre-charge Pressure of Pilot Oil Supply 2. Move the pilot control lever to any directions
Valve Accumulator--Check continuously to discharge the high pressure
oil inside the accumulator.
Check the accumulator pre-charge pressure at
the first 50, 100, 250, 500, 1000 service hours of
operation. Check once every 2000 services
hours later on.
Do not let the residual pressure oil in the
The accumulator for pilot oil supply valve is accumulator spray any one as this can
located at the right side of the machine, under cause injury or death.
the cab. Open the side door to get access to it.
3. Remove the protection cap of the charge
valve from the accumulator.
4. Tighten the valve A (rightwards) on the
accumulator charge tool, turn off the valve B
then tighten the cap of valve C. Install the
charge tool to the charge valve of the
accumulator with slotted nut D.

A. Valve
B. Exhaust valve
C. Anti-return valve
D. Slotted nut
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5. Slowly open the valve A on the charge tool 3. Remove the protection cap of the charge
(leftwards), the reading available on the valve from the accumulator.
pressure gauge is the pre-pressure of the
accumulation. The reading should be
1.0± 0.05MPa.
6. Add nitrogen if the pressure is low; if the
pressure is higher than expected, adjust the
exhaust valve B to get the desired pressure
reading.
7. Turn off the valve A on the charge tool
(rightwards), and then remove the charge
tool from the accumulator. Install the
protection cap of the charge valve.

Accumulator of Pilot Oil Supply Valve-- 4. Tighten the valve A (rightward) on the
Charge accumulator charge tool, turn off the valve B
then tighten the cap of valve C. Install the
charge tool to the charge valve of the
accumulator with slotted nut D.

If nitrogen pre-pressure of the accumulators

is insufficient, refill in time, otherwise the
normal use of the pilot oil supply valve could
be affected.

Charge the accumulator by trained personnel

with special tools only.

1. Park the machine on flat ground and lay the 5. Take off the cap of anti-return valve C.
bucket flatly on the ground. Place the shift Connect a hose with one end of it and the
control lever to NEUTRAL position and shut another end to the nitrogen bottle.
down the engine.
6. Open the nitrogen bottle valve. Slowly open
2. Move the work implement lever to any the valve A (leftward) to charge the
directions continuously to discharge the high accumulator after the pointer of the pressure
pressure oil inside the accumulator. gauge is stable.
7. The inflated pressure may be obtained in a
short period. Turn off the nitrogen bottle valve
to check whether the pressure on the gauge
Do not let the residual pressure oil in the have reached 1.0± 0.05MPa. Recharge if the
accumulator spray any one as this can pressure is not sufficient and adjust exhaust
cause injury or death. valve B on the charge tool to lower the
pressure to appropriate value if the pressure
is too high.
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8. If the desired pressure is available, turn off 2. Start and drive the machine at 32km/h.
the nitrogen bottle valve then take off the Perform spot braking, the machine should
valve A on the charge tool. Remove the stop immediately without deflection.
charge tool.
If the brake distance exceeds 15m, consult your
9. Apply a coat of engine oil to the top of the Liugong dealer for brake system checking.
charge valve to check if any leakage occurs. Eliminate the problems before going on working.
There is a leak if air bubbles are found.
Consult your LiuGong dealer to eliminate the Parking Brake Performance--Inspect
fault.
10. Install the protection cap of the charge valve
on the accumulator.
Check the parking brake performance
frequently to ensure the machine can safely
stop and ensure its emergency braking
When removing the protection cap of the capability.
charging valve, do not rotate the steering
wheel and ensure the engine has been 1. Adjust the air pressure of the machine tires to
stopped to avoid personnel injury. the specified value, lay the bucket flatly with
Charge the accumulator with nitrogen only. a distance about 300mm above the ground.
Do not charge it with oxygen, compressed air Make sure the service brake is performing
or other flammable gas to avoid explosion. normally.
2. Start the engine and drive the machine to a
Brake System slope with a gradient of 20% (the angle is
about 11°18'). The slope surface should be
smooth and dry.
Service Brake Performance--Inspect

Before checking the service brake ability,

make sure the machine's parking brake
system works normally in case of any 11°18’
emergency.

3. Depress the service brake pedal to stop the

Check the service brake performance of the
machine. Turn the shift control lever to
machine on hard, dry and flat road surface. Make
NEUTRAL position, and do not stop the
sure no personnel or obstacles are around when
engine.
checking. Fasten the seat belt before checking.
4. Engage the parking brake and slowly release
1. Start and drive the machine at 32km/h.
the service brake pedal. Check to see if the
Depress the service brake pedal to fully
machine has moved from its original location.
brake the machine. After the machine stops,
turn the shift control lever to NEUTRAL,
engage the parking brake then release the
service brake pedal. The brake distance
should not exceed 15m.
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If the machine moves while checking, consult 2. Press the parking brake button to disengage
your LiuGong dealer for brake system checking. the parking brake.
Eliminate the problems before going on working.

Personal injury can result if the machine

moves while checking.

Parking Brake Clearance--Check/Adjust

3. Use a clearance gauge to measure the

clearance between the brake shoe and brake
drum. The clearance should be within the
Check and adjust the parking brake clearance range of 0.15~0.22mm.
after the brake cools down.
1
2
Check the parking brake clearance at the first 50
hours, then check it every 250 hours later on to
ensure good braking ability.
3
The parking brake is located at the front side of
the output shaft of the transmission.

2
4

1. Adjusting rod
2. Brake shoe
3. Brake drum
4. Brake shoe friction disc
4. If the clearance is beyond 0.15~0.22 mm,
rotate the adjusting rod to adjust the
clearance between the brake shoe and brake
drum.
1. Park the machine on flat ground, stop the
5. If the clearance still can not meet the
engine and install the steering frame lock.
requirement after adjusting by the rod,
replace the friction plates of the brake shoe.
6. Operate the parking brake button repeatedly
to check the parking brake ability by stopping
the machine on a slope.
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Parking Brake and Service Brake

Accumulator Pre-charge Pressure
--Check

Check the accumulator pre-charge pressure at Check accumulator nitrogen precharge

the first 50, 100, 250, 500, 1000 service hours of pressure according to the intervals specified
operation. Check once every 2000 services in Maintenance Interval Schedule section to
hours later on. ensure the proper working of the service
brake system and parking brake system.
The accumulator assembly is located on the right Checking of the pre-charge pressure should
side of the rear frame. Open the side door to get only be done by trained personnel with
access to it. It mainly includes service brake special tools only.
accumulator and parking brake accumulator.
From front to back, there is the service brake 1. Park the machine on flat and open ground,
accumulator BR1( rear axle), service brake and lower the bucket on the ground. Turn the
accumulator BR2( front axle) and parking brake shift control lever to NEUTRAL, stop the
accumulator BR3 respectively. engine. Then turn the start switch clockwise
to the I position to turn on power.
2. Continuously depress the brake for about 20
times, then press down and pull up the
parking brake button for about 20 times,
release high pressure oil from the
accumulators.
3. Slowly loosen the exhaust valve on the
accumulator. Drain out the residual pressure
oil in the accumulator.

Accumulator I and II are used for the service

brake circuit and accumulator III is used for the Do not let the residual pressure oil in the
parking brake circuit. accumulator spray any one as this can cause
injury or death.
Ⅰ Ⅱ Ⅲ
4. Remove the protection cap of the charge
1 valve from the accumulator.

1. Protection cap of the charge valve

2. Exhaust valve
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5. Tighten the valve A (turn rightwards) on the Parking Brake and Service Brake
accumulator charge tool, turn off the valve B Accumulators--Charge
then tighten the cap of valve C. Install the
charge tool to the charge valve of the
accumulator with slotted nut D.

If nitrogen pre-pressure of the accumulators

is insufficient, refill in time, otherwise the
normal use of the brake system could be
affected. Charge the accumulator by trained
personnel with special tools only.

1. Park the machine on flat ground and lay the

bucket flatly on the ground. Place the shift
control lever to NEUTRAL position and shut
down the engine. Then turn the start switch
clockwise to I position to turn on the power.
A. Valve
B. Exhaust valve 2. Depress the brake pedal repeatly for 20
C. Anti-return valve times, then pull up and push down the
D. Slotted nut parking brake button for about 20 times to
6. Slowly open the valve A (turn leftwards) on discharge the high pressure oil inside the
the charge tool. After the pressure reading is accumulator.
stable, the reading available on the pressure 3. Loosen the exhaust valve of the accumulator
gauge is the nitrogen pre-charge pressure of to drain the residual pressure oil inside the
the accumulator. The reading should comply accumulator.
with the following table.
Ⅰ Ⅱ Ⅲ
Nitrogen pre-charge
Name
pressure 1
Accumulator I & II 5.5±0.5Mpa
Accumulator III 9.2±0.5Mpa

7. Add nitrogen if the pressure is low; if the

pressure is higher than expected, adjust the
exhaust valve B to get the desired pressure
reading. 2
8. Close the valve A (turn rightwards) on the
charge tool, and then remove the charge tool 1. Protection cap of charge vavle
2. Exhaust valve
from the accumulator. Install the protection
cap of the charge valve.

Do not let the residual pressure oil in the

accumulator spray any one as this can cause
injury or death.

4. Remove the protection cap of the charge

valve from the accumulator.
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5. Tighten the valve A (turn rightwards) on the 10. Apply a coat of engine oil to the top of the
accumulator charge tool, turn off the valve B. charge valve to check if any leakage occurs.
Install the charge tool to the charge valve of There should be a leak if air bubbles are
the accumulator with slotted nut D. found. Contact your Liugong dealer for repair
information.
B A C
11. Install the protection cap of the charge valve
on the accumulator.

D Charge the accumulator with nitrogen only.

Do not charge it with oxygen, compressed air
or other flammable gas to avoid explosion.

A. Valve
B. Exhaust valve
C. Anti-return valve
D. Slotted nut
6. Take off the cap of the anti-return valve C.
Connect a hose with one end to the anti-
return valve C and the other end to the
nitrogen bottle.
7. Open the nitrogen bottle valve. After the
pointer of the pressure gauge is stable,
slowly open the valve A (turn leftwards) to
charge the accumulator. The reading should
comply with the following table.

Nitrogen pre-charge
Name
pressure
Accumulator I & II 5.5±0.5Mpa
Accumulator III 9.2±0.5Mpa

8. The charge pressure may be obtained in a

short time. Close the nitrogen bottle valve to
check whether the pressure on the gauge
has met the standard. Recharge if the
pressure is insufficient and adjust exhaust
valve B on the charge tool to lower the
pressure to the appropriate value if the
pressure is too high.
9. If the pressure reaches the required value,
close the nitrogen bottle valve first, and then
close the valve A on the charge tool. Remove
the charge tool.
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Electrical System 3. Check the battery hydrometer color. Green

indicates a full battery and the machine can
be started normally. Black indicates a low
Battery--Check battery which need charging at once. White
indicates a discarded battery which needs to
replace.
4. Close the battery box cover.
Stop the engine before working with
batteries.

1. Open the engine hood and remove the The battery clamp plate, battery terminals
cooling system cover to get access to the and cable leads will become loose due to
battery. the machine vibration after operating the
machine for a period of time. Check the
tightness of the nut located in the middle of
the clamp plate. Tighten it if it is loose.

Battery--Install

Before installing the battery to the machine,

1 make sure that the battery hydrometer is green.

1. Cover The battery should not be inclined over 40°.

Do not place the battery reversely or by any
2. Check whether the clamp nut, battery
side of it.
terminal and cable lead are loose. Tighten
them if they are loose. Make sure the hydrometer is green before
installing the battery. It is not allowed to
install the battery with a black hydrometer
onto the machine.
1 1 3 1 Do not install a leaked battery onto the
4 machine.
4 1. Turn the start switch (also called ignition
switch) to OFF position then remove the key.
Turn disconnect switch to OFF position.
2 5 2 2. Clean the battery terminals and surface with
a clean cloth. Do not use petrol or other
1. Battery terminal organic impregnant or cleanser.
2. Nut
3. Battery terminal(without jacket) 3. When connecting:
4. Hook bolt
5. Hydrometer a) Connect the positive post of one battery
to the negative terminal of the other
battery with the cable.
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b) Connect one end of the battery positive Battery--Charge

lead terminal to the battery positive post,
the other end to start motor. A maintenance-free battery is used in this
c) Connect one end of the battery negative machine. Obey the following instructions when
lead terminal to the battery negative post, dealing with the battery.
the other end to the battery disconnect A long-time use of the electric appliances without
switch. starting the engine or a long-time stop, electricity
d) Connect the battery disconnect switch to leakage, or the alternator can not charge; all
ground cable. these reasons could lead to an abnormal battery
charge and result in an electricity insufficiency or
even can not start the machine. Recharge the
To start motor
battery if this happens.
5 3

4 Charge the battery to let it work normally if

the above-mentioned phenomenon
happens.

1 To battery Check the outlook of the battery before charging:

disconnect
switch 1. Do not charge the battery if the battery
2 housing cracks or there is an acid leakage.
Check the reason and replace with a new
1. Battery one.
2. Battery
3. Cable
2. Do not charge the battery if the battery
4. Battery negative lead terminal cracks. Check the reason and
5. Battery positive lead replace with a new one.
4. Tighten the nut. 3. Do not charge the battery if the hydrometer is
5. Turn on the battery disconnect switch. Insert clear. Replace with a new one.
the key and start the engine. 4. Do not charge the battery if it is distensible by
over-charging or over-discharging. Replace
with a new one.

A wrong installation of the negative and

positive terminal will result in a serious
damage to the battery. Distinguish the
positive (+) and negative terminal (-)
correctly.
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Battery charging ● Table of charge time and battery voltage for

reference(lower current means a longer
charging time).

Battery Voltage Charge Time

Wear safety goggles when charging. 12.55-12.45VDC 2h
Keep ventilated when charging. Charge the 12.45-12.35VDC 3h
battery under normal temperature. 12.35-12.20VDC 4h

Do not smoke when charging the battery, 12.20-12.05VDC 5h

keep any kindling away. 12.05-11.95VDC 6h

The battery could have an explosion danger 11.95-11.80VDC 7h

if it is deposed improperly when charging. 11.80-11.65VDC 8h
11.65-11.50VDC 9h
1. Turn the start switch to OFF position and take 11.50-11.30VDC 10h
out the key, and then turn the disconnect 11.30-11.00VDC 12h
switch to OFF position. Below 11.00VDC 14h
2. Clean the battery terminals and surface with
a clean cloth, remove the oxidation surface. ● Check the hydrometer color after finishing
charging. Green hydrometer indicates that
3. Remove the battery from the machine. When the battery is fully charged.
removing, first disconnecting the negative
terminal of the battery. ● If the hydrometer is black, check the cable
connection and connecting points. Charge
4. Connect the cables after finishing charging. the battery again according to the above
Cennect the positive cable first. table until the hydrometer is green.
● If the hydrometer lost color, bubbles might
exist in the hydrometer. Shake the battery
slightly to remove the bubbles. If the
When connecting the battery, first connect hydrometer still lost color, then electrolyte is
its positive terminal; when disconnecting lost seriously, discard the battery and replace
the battery, first disconnect its negative with a new one.
terminal.

5. Connect the positive clamp of the charger to

the positive terminal of the battery, the
negative clamp to the negative terminal
under room temperature.
6. It is recommended to use a charger with a
constant voltage of 16VDC (the maximum
voltage cannot exceed 16 ± 0.1 V, maximum
current can not exceed 25A) to charge the
battery. Green hydrometer indicates the
battery charging is finished.
7. Charge the battery according to the following
specification if the above-mentioned
requirement can not meet:
● 1/10 of rated current to charge.
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8. As for the battery with a voltage under 1. Start the engine, and ensure that the battery
11.0VDC, it may not be able to be charged at charging system is in normal (observe the
the beginning. Due to the serious battery voltage through gauge), keep the
insufficiency of electricity, the proportion of engine speed at second gear to charge the
vitriol is close to water, therefore, the battery battery until the hydrometer turns green.
resistance is higher. The vitriol proportion
2. Turn off the A/C, radio, lights (except night)
increases during recharge and the circuit can
and other high-power electric equipment
get right gradually.
during battery charging.
3. Avoid starting the machine frequently as far
as possible during battery charging. If restart
Fix the two terminals tightly. Do not charge is necessary, it is recommended to restart the
the battery of 24VDC voltage in serial machine after finishing charging the battery.
connection.
Battery--Store/ Service
Stop charging immediately to check the
reason if the battery discharge hole spurts 1. Turn off the battery disconnect switch when
acid during the charging process. storing the batteries being installed on a
9. Stop charging if the battery temperature machine, and check the battery voltage state
exceeds 45°C during the charging process. at least every other month.
Halve the circuit before recharging after the 2. Disconnect the negative terminal of the
battery temperature drops to the ambient battery if the machine is stored over 15 days.
temperature. Check the electricity state of the battery
10. Check the battery voltage every hour during every 3 months (with cable disconnected).
the charging process. The battery is fully ● Green hydrometer means the battery is in
charged if the hydrometer is green. normal condition. Black hydrometer means
the battery needs charging.
● Replace the battery if its electrolyte was lost
seriously and hydrometer lost color.
If the hydrometer is black, check for loose
● Check the battery voltage every 3 months
cable and clean connecting terminal. Check
during machine storage. Recharge if the
whether the voltage has come to 16VDC. If
battery lacks for electricity. Recharge
the hydrometer is clear, it is likely that air
according to special procedures.
bubble exist in it. If the hydrometer is still
clear after slight shaking (indicates that the 3. Recharge if the battery lacks for electricity.
electrolyte loss), replace with a new battery. Recharge according to special procedures

11. It is recommended applying vaseline on the 4. As for the machine which has not
battery terminals to avoid electric corrosion disconnected the battery terminals, check the
after charge is completed. battery voltage state every month. If the
voltage is under12.4V, recharge it according
Charge the battery according to the following to special procedures.
method when the battery voltage is low, but the
machine still can be started and alternator works 5. As for the machine which is stored over 1
normally. year, replace with a new battery and dispose
the old one if the above- mentioned
requirements can not be followed.
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Battery--Recycle 8. Connect the battery cable with the battery

disconnect switch.
When discarding a battery, its inner material 9. Install the switch key and turn the battery
such as lead, acid and plastic shell can pollute disconnect switch to ON position.
the environment due to its outer frayed structure
or other reasons. Therefore, do not throw away
Fuse--Check/ Replace
the old battery randomly, deal with it by collecting
for a battery disposal station or put it into a
The fuses protect the electrical system from
recycle can set by the manufacturer (if there is
being damaged due to circuit overload. If the
any) in a local place.
fuse is broken, replace with a new one. Check
the circuit if the new fuse is broken again. Repair
Battery, Cable, Battery Disconnect the circuit, if necessary.
Switch--Replace

1. Turm the engine start switch key to OFF

position. Turn all of the switches to OFF
position. Take out the switch key. Replacing fuses with the same type and size
from different brands is allowed. Do not use
2. Turn the battery disconnect switch to OFF copper wire, otherwise the circuit could be
position. damaged.
3. Disconnect the negative battery cable from It is recommeded to use fuse supplied by
the battery disconnect switch. Liugong if it needs to replace the fuse when
4. Sequences for disconnecting the battery repairing. Do not buy the fuse randomly in
cables: the market as fuse of poor quality will bring
bad effect to the machine, even could cause
● Disconnect the negative battery cable from a fire.
the battery.
● Disconnect the positive battery cable from
the battery.
If it is necessary to replace fuses frequently,
an electrical problem may occur. Contact
your Liugong dealer.
Do not let the disconnected negative battery The centralized control box is located in the cab
cable contact with the battery disconnect on the rear left side of the driver’s seat, open the
switch. cover to maintain the fuses.
5. Inspect the battery terminals for corrosion.
Inspect the battery cables for wear or
damage.
6. Make any necessary repairs. If necessary,
replace the battery cables or the battery.
7. Sequences for connecting the battery cables:
● Connect the positive battery cable to the
battery.
● Connect the negative battery cable to the
battery.
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See the picture inside the centralized control box for the fuse distribution.

No. Definition Specification No. Definition Specification

F1/F2 Automatic ride control relay K5 F19 Wiper system 20A
F3/F4 Secondary steering relay K26 F20 Seat 15A
F5/F6 Cooling fan reverse soleniod relay K27 F21 DC-DC/ FUEL HEATER 20A
F7 / 15A F22 Defroster 20A
F8 / 25A F23 Real work lamp 15A
F9 Horn/ back-up alarm 10A F24 Front floodlamp 10A
F10 Stop lamp 7.5A F25 AUxiliary control 3 7.5A
F11 Auxiliary control 1 10A F26 AUxiliary control 2 10A
F12 / 25A F27 Instrument 7.5A
F13 DEF supply module 15A F28 Aftertreatment 10A
F14 Flasher/ position lamp 7.5A F29 ECM switched pwr 2 10A
F15 ECM unswitched pwr 1 7.5A F30 Secondary steering 7.5A
F16 Key start sw 7.5A F31 AUxiliary control 4 7.5A
F17 DEF sensor 10A F32 Radio/ lighter 10A
F18 Front worklamp 15A

Check and replace the fuse as follows:

1. Turn the start switch to OFF position.
2. Open the fuse box cover. Take off the broken fuse with a clamp.
3. Replace the broken fuse with a new one with same specification.
4. Install the fuse box cover.
The slice type fuse and flat type fuse that used in this machine should meet the regulation in standard of
QC/T420 Fuse-Links for Motor Vehicles.
See the following table for the fuse color:
Model Color
ATM-5 Tawny
ATM-7.5 Brown
ATM-10 Red
ATM-15 Light blue
ATM-20 Yellow
ATM-25 Colorless
ATM-30 Green
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Alternator--Maintain 3. Start the engine and increase the engine

speed to rated speed. Check the voltage of
the alternator again and write down the
reading of the multimeter. The latter reading
should be higher than the former one.
It is forbidden to check the alternator by 4. In case the alternator does not work:
short-circuiting the negative and positive
terminals of the alternator, otherwise the a) Check the drive belt of the alternator for
diode will be burnt and the voltage regulator looseness.
could be affected. b) Turn off the start switch, and then use a
Keep any metallic conductor away from wrench to check the connections of the
positive terminals of the alternator. alternator terminals.
c) Check to see whether the alternator
The alternator is a supporting component of the connects correctly to the ground.
diesel engine, refer to specification section or the
alternator’s nameplate for the working voltage Starter Motor--Maintain
and current value of the alternator. It has a built-
in electronic voltage regulator. Check the The starter motor is a supporting component of
connections of the alternator terminals the diesel engine. It mainly consists of a
frequently. Connection looseness at either solenoid, DC motor, shifting fork and driving
positive terminal or negative terminal will result in gear. The starter motor converts electrical energy
trouble of the electrical system, even cause of the battery into mechanical energy through the
serious failure. DC motor. Then the driving gear will drive the
Turn off the start switch before checking the two flywheel of the engine to start the engine.
terminals for good connection. After the engine starts, the starter motor should
immediately stop. Otherwise, the driving gear
may be damaged, the DC motor may be burnt,
the chock electromagnet may be damaged, and
The cable of the terminals can not be capacity and service life of the battery may also
incorrectly connected, otherwise the diode be greatly affected.
could be burnt and result in serious failure. It is prohibited to allow any metallic conductor to
approach any naked terminal freely. Especially
Method of judging whether the alternator
ensure that the other metallic articles around the
works normally and the handling measures:
starter motor will not contact or rub the naked
1. Turn on the start switch and observe the terminal after a long and severe shock or
reading of the voltmeter, and then start the operation of the machine. Otherwise, fire may
diesel engine and observe reading of the occur to the machine.
voltmeter again. The latter reading should be
higher than the former one.
2. You can also use the 200V DC voltage
position of a multimeter to check. Turn on the
start switch, measure terminal voltage of the
alternator (red meter pen connects positive
terminal of the alternator while black meter
pen connects the ground), and then write
down the reading of the multimeter.
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Important Maintenance Procedures CLG856H

Air Conditioning System See the following picture for the refrigerant level:

1
Refrigerant Level--Check

Personnel injury or death could result due

to the inhaled refrigerant gas or frog
4
through lighting the cigarette or other
smoking ways. Never smoke when
maintaining the air conditioner or in the
place where refrigerant gas may exist. 5

After turning on the air conditioner, check the 2

refrigerant in the refrigerant receiver for bubbles
1. Sight glass
through the sight glass to judge if the refrigerant 2. Refrigerant receiver
is sufficient or not. Many bubbles indicate 3. Few refrigerant
refrigerant is insufficient while few bubbles or no 4. Insufficient refrigerant
bubbles indicate the refrigerant is sufficient. 5. Enough refrigerant

The refrigerant receiver

R134a refrigerant is used in this air

conditioning system. Do not use other
refrigerant or refrigerant with low quality to
avoid damaging the compressor.
Do not add excess refrigerant when adding
refrigerant to avoid compressor liquid
impact damage caused by insufficient space
for refrigerant vaporization in the air
conditioning system.
If refrigerant leakage is found, check all the
joints that connect to the hoses for loose
conditions.
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Evaporator--Check Compressor Belt Tension--Check/

Adjust/ Replace
The evaporator is located in the cab on the rear
side of the driver’s seat. The compressor belt tension: apply(W=1.3Kg)
The fresh air strainer (fresh air vent) and force in the center span of the pulleys
recirculating air vent of the evaporator should be (compressor pulley and engine pulley). The
regularly checked and cleaned to avoid being deflection of the belt center distance should be
blocked by accmulated dirt. If not, the fresh air 4 ± 1mm. See the following picture:
will be reduced due to clogging of the fresh air
vent or recirculating air vent, which could affect
the comfort in the cab.
Evaporator (recirculating air vents)

Replace with a new belt if the belt is not tense.

That is, the deflection of the belt center distance
is more than 4±1mm when applying (W=1.3Kg)
1 force in the center span of the pulleys
(compressor pulley and engine pulley).
1. Recirculating air vent Replace the belt if the belt has cracks or splits.
2. Fresh air vent

Condenser--Clean

Condenser is located on the front end of radiator.

Clean the condenser regularly. Mainly need to

clean the radiator fin of the condenser, too much
dirt on the radiator fin will affect the condenser
cooling and reduce its performance, and finally
affect the cooling of the air conditioning system.
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Cab Air Strainer--Clean and Replace 2. Clean the strainer with compressed air. If the
strainer is too dirty or too oily, wash it with
The cab air strainers consist of the fresh air neutral detergent. Dry the strainer completely
strainer and recirculating air strainer. The before reuse.
blockage condition of the strainers is entirely
depending on the working environment of the
machine. In order to prolong the service life of
the strainers, keep clean in the cab. If the recirculating air strainer is still
blocked or damaged after being cleaned by
compressed air or water, replace it with a
new one.
The cab strainers are only intended to
separate particles (dust and sundries) from 3. Install the recirculating air strainer after
the air. Do not use it for poisonous gas. cleaning it. Install the access door cover
plate.
The air flow rate will reduce if the
recirculating air strainer is blocked, and the 4. Replace the recirculating air strainer every
effect of cooling and heating will be 2000 hours. Choose an air strainer which
weakened. The fresh air will reduce if the meets the standard of ISO10263-2.
fresh air strainer is be blocked.
Clean /replace the fresh air strainer
It may be dangerous when using compressed
air or high-pressured water to clean dust or 1. Remove the strainer cover fixed bolts on the
dirty materials. Wear protective glasses, rear left downside of the cab, then remove
shields or other protective devices. the strainer cover plate and the fresh air
strainer.
Clean /replace the recirculating air strainer

1. Remove the cover plate bolts underneath the

evaporator assembly, then remove the cover
plate. Remove the recirculating air strainer
from the air conditioning evaporator.

2. Clean the strainer with compressed air. If the

strainer is too dirty or too oily, wash it with
neutral detergent. Dry the strainer completely
before reuse.
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7. Do not turn the temperature control switch to

High position with fan speed switch at low
position, otherwise the evaporator could be
frosted.
If the fresh air strainer is still blocked or 8. In moist weather, air is wet due to humidity.
damaged after being cleaned by Turn the temperature control switch to
compressed air or water, replace it with a Medium cooling position and fan speed
new one. switch to Low position to dehumidify.
3. Install the cleaned fresh air strainer in the 9. R12 and R134a refrigerant can not
groove of the strainer cover, and then install it interchanged in the air conditioning system.
together with the strainer cover to the original The reparing tools and spare parts for them
position, screw the bolts at last. are also non-interchangable.

Compressor--Maintain 10. R134a is immiscible with the mineral

lubricant which is used in the system with
R12. Therefore, PAG polyolefin glycol
lubricant and synthetic PAG lubricant that
contains various additives should be used for
R134a refrigerant is used in this air a system adopts R134a.
conditioning system. 11. Since R134a can dissolve rubber hoses and
seals that used in the system with R12,
1. When the air conditioner isn’t used in cool therefore, rubber materials that can adapt to
weather, such as spring, autumn or winter, it the R134a refrigerant, such as polyethylene-
must be started running for about 5 minutes propylene rubber, EPDM. etc should be
every other week, in order to prevent the used.
system internal moving parts from producing 12. R134a can not use the desiccant which is
dry friction due to long-term disuse, thus used in the system with R12, it must use a
damag the internal parts of the compressor. new type of desiccant, such as XH-7, zeolite.
2. If the compressor doesn’t run for a long time, 13. When the air conditioner compressor is
do not wet the compressor. stocked for one year, turn the compressor
3. Do not let oil, water etc. enter into the clutch, with hands first before installation to ensure
otherwise the compressor cannot work that it works well. If the compressor is
normally. stocked for more than two years, replace the
refrigeration oil and refill nitrogen before
4. Although the bearing being used has
installation. (Turn the compressor with hands
waterproof and dustproof protection, in order
to drain the old oil as far as possible when
to prevent function failure, do not wash them
changing refrigeration oil).
if unneeded.
5. Air conditioner system only can be used after
the engine is started. After stopping the
engine, turn off the power / fan speed switch.
(it’s better not to start the air conditioner
suddenly during high engine speed).
6. Normally, turn the temperature control switch
to the High position to decrease the
temperature, and turn it to Medium or Low
position to keep the temperature.
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Other Maintenance 8. After a few hours of operation, check the

bolts for proper torque.

Bucket Cutting Edges--Check/Replace Bucket Positioner--Adjust (The Machine

(The Machine Equipped with Movable Equipped with Bucket Positioner)
Cutting Edges )
1. Park the machine on flat ground, push the
shift control lever to NEUTRAL position.

Personal injury or death can result from

bucket falling. Chock the bucket before
replacing bucket cutting edges.

Cutting edge

2. Lower the bucket onto ground, pull up the

parking brake button, shut down the engine.
3. Install the steering frame lock.

Check the cutting edges and the end bits for

wear and for damage. Use the following
procedure to service the cutting edges and the
end bits: 4. Loosen the bolts in following picture, adjust
1. Raise the bucket and chock the bucket. the bracket in back and forth direction until it
reaches proper position. Tighten the bolts.
2. Lower the bucket onto the wedge. Stop the
engine. 2
1
3. Remove bolts, cutting edge and the end bits.
4. Clean all contact surfaces.
5. lf the opposite side of the cutting edge is not
worn, use the opposite side of the cutting
edge. The end bits are not overturned. If both
sides are worn, replace a new cutting edge. 1. Bolt
2. Bracket
6. Screw the bolts to the specified torque.
5. Remove the steering frame lock and start the
7. Start the engine. Raise the bucket and engine. Check whether the above adjustment
remove the wedge. Lower the bucket to the is suitable or not.
ground.
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Boom Lift Kickout--Adjust 5. Loosen the bolt and adjust the bracket
forward and backward to proper distance.
Tighten bolt.

Pay close attention to safety when adjusting

the boom lift kickout. Keep any unauthorized
persons away from the machine. Do not allow
2
2
any person to stand under the boom.

1. Park the machine on flat ground and turn the

shift control lever to NEUTRAL position.
1

1. Bolt
2. Bracket
6. After adjustment, remove the steering frame
lock and start the engine. Check whether the
above adjustment is suitable or not.

Backup Alarm--Test (Optional)

2. Turn the pilot control lever to lower the bucket
onto ground, and then pull up the parking Turn the engine start switch to I or ON position to
brake handle. Stop the engine. turn on the power of the machine.

3. Install the steering frame lock. Pull the parking brake button (parking brake
handle) up to engage the parking brake.
Turn the engine start switch to II or START
position to start the diesel engine.
Turn the shift control lever to REVERSE position,
the backup alarm should sound immediately.
The backup alarm will sound continuously until
the shift control lever is turned to NEUTRAL or
FORWARD position.

4. Turn the start switch clockwise to ON position Seat Belt--Inspect (Optional)

to turn on power. Pull the work implement
control lever to the most backwards position, The driver should check the seat belt for its
then the lift kickout will be attracted by condition and security before use. Replace it, if
electromagnetic force. necessary.
Adjust the length of the seat belt to ensure its
restraint and comfort ability before use. Adjust it
by moving its buckle position on the belt.
Replace the seat belt every 3 years even though
it is in good condition. A valid date is provided on
every seat belt, confirm the use deadline of the
seat belt according to it.
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Maintenance Manual October 12, 2019
Important Maintenance Procedures CLG856H

For further information of the seat belt Welding Operation

replacement, refer to your LiuGong dealer.
To avoid possible damage to the machine, read
Window Washer Reservoir--Fill and understand the following cautions before
welding and always observe the welding
The washer reservoir is located on the right side operation procedures as follows:
of the seat in the cab. Add washer through the
1. Park the machine on flat ground.
water filler of the washer reservoir.
Washer reservoir location 2. Engage the parking brake.
3. Turn the pilot shutoff lever to OFF position (if
equipped) or turn the hydraulic lock switch to
LOCK position (if equipped).
4. Turn off the start switch to stop the engine.
5. Turn off the battery disconnect switch to　
disconnect the battery and frame.
6. If the machine is equipped with ZF control
unit, to avoid damage of it, always remove all
connectors of the instruments connected to
the machine harness and ZF transmission
control unit before welding.
Check the washer reservoir frequently to 7. If your machine is equipped with other
ensure enough water in it, otherwise dirty electronic components such as
windshield may impact the visibility of the loudspeakers, remove all connectors of the
operator. electronic components connected to the
Do not use wiper to wipe windshield when machine harness before welding to avoid
the washer reservoir is out of water, possible loss.
otherwise the wiper motor may be burnt out. 8. Clear away paint from those parts to be
The washer reservoir should be emptied or welded to prevent harmful air from
filled with antifreeze when the ambient production.
temperature is below 0 °C, otherwise the 9. Clamp the earth cables of the welder with the
washer will not work or even be damaged by parts to be welded, keep the earth position
being frozen. close to the welded place. Check and confirm
As the washer with additive may be harmful the circuits from the earth cables to the
to human body, dispose of it according to welded parts don't get across any of the
local laws and regulations. following parts:
● Bearings
● Hydraulic cylinders
● Controllers
● Internal circuit of other electronic parts
Any damage to the following parts could be
avoided by doing so:
● Bearings
● Hydraulic parts
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October 12, 2019 Maintenance Manual
CLG856H Important Maintenance Procedures

● Electronic parts
● Other possible parts on the machine
10. Keep any inflammable and explosive
materials away from the welding site, protect
any cable, do not allow sparks and solders
produced in welding to splash onto the
cables, thus cause a fire and resulting in loss
and injury.
11. Use proper safety welding operation
procedures for welding.

Cautions for Welding Operation

● Never use the earth position of the electrical

parts on the machine as that of the welder.
● When performing welding near the earth
position of an electrical part, always
disconnect the earth position of this electrical
part, and perform welding operation after
ensuring that the welding circuit of the welder
doesn't get across this electrical part.
Otherwise it will result in damage to this
electrical part or even result in a fire.
● Do not keep using voltage above 200V. Keep
the welding area and earth cables within 1m
(3'3").
● Avoid seals and bearings located between
the welding area and earth cables.
● Never weld any pipe or container with fuel,
engine oil or hydraulic oil.
● Never weld any sealed container or container
which is poorly ventilated.
● Do not allow sparks and solders produced in
welding to splash onto the cables, rubber
hoses and other inflammable materials, thus
cause a fire and resulting in loss and injury.
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Fault Diagnosis and Troubleshooting CLG856H

Fault Diagnosis and Troubleshooting

Fault Code Index of ZF4BP210 Gearbox

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Status status Status Status Atatus Document

Source SPN FMI
code level part type description address
Power train Speed shift Battery low
0001 TCU 523000 01
system controller undervoltage
Power train Speed shift
0003 TCU Battery overvoltage 523000 03
system controller
Power train Speed shift Battery
0004 TCU 523000 04
system controller undervoltage/
TCU internal 5V
Power train Speed shift
03EB TCU power supply 523010 03
system controller
overvoltage
TCU internal 5V
Power train Speed shift
03EC TCU power supply 523010 04
system controller
undervoltage
TCU internal 7V
Power train Speed shift
0450 TCU power supply 523011 04
system controller
undervoltage
Supply for speed
Power train Speed shift
0837 TCU sensors (AU2) 523021 03
system controller
overvoltage

Supply for speed

Power train Speed shift
0838 TCU sensors (AU2) 523021 04
system controller
undervoltage/

Supply for speed

Power train Speed shift
083A TCU sensors (AU2) 523021 06
system controller
short to ground

Supply 1 for
Power train Speed shift
089B TCU sensors (AU1) 523022 03
system controller
overvoltage

Supply 1 for
Power train Speed shift
089C TCU sensors (AU1) 523022 04
system controller
undervoltage

Supply 1 (AU1) for

Power train Speed shift
089E TCU sensors short to 523022 06
system controller
ground
Propvalve power
Power train Speed shift
0BBB TCU supply 1 (VPS1) 523030 00
system controller
overvoltage
Power train Speed shift TCU
0FA0 TCU 523040 00
system controller overtemperature
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CLG856H Fault Diagnosis and Troubleshooting

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Power train Speed shift TCU temperature
0FA2 TCU 523040 02
system controller invalid value
Power train Speed shift Internal TCU Error
11A0 TCU 523045 12
system controller 1
Power train Speed shift Internal TCU Error
1204 TCU 523046 12
system controller 2
Power train Speed shift Internal TCU Error
1268 TCU 523047 12
system controller 3
Power train Speed shift TCU invalid for
1330 TCU 523049 12
system controller application
Turbine speed
Power train Speed shift
2713 TCU sensor input (EF1) 523100 03
system controller
overvoltage
Turbine speed
Power train Speed shift sensor input (EF1)
2716 TCU 523100 06
system controller open or short to
ground
Internal speed
Power train Speed shift
2907 TCU sensor 1 input 523105 03
system controller
(EF2) overvoltage
Internal speed
Power train Speed shift sensor 1 input
290A TCU 523105 06
system controller (EF2) open or short
to ground
Output speed
Power train Speed shift
2AFB TCU sensor input (EF3) 523110 03
system controller
overvoltage
Output speed
Power train Speed shift sensor input (EF3)
2AFE TCU 523110 06
system controller open or short to
ground
Engine speed
Power train Speed shift
2CEF TCU sensor input (EF4) 523115 03
system controller
overvoltage
Engine speed
Power train Speed shift sensor input (EF4)
2CF2 TCU 523115 06
system controller open or short to
ground
Sump temperature
sensor (ER1) open
Power train Speed shift
36B3 TCU circuit or shorted to 523140 03
system controller
high
source
Sump temperature
Power train Speed shift
36B6 TCU sensor (ER1) short 523140 06
system controller
to ground
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Fault Diagnosis and Troubleshooting CLG856H

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Unknown electrical
Power train Speed shift component at
4E22 TCU 523200 02
system controller (AIM01) current
output 0
Propvalve for
Power train Speed shift
4E23 TCU Clutch A (AIM01) 523200 03
system controller
short to battery

Propvalve for
Power train Speed shift
4E25 TCU Clutch A (AIM01) 523200 05
system controller
open circuit

Propvalve for
Power train Speed shift
4E26 TCU Clutch A (AIM01) 523200 06
system controller
short to ground
Propvalve for
Power train Speed shift Clutch A (AIM01)
4E28 TCU 523200 08
system controller short circuit to
another valve
Unknown electrical
Power train Speed shift component at
5016 TCU 523205 02
system controller (AIM02) current
output 1
Propvalve for
Power train Speed shift
5017 TCU Clutch B (AIM02) 523205 03
system controller
short to battery

Propvalve for
Power train Speed shift
5019 TCU Clutch B (AIM02) 523205 05
system controller
open circuit

Propvalve for
Power train Speed shift
501A TCU Clutch B (AIM02) 523205 06
system controller
short to ground
Propvalve for
Power train Speed shift Clutch B (AIM02)
501C TCU 523205 08
system controller short circuit to
another valve
Unknown electrical
component at
Power train Speed shift
520A TCU (AIM03) current 523210 02
system controller
output 3 (Clutch C
output)
Propvalve for
Power train Speed shift
520B TCU Clutch C (AIM03) 523210 03
system controller
short to battery

Propvalve for
Power train Speed shift
520D TCU Clutch C (AIM03) 523210 05
system controller
open circuit
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October 12, 2019 Maintenance Manual
CLG856H Fault Diagnosis and Troubleshooting

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Propvalve for
Power train Speed shift
520E TCU Clutch C (AIM03) 523210 06
system controller
short to ground
Propvalve for
Power train Speed shift Clutch C (AIM03)
5210 TCU 523210 08
system controller short circuit to
another valve
Unknown electrical
Power train Speed shift component at
53FE TCU 523215 02
system controller (AIM04) current
output 3
Propvalve for
Power train Speed shift
53FF TCU Clutch D (AIM04) 523215 03
system controller
short to battery

Propvalve for
Power train Speed shift
5401 TCU Clutch D (AIM04) 523215 05
system controller
open circuit

Propvalve for
Power train Speed shift
5402 TCU Clutch D (AIM04) 523215 06
system controller
short to ground
Propvalve for
Power train Speed shift Clutch D (AIM04)
5404 TCU 523215 08
system controller short circuit to
another valve
Unknown electrical
Power train Speed shift component at
55F2 TCU 523220 02
system controller (AIM05) current
output 4
Propvalve for
Power train Speed shift
55F3 TCU Clutch R (AIM05) 523220 03
system controller
short to battery

Propvalve for
Power train Speed shift
55F5 TCU Clutch R (AIM05) 523220 05
system controller
open circuit

Propvalve for
Power train Speed shift
55F6 TCU Clutch R (AIM05) 523220 06
system controller
short to ground
Propvalve for
Power train Speed shift Clutch R (AIM05)
55F8 TCU 523220 08
system controller short circuit to
another valve
Unknown electrical
Power train Speed shift component at
57E6 TCU 523225 02
system controller (AIM06) current
output 5
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FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Propvalve for
Power train Speed shift
57E7 TCU Clutch F (AIM06) 523225 03
system controller
short to battery

Propvalve for
Power train Speed shift
57E9 TCU Clutch F (AIM06) 523225 05
system controller
open circuit

Propvalve for
Power train Speed shift
57EA TCU Clutch F (AIM06) 523225 06
system controller
short to ground
Propvalve for
Power train Speed shift Clutch F (AIM06)
57EC TCU 523225 08
system controller short circuit to
another valve
Unknown electrical
Power train Speed shift
59DA TCU component at 523230 02
system controller
(AIM07)
Propvalve for
Power train Speed shift
59DB TCU (AIM07) short to 523230 03
system controller
battery
Propvalve for
Power train Speed shift
59DD TCU (AIM07) open 523230 05
system controller
circuit
Propvalve for
Power train Speed shift
59DE TCU (AIM07) short to 523230 06
system controller
ground
Propvalve for
Power train Speed shift (AIM07) short
59E0 TCU 523230 08
system controller circuit to another
valve
Short to Battery
Power train Speed shift
6D63 TCU Digital Output1 523280 03
system controller
(ADM1)
Power train Speed shift Open Circuit Digital
6D65 TCU 523280 05
system controller Output1 (ADM1)
Short to Ground
Power train Speed shift
6D66 TCU Digital Output1 523280 06
system controller
(ADM1)
Power train Speed shift
6D6C TCU ADM1 Defective 523280 12
system controller
Short to Battery
Power train Speed shift
6DC7 TCU Digital Output2 523281 03
system controller
(ADM2)
Power train Speed shift Open Circuit Digital
6DC9 TCU 523281 05
system controller Output2 (ADM2
Short to Ground
Power train Speed shift
6DCA TCU Digital Output 523281 06
system controller
(ADM2)
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CLG856H Fault Diagnosis and Troubleshooting

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Power train Speed shift
6DD0 TCU ADM2 Defective 523281 12
system controller
Transmission sump
Power train Speed shift
7530 TCU oil temperature 523300 00
system controller
critical

Power train Speed shift Transmission sump

7540 TCU 523300 16
system controller oil overtemperature

Power train Speed shift Oil Filter

7724 TCU 523305 00
system controller contaminated
Power train Speed shift Transmission input
7918 TCU 523310 00
system controller torque too high
Power train Speed shift Transmission input
797C TCU 523311 00
system controller power too high
Power train Speed shift Overspeed at
7D0F TCU 523320 15
system controller transmission output
Output shaft
Power train Speed shift
7D6D TCU acceleration or 523321 09
system controller
deceleration critical
Power train Speed shift Transmission input
80F7 TCU 523330 15
system controller speed too high
Transmission
Power train Speed shift
84D0 TCU output torque too 523340 00
system controller
high
Power train Speed shift Clutch CF
8AAC TCU 523355 00
system controller temperature critical
Power train Speed shift Clutch CR
8B10 TCU 523356 00
system controller temperature critical
Calibration Data
Lost. TCU was not
Power train Speed shift
8CA9 TCU able to read correct 523360 09
system controller
calibration
parameters
Power train Speed shift clutch Calibration
8D11 TCU 523361 13
system controller failure
Power train Speed shift
9C49 TCU Vehicle CAN failure 523400 09
system controller
Power train Speed shift ECU connection
9D11 TCU 523402 09
system controller loss
Power train Speed shift VCU connection
9D75 TCU 523403 09
system controller loss
Power train Speed shift I/O-Extension
9E3D TCU 523405 09
system controller connection loss
Power train Speed shift Message ZFTC1
A095 TCU 523411 09
system controller invalid or timeout
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FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Power train Speed shift Message EEC1
A15D TCU 523413 09
system controller invalid or timeout
Power train Speed shift Message EEC2
A1C1 TCU 523414 09
system controller invalid or timeout
Power train Speed shift Message EEC3
A225 TCU 523415 09
system controller invalid or timeout
Power train Speed shift Message EC1
A289 TCU 523416 09
system controller invalid or timeout
Power train Speed shift Message B invalid
A2ED TCU 523417 09
system controller or timeout
Power train Speed shift Message EBC1
A351 TCU 523418 09
system controller invalid or timeout
Power train Speed shift Message CCVS
A419 TCU 523420 09
system controller invalid or timeout
Power train Speed shift Operation Mode
B7AB TCU 523470 19
system controller command invalid
Power train Speed shift Transmission
B80F TCU 523471 19
system controller command invalid
Machine
Power train Speed shift
BB89 TCU Configuration 523480 09
system controller
Invalid
Testmode
Power train Speed shift requested but
BBE4 TCU 523481 00
system controller conditions not
complied
Engine speed limit
Power train Speed shift
C3B4 TCU request does not 523501 00
system controller
take effec
Engine speed
Power train Speed shift
C418 TCU control does not 523502 00
system controller
take effect
Engine torque limit
Power train Speed shift
C47C TCU request does not 523503 00
system controller
take effect
Engine torque
Power train Speed shift
C4E0 TCU control does not 523504 00
system controller
take effect
Neutral shift to
Power train Speed shift
C544 TCU protect engine from 523505 00
system controller
stalling
Power train Speed shift Protection Function
EA60 TCU 523600 00
system controller Error
Protection Function
Power train Speed shift
EA61 TCU 1 (SF01)Unwanted 523600 01
system controller
driveaway
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October 12, 2019 Maintenance Manual
CLG856H Fault Diagnosis and Troubleshooting

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Protection Function
Power train Speed shift
EA62 TCU 2 (SF02)Unwanted 523600 02
system controller
driving direction
Protection Function
3 (SF03)Safely
Power train Speed shift
EA63 TCU limited acceleration 523600 03
system controller
(blocked
Transmission)
Protection Function
Power train Speed shift 4 (SF04)Safely
EA64 TCU 523600 04
system controller limited acceleration
(Downshift)
Protection Function
Power train Speed shift
EA65 TCU 5 (SF05)Safe 523600 05
system controller
Output
Protection Function
Power train Speed shift
EA66 TCU 6 Safely limited 523600 06
system controller
speed in Reverse

Protection Function
Power train Speed shift
EA67 TCU 7 (SF07)Unwanted 523600 07
system controller
direction change
Power train Speed shift Protection Function
EA68 TCU 523600 08
system controller 8 triggered
Protection Function
Power train Speed shift
EA69 TCU 9 (SF09)Safely 523600 09
system controller
limited torque

Protection Function
Power train Speed shift 10 (SF10) Safely
EA6A TCU 523600 10
system controller limited delayed get
into gear

Power train Speed shift Protection Function

EA6B TCU 523600 11
system controller 11 Safe Lock
Protection Function
12 Safe
Power train Speed shift
EA6C TCU Transmission 523600 12
system controller
Output Shaft
Speed
Power train Speed shift
EAC4 TCU Gear inconsistent 523601 00
system controller
Power train Speed shift
EB28 TCU FNR request error 523602 00
system controller
Power train Speed shift Safety event
EB8C TCU 523603 00
system controller handling wrong
Power train Speed shift EU1 Short To
30D7 TCU 523125 03
system controller Battery
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Maintenance Manual October 12, 2019
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FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

30DA TCU Power Speed EU1 open or 523125 06

train shift short to
system controller ground
Power train Speed shift EU1 Sensor
30E0 TCU 523125 12
system controller defective
ER2 Short To
Power train Speed shift
38A7 TCU Battery Or Open 523145 03
system controller
Circuit
Power train Speed shift ER2 short to
38AA TCU 523145 06
system controller ground
Torque converter
Power train Speed shift
75F8 TCU oil temperature 523302 00
system controller
critical

Power train Speed shift Torque converter

7608 TCU 523302 16
system controller oil overtemperature

Engine reference
Power train Speed shift
AFDB TCU torque signal 523450 19
system controller
invalid
ACTUAL ENGINE
Power train Speed shift
B03F TCU TORQUE SIGNAL 523451 19
system controller
invalid
Engine nominal
Power train Speed shift
B0A3 TCU friction torque 523452 19
system controller
signal invalid
Power train Speed shift Launch gear
B16B TCU 523454 19
system controller request invalid
ZFSL1 message
Power train Speed shift
B1CF TCU TIMEOUT or wrong 523455 19
system controller
Signals
invalid combination
Power train Speed shift
B233 TCU of FNR Switch 523456 19
system controller
signals
Neutral selected
Power train Speed shift while vehicle
FDE8 TCU 523650 00
system controller moves with
overspeed
Oil Filter
Power train Speed shift
3A9B TCU Restriction Switch 523150 03
system controller
(EI2) overvoltage
Oil Filter
Power train Speed shift Restriction Switch
3A9E TCU 523150 06
system controller (EI2) short to
ground
Power train Speed shift AU_ER
08FF TCU 523023 03
system controller overvoltage
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October 12, 2019 Maintenance Manual
CLG856H Fault Diagnosis and Troubleshooting

FAULT CODE INDEX OF DOMESTIC BP TRANSIMISSON

Power train Speed shift AU_ER
0900 TCU 523023 04
system controller undervoltage
Power train Speed shift Clutch CA slipping
U170 TCU 523700 00
system controller unintendedly
Power train Speed shift Clutch CB slipping
U364 TCU 523705 00
system controller unintendedly
Power train Speed shift Clutch CC slipping
U558 TCU 523710 00
system controller unintendedly
Power train Speed shift Clutch CF slipping
U74C TCU 523715 00
system controller unintendedly
Power train Speed shift Clutch CG slipping
U940 TCU 523720 00
system controller unintendedly
Power train Speed shift Clutch CR slipping
UB34 TCU 523725 00
system controller unintendedly/
Power train Speed shift EU2
32CB TCU 523130 03
system controller ShortToBattery
Power train Speed shift EU2 open or short
32CE TCU 523130 06
system controller to ground
Power train Speed shift EU2 Sensor
32D4 TCU 523130 12
system controller defective
Power train Speed shift
1388 TCU ADC test error 523050 00
system controller
Power train Speed shift Driveline
90EC TCU 523371 00
system controller engagement failed
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Fault Diagnosis and Troubleshooting CLG856H

Troubleshooting

Power train System

Item Features Causes Troubleshooting

1. Oil level of transmission oil sump is too 1. Replenish oil to specified oil level.
low. 2. Check main oil passage.
2. Leakage in main oil passage. 3. Clean or replace the oil filter.
Shift pressure is 3. Transmission oil filter is blocked. 4. Check or replace the gear shift pump.
4. Gear shift pump failure. 5. Readjust according to the regulation.
1 low in each
5. Pressure regulating valve spring 6. Replace the pressure regulating valve
speed. problem. spring.
6. Pressure regulating valve spring failure. 7. Remove and check.
7. Pressure regulating valve or
accumulator piston is blocked.
1. Piston seal ring in this speed is 1. Replace the seal ring.
Shift pressure is damaged. 2. Replace the seal ring.
2 low in some 2. Seal ring in this oil passage is 3. Check and eliminate the leakage.
speed. damaged.
3. Leakage in this speed passage
1. Oil level of transmission oil sump is too 1. Replenish oil to specified oil level.
low. 2. Drain oil to specified oil level.
Torque converter 2. Oil level of transmission oil sump is too 3. Refer to Item1 and Item 2.
high. 4. Clean or replace the coole.
3 oil temperature is 3. Low shift pressure, clutch slipping. 5. Park to let the machine cool down.
too high. 4. Torque converter oil cooler is blocked.
5. Torque converter works overlong with
high load.
1. Cut-off valve spool of shift control valve 1. Check cut-off valve, find out the cause and
Engine operates can not return. eliminate the fault.
in high speed, but 2. Gear engagement failure 2. Shift gear again or adjust the shift control
4 3. Pressure regulating valve spring lever.
the machine breaks. 3. Replace the pressure regulating valve
doesn’t move. 4. Refer to Cause 1~4 in No.1. spring.
4. Refer to causes 1~4 in Item 1.
1. Shift pressure is too low. 1. Refer to Item 1 and Item 2.
2. Torque converter oil temperature is too 2. Refer to Item 3.
high. 3. Check torque converter and replace the
5 Poor drive force 3. Torque converter impeller is damaged. impeller.
4. Overrun clutch is damaged. 4. Check the overrun clutch and replace the
5. Engine output power is poor. damaged parts.
5. Check and repair the engine.
1. Oil intermingle at steering pump shaft 1. Replace the seal at steering pump shaft end
Transmission oil end . .
6
level increased. 2. Oil intermingle at working pump shaft 2. Replace the seal at working pump shaft
end . end.
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October 12, 2019 Maintenance Manual
CLG856H Fault Diagnosis and Troubleshooting

Brake System

Item Features Causes Troubleshooting

Air exists in brake lines. Exhaust the air.
Check the brake valve, measure
Brake valve failure.
the pressure of outlet BR1 & BR2.
Pump failure. Check the pump.
1 Poor foot brake force
Leakage in brake lines. Check the brake lines.
Accumulator damage. Check the pressure of accumulator.
Friction disc of wheel brake has been worn
Replace the friction disc.
completely.
Check the brake valve, measure
Brake valve failure.
the pressure of outlet S3.
2 Shift failure
Check the pressure switch under
Pressure switch failure.
the S3 of the accumulator.
Check the brake valve, measure
Parking brake can not be Brake valve failure.
3 the pressure of outlet BR3.
disengaged normally.
Leakage of parking brake cylinder. Replace the seals of the cylinder.
Excessive clearance between the brake Adjust according to the
4 Poor parking barke force drum and the brake shoe. requirement.
Oil on the brake shoe. Clean the brake shoe.
Leakage of air valve. Check the air valve, add nitrogen.
5 Accumulator dont’t work. Capsule damage and the leakage of Remove and check the capsule or
nitrogen in the capsule. replace the capsule.
Check the pressure of outlet
6 Without barke piont. Brake valve failure.
BR1?BR2.
Insufficient system oil pressure in a short
Please hold on.
Service brake low time when start the machine.
pressure alert indicator or In the process of operation, the system
7 emergency brake low failure occurred and the oil pressure Stop and check the machine.
pressure alert indicator decreased.
flash. Check the pressure of the
Air leakage of accumulator capsule.
accumulator capsule.

Work Hydraulic System

Item Features Causes Troubleshooting

1. Cylinder seals have worn away or 1. Replace the seals.
damaged. 2. Check and repair to make the clearance
2. Control valve is excessively worn. The reach the specified value or replace the
Poor boom lifting fit clearance between spool and valve control valve.
body exceeds the specified value. 3. Find the leakage position and eliminate the
force or poor
1 3. System leaks oil. fault.
bucket tilting 4. Serious oil leakage in work pump . 4. Replace the work pump.
force. 5. Improper adjustment on relief valve, 5. Adjust the system pressure to the specified
system pressure is low. value.
6. Oil suction tube and oil filter are 6. Clean the oil filter and change oil.
blocked.
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Fault Diagnosis and Troubleshooting CLG856H

Work Hydraulic System

Item Features Causes Troubleshooting

Slow bucket tilting 1. Refer to Item 1. 1. Refer to Item 1.
or boom lifting 2. Double acting relief valve is blocked. 2. Check the double acting relief valve.
2
when engine runs
at high speed.

Steering Hydraulic System

Item Features Causes Troubleshooting

1. Oil temperature is too low. 1. Work after the oil temperature rises.
2. Pilot oil line is blocked. 2. Clean the pilot oil line.
3. Improper pilot oil line connection. 3. Connect the oil line according to the
1 Hard steering 4. Steering pump pressure is low. regulation.
5. Bolts on the steering motor are over 4. Adjust the relief valve pressure according to
tightened. the regulation.
5. Loosen the bolts.
Unsmooth
2 Flow control valve response failure. Check or replace the flow control valve.
machine steering
1. Pressure regulating valve leakage. 1. Repair or replace the flow amplifying valve.
Left turn and right 2. Insufficient steering pump flow. 2. Repair or replace the steering pump.
3
turn are slow. 3. Flow amplifying valve spool movement 3. Adjust the pilot oil lines pressure or replace
limitation. the spring.
Left and right Adjusting shim quantity on two ends of the
Adjust the shim quantity of the valve spool as
4 turning speeds are flow amplifying valve does not meet the
required.
different. need.
Machine turns 1. Valve base of relief valve in main oil 1. Repair the valve base or replace the seal
normally with lines leaks seriously. ring.
small steering 2. Pressure regulating valve leaks 2. Repair or replace the valve and seal ring.
seriously.
5 resistance and
slowly with big
steering
resistance.
Machine doesn’t 1. Metering pump has fault. 1. Repair or replace the metering pump.
turn when turning 2. Relief valve in pilot oil lines (or pressure 2. Repair the relief valve in pilot oil lines (or
6 reducing valve) has fault. pressure reducing valve).
the steering
wheel. 3. Relief valve in main oil lines has fault. 3. Repair the relief valve in main oil lines.

1. Valve spool of flow amplifying valve can 1. Repair valve spool and return spring.
Machine turns not return to Neutral position. 2. Loosen the bolt.
automatically 2. Mounting bolt of flow amplifying valve is 3. Loosen the bolt.
over tightened. 4. Repair or replace the valve spool.
7 without operating
3. Bolt on end cap of flow amplifying valve
the steering is over tightened
wheel. 4. Improper mating between valve spool
and bore of flow amplifying valve.
Steering wheel 1. Full-hydraulic steering gear valve 1. Clear away the foreign matter inside the
rotates bushing is blocked. valve.
8 2. Full-hydraulic metering pump spring 2. Replace the spring leaf.
automatically
reed broke.
without operation.
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October 12, 2019 Maintenance Manual
CLG856H Fault Diagnosis and Troubleshooting

Steering Hydraulic System

Item Features Causes Troubleshooting

1. Incorrect adjustment of the flow control 1. Adjust the adjusting shim as required.
valve . 2. Repair or replace the valve spool.
Machine turns too 2. Valve spool of flow amplifying valve 3. Clean or replace the valve spool.
9 fast when running reponses failure.
at high speed. 3. Metering holes on two ends of flow
amplifying valve spool are blocked or
hole position is improper.
1. Air exists in the steering oil lines. 1. Start the machine, turn left and right
2. Steering pump is worn, flow is deficient. repeatly.
Big noise in 3. Low oil viscosity. 2. Replace the steering pump.
steering pump, 4. Insufficient hydraulic oil. 3. Change oil according to right oil brand.
10 5. Setting pressure of relief valve in 4. Replenish hydraulic oil.
steering cylinder
control lines (pressure reducing valve) 5. Adjust the relief valve (pressure reducing
reponses slowly. is incorrect. valve) as required.
6. Steering cylinder internal leakage. 6. Check and repair the cylinder or replace the
seal.

Electrical System

Item Features Causes Troubleshooting

1. Commutator has oil smear or wear 1. Clean it with gasoline by clean cloth or
away. planish it with 00 emery paper.
Alternator failure 2. Residual magnetism coil interruption. 2. Check the external magnetic field and check
1 or low output 3. Residual magnetism disappears. excitation circuit with bulb.
voltage 4. Alternator belt is over loosened. 3. Charge the magnetism or replace with new
alternator.
4. Readjust it.
1. Bearing is worn or lacks lubricant. 1. Replace the bearing or replenish lubricant.
Alternator over 2. Commutator or electrical coil has 2. Disassemble the alternator, check the
2
heating. internal short circuit. commutator and armature coil to eliminate
the short circuit.
1. Alternator magnetic field coil has short 1. Alternator magnetic field coil should be
circuit or open circuit. good, the resistance of magnetic field coil is
Battery can not be 2. Alternator positive wire broke off. about 20Ω.
charged or the 3. Battery cable over loosened or broke 2. Turn the start switch to ON, but do not start
3 the engine, the alternator“+”should have
charging current is off.
small. 4. Alternator belt over loosened. 24V voltage.
3. Eye check and tighten it.
4. Eye check and tighten it.
1. Battery capacity loses seriously. Start the alternator, check the battery voltage
2. Battery has short circuit and damaged. with multimeter, the battery has fault if the
3. Alternator ground cable is loose. charging current is too big but the voltage is
below 25V. If the alternator“+”voltage is higher
Too big currect than 30V, please check the alternator“-
4 and too long for ”grounding to see it is normal or not. Connect
battery charging the voltmeter negative terminal to the ground,
and positive to the alternator negative, if
voltage value is shown in the voltmeter, then
the problem is ground cable open circuit, or the
alternator inner fault.
1. Instrument damaged. 1. Replace the instrument.
No reading on 2. Sensor damaged. 2. Replace the sensor.
5
instrument. 3. Alternator or battery has fault. 3. Check the alternator or battery terminal
voltage is normal or not.
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Fault Diagnosis and Troubleshooting CLG856H

Electrical System

Item Features Causes Troubleshooting

1. Battery damaged or lacks electricity. 1. Replace with new battery or charge.
2. Start switch damaged. 2. Replace the start switch.
3. Wires are in poor connection or open 3. Check and repair.
circuit. 4. Check the coil, contact point, shift fork,
Engine start failure 4. Starting motor solenoid switch or shift spring for good condition, repair them if
6
or start difficulty. fork damaged. there are faults.
5. Starting motor rotor burnt out. 5. Replace the starting motor.
6. Main power relay, start relay or gear/ 6. Replace the relay.
start interlock relay damaged. 7. Replace lubricant.
7. Lubricant is too dense.
1. Wires are in poor connection or open 1. Check and repair.
Engine can not circuit. 2. Replace the choke relay.
7
shut down. 2. Choke relay damaged. 3. Replace the electromagnet.
3. Choke electromagnet damaged.
Lights don’t Check the switch, fuse, bulb and wires.Replace
8 Circuits fault.
illuminate. or repair if necessary.
Instrument
9 indicates the max. Loose instrument grounding wire Tighten or connect the grounding wire again.
range.
 181
October 12, 2019 INDEX
CLG856H

INDEX

A Central Instrument Panel ................................ 45

Check Before Starting the Engine .................. 79
Combination Switch ........................................ 62
A/C Panel ........................................................53 Compressor Belt Tension--Check/Adjust/
Accelerator Peda ............................................64 Replace ........................................................ 159
Accumulator of Pilot Oil Supply Valve--Charge Compressor--Maintain .................................. 161
......................................................................145 Condenser--Clean ........................................ 159
Air Conditioning System ................................158 Control Devices .............................................. 57
Air Filter Service Indicator--Check ................113 Coolant Level--Check ................................... 108
Alternator--maintain ......................................157 Coolant--Add ................................................ 109
Application and Specification ..........................35 Coolant--Replace .......................................... 111
Applications .....................................................35 Crushing and Cutting Prevention .................... 20
Attachment Cautions .......................................24
Axle Oil Level--Check ...................................128
Axle Oil--Replace ..........................................128 D

B Daily Inspection ............................................ 106

Door Lock ....................................................... 75
Downhill Operation ......................................... 83
Backup Alarm System (Optional) ....................78 Driving Operation of the Machine ................... 81
Backup Alarm--Test ......................................163 Driving the Machine ........................................ 90
Battery Disconnect Switch ..............................41 Dumping Operation ........................................ 85
Battery, Cable, Battery Disconnect Switch-- During Storage ............................................... 89
Replace .........................................................155
Battery--Charge ............................................152
Battery--Check ..............................................151 E
Battery--Install ...............................................151
Battery--Recycle ...........................................155 Electrical Storm Injury Prevention .................. 23
Battery--Store/ Service ..................................154 Electrical System .......................................... 151
Before Operation .............................................41 Engine Air Intake System--Check ................. 123
Before Reuse ..................................................89 Engine Belt--Check ....................................... 123
Before Storage ................................................89 Engine Hood ................................................... 77
Boom Lift Kickout--Adjust ..............................163 Engine Oil Filter--Replace ............................ 122
Brake Operation of the Machine .....................82 Engine Oil Level--Check ............................... 120
Brake System ................................................146 Engine Oil--Replace ..................................... 121
Breather Filter of Hydraulic Oil Tank--Clean .142 Engine Start Switch ........................................ 42
Bucket Cutting Edges--Check/Replace .........162 Engine Starting ............................................... 79
Bucket Positioner--Adjust ..............................162 Engine System ............................................. 107
Burn Prevention ..............................................20 Engine Tensioner Bearing and Fan Hub--Check
...................................................................... 123
C Engine Valve Lash--Adjust ........................... 123
Evaporator--Check ....................................... 159
Excavating With Bucket .................................. 84
Cab Air Strainer--Clean and Replace ...........160
Cautions about Machine Maintenance ............31
Cautions about Machine Operation ................24
182
INDEX October 12, 2019
CLG856H

F L

Fan Belt Tension--Check/Adjust ...................123 Latch ............................................................... 76

Fault Code Index of ZF4BP210 Gearbox ......166 Leaving the Machine ...................................... 88
Fault Diagnosis and Troubleshooting ...........166 Lifting the Machine ......................................... 91
Fire &Explosion Prevention .............................21 Lights .............................................................. 74
Fire Extinguishers and First-aid Kit .................22 Lowering the Work Implement with Engine
Front Left Instrument Panel ............................49 Stopped .......................................................... 88
Front Right Instrument Panel ..........................50 Lubrication Specifications ............................. 103
Front Right Upright Column Instrument Panel 51
Fuel Filter--Replace ......................................119
Fuel Level--Check .........................................116
M
Fuel Pre-filter--Replace .................................119
Fuel Strainer--Clean ......................................118 Machine Operation ......................................... 83
Fuel Tank--Clean ..........................................117 Main Components ............................................ 3
Fuel--Add ......................................................116 Main Filter Element of the Air Filter--Clean/
Fuse--Check/ Replace ..................................155 Replace ........................................................ 114
Main Specifications ......................................... 36
Maintenance Guidance ................................... 94
G Maintenance Interval Schedule ...................... 97
Maintenance Manual ...................................... 94
General Hazard Information ............................16
General Torque Specifications ......................101
O
H Oil Change Interval and Refill Capacities ..... 103
Oil Specifications .......................................... 103
Horn Switches .................................................58 Operation during Cold Weather ...................... 83
Hydraulic Oil Level--Check ...........................139 Operation Information ..................................... 80
Hydraulic Oil Tank--Clean .............................143 Operation Manual ........................................... 41
Hydraulic Oil--Add .........................................139 Operation Method ........................................... 87
Hydraulic Oil--Replace ..................................140 Operation Techniques .................................... 80
Hydraulic System ..........................................138 Operator Controls and Instrument Panels ...... 41
Operator Station ............................................. 24
Other Devices ................................................. 66
I Other Maintenance ....................................... 162

Important Maintenance Procedures ..............106

Important Safety Information .............................1
P
Instrument Panels ...........................................44
Parking ........................................................... 88
Parking Brake and Service Brake Accumulator
K Pre-charge Pressure--Check ........................ 148
Parking Brake and Service Brake Accumulators--
Key Spare Parts to be Periodically Changed ..34 Charge .......................................................... 149
Parking Brake Button ...................................... 64
Parking Brake Clearance--Check/Adjust ...... 147
Parking Brake Performance--Inspect ........... 146
Power Train System ..................................... 124
 183
October 12, 2019 INDEX
CLG856H

Pre-charge Pressure of Pilot Oil Supply Valve T

Accumulator--Check .....................................144
Preface ..............................................................1
Preparation before Operation .........................83 Tire Explosion Prevention ............................... 23
Tire Inflation Information ............................... 102
Top Switch Panel ............................................ 55
R Towing Information ......................................... 92
Towing the Machine ....................................... 92
Radiator Group--Clean ..................................123 Towing with a Running Engine ....................... 93
Rear View Mirrors ...........................................77 Transmission Oil Filter--Replace .................. 127
Refrigerant Level--Check ..............................158 Transmission Oil Level--Check ..................... 125
Return Oil Filter Element of Hydraulic Oil Tank-- Transmission Oil--Replace ........................... 126
Replace .........................................................143 Transportation Information ............................. 89
Right Armrest Box ...........................................69 Transportation of Materials ............................. 85
Right Instrument Panel ...................................56 Transportation of the Machine ........................ 89
ROPS/FOPS ...................................................24 Troubleshooting ............................................ 176
Run-in .............................................................96 Turning off the Engine .................................... 88
Type and Serial Number of the Machine and
Parts ................................................................. 4
S
W
Safety Decals and Decal Locations ..................5
Safety Information .............................................5
Safety Signs ......................................................5 Water and Impurity--Remove ....................... 118
Safety Symbol ...................................................5 Welding Operation ........................................ 164
Scraping Operation .........................................86 Window Washer Reservoir--Fill .................... 164
Seat .................................................................67 Work Implement Control Lever ....................... 65
Seat Belt (Optional) .........................................70
Seat Belt--Inspect .........................................163
Serious Polluted Hydraulic Oil--Replace .......141
Service Brake Pedal .......................................63
Service Brake Performance--Inspect ............146
Shift Control Lever ..........................................59
Shift Operation of the Machine .......................82
Shoveling ........................................................83
Shoving Operation ..........................................86
Sound and Vibration .......................................33
Sound System (Optional) ................................70
Starter Motor--Maintain .................................157
Steering Column .............................................66
Steering Frame Lock ................................ 24, 78
Steering Operation of the Machine .................82
Steering Wheel ...............................................58
Stopping the Machine .....................................88
Storage ...........................................................89
184
INDEX October 12, 2019
CLG856H