Page 1 201801001 CLG835H WHEEL LOADER PERKINS POWER T4f / LIUGONG WET AXLE / ZF158A GEARBOX / ZF160 GEARBOX ( 英语 ) OPERATION AND MAINTENANCE MANUAL...
Page 3 The specification, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. LiuGong has the most current information available.
Page 5: Table Of Contents
CONTENTS January 12, 2018 CLG835H CONTENTS Preface Operation Manual Before Operation ..........47 Safety Information Operator Controls and Instrument Panels ..48 Safety Decals and Decal Locations ....7 Engine Starting ..........108 General Hazard Information ......21 Operation Techniques ........110 Crushing and Cutting Prevention .....25...
Page 6 CONTENTS January 12, 2018 CLG835H...
Page 7: Preface
This section includes a Use this machine only for the purpose described description of gauges, machine controls, in this manual. Contact your Liugong dealer for switches and other controls at the operators’ approval before making any modifications or station.
Page 8 250 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.
Page 9 Preface January 12, 2018 CLG835H Main Components FRONT RIGHT LEFT REAR 1. Bucket 6. Cab 11. Front frame 16. Engine hood 2. Rocker arm 7. Rear fender 12. Front fender 17. Rear combination lights 3. Bucket cylinder 8. Counterweight 13. Boom cylinder 18.
Page 10 Preface January 12, 2018 CLG835H 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...
Page 11 As proof that the requirements are met, the machines marketed within the EU/EEA) machine is supplied with an EU Declaration of Conformity, issued by LiuGong CE for each This CE marking is located on the right side of separate machine. This EU declaration does not the front frame.
Page 12 RESPONSIBLE FOR MARKING THIS DECLARATION IS THE: MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■ MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD. MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA. AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.
Page 13: Safety Information
Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Safety Information "Caution" is also used to indicate safety information relating to unsafe operations which may cause personal injuries. "Danger" represents the most dangerous conditions. The Safety Symbol safety signs "Danger" or "Warning" are placed near particular dangerous places.
Page 14 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Location 1. WARNING DECAL 13. CAUTION DECAL 25. SYMBOL 37. DECAL 2. DANGER DECAL 14. WARNING DECAL 26. SYMBOL 38. DECAL 3. DANGER DECAL 15. WARNING DECAL 27. WARNING DECAL 39.
Page 15 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Location 25. SYMBOL 37. DECAL 1. WARNING DECAL 13. CAUTION DECAL 2. DANGER DECAL 14. WARNING DECAL 26. SYMBOL 38. DECAL 3. DANGER DECAL 15. WARNING DECAL 27. WARNING DECAL 39.
Page 16 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H 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.
Page 17 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information 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.
Page 18 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 6 NOTICE DECAL (Located in the cab) DW-3 shifting lever plus FNR switch operating instruction: To Start Machine: 1. Apply parking brake 2. Move DWG-3 shifting lever on steering column to “N”position...
Page 19 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 7 NOTICE DECAL (Located in the cab) ULTRA LOW-SULFUR DIESEL FUEL (ULSD) ONLY If ULSD is not used, the engine could possibly not meet emission regulations and...
Page 20 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 11 WARNING DECAL (Located in the cab) Improper engagement of worktools could result in serious injury or death. Do not operate this machine until you have positive indication that: 1.
Page 21 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 13 CAUTION DECAL (Located on the hot surface) Hot surface, keep clear. 74A3168 Fig. 14 WARNING DECAL (Located on the engine) RUNOVER HAZARD. Start engine from operator's seat, transmission in NEUTRAL.
Page 22 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 16 WARNING DECAL (Located near the battery) Only attempt to use jumper cables from an operating machine with a 24 volt negative ground system, failure to observe could result in serious injury.
Page 23 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 27 WARNING DECAL (Located near the articulation joint) CRUSH HAZARD. Engage articulation lock before service or transport. 74A4507 Fig. 28 WARNING DECAL (Located near the ladder)
Page 24 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H 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.
Page 25 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 38 DECAL (Located in the cab) 74A2875 Fig. 39 WARNING DECAL (Located near the engine fan) CUTTING HAZARD. Keep clear or stop engine before servicing. 74A3161 Fig.
Page 26 Safety Information January 12, 2018 Safety Decals and Decal Locations CLG835H Decal Information Fig. 44 WARNING DECAL (Located on the tail of machine) RUNOVER HAZARD. Keep clear. 74A2846 Fig. 46 WARNING DECAL (Located near the coolant filler cap) Hot liquid under pressure, service when cool.
Page 27: General Hazard Information
Safety Information January 12, 2018 General Hazard Information CLG835H 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.
Page 28 Safety Information January 12, 2018 General Hazard Information CLG835H 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.
Page 29 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.
Page 30 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...
Page 31: Crushing And Cutting Prevention
Safety Information January 12, 2018 Crushing and Cutting Prevention CLG835H 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.
Page 32: Fire & Explosion Prevention
Safety Information January 12, 2018 Fire & Explosion Prevention CLG835H 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. Hot oil and components can cause personal injury.
Page 33: Fire Extinguishers And First-Aid Kit
Post the or oil lines, tubes or hoses. Leaks can cause contact telephone numbers in regulated places. fires. Contact Liugong or your Liugong Dealer for factory authorized replacement parts. Ensure that all persons know where the...
Page 34: Electrical Storm Injury Prevention
Safety Information January 12, 2018 Electrical Storm Injury Prevention CLG835H 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.
Page 35: Rops/Fops
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.
Page 36 Safety Information January 12, 2018 Cautions about machine operation CLG835H 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.
Page 37 Safety Information January 12, 2018 Cautions about machine operation CLG835H 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.
Page 38 Safety Information January 12, 2018 Cautions about machine operation CLG835H 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.
Page 39 Safety Information January 12, 2018 Cautions about machine operation CLG835H 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.
Page 40 Safety Information January 12, 2018 Cautions about machine operation CLG835H 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.
Page 41 Safety Information January 12, 2018 Cautions about machine operation CLG835H 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.
Page 42: Cautions About Machine Maintenance
Safety Information January 12, 2018 Cautions about Machine Maintenance CLG835H 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.
Page 43 Safety Information January 12, 2018 Cautions about Machine Maintenance CLG835H 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).
Page 44: Sound And Vibration
A-Weighted emission sound pressure level, L at the operator's position measured according to work cycle procedures specified in "ISO 6396" is 72.5 dB(A), for the cab offered by LiuGong. A weighted sound power level of the cab measured according to work cycle procedures Clean the Equipment Periodically specified in "ISO 6395"...
Page 45: Key Spare Parts To Be Periodically Changed
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...
Page 46: Application And Specification
Do not use the machine beyond the stipulated application scope, Guangxi Liugong Machinery Co., Ltd will not bear any safety liabilities, and these safety liabilities will be born by users. Under any cases, do not use the forbidden operation outlined in this manual.
Page 47: Main Specifications
Application and Specification January 12, 2018 Main Specifications CLG835H Main Specifications All rated lift capacities specifications are collected from the machine operation on a hard and flat ground. When the machine is operated in conditions that differ from the above-mentioned conditi on (e. g. on soft or uneven ground, on a slope), these conditions shall be taken into account by the operator.
Page 48 Application and Specification January 12, 2018 Main Specifications CLG835H Machine Specifications CLG835H T4f CLG835H T4f (with ZF158 gearbox) (with ZF160 gearbox) Item Unit Quick Quick Pin On Pin On coupler coupler Rated load weight kg (lb) 3000 (6615) 3000 (6615)
Page 49 Application and Specification January 12, 2018 Main Specifications CLG835H Machine Specifications CLG835H T4f CLG835H T4f (with ZF158 gearbox) (with ZF160 gearbox) Item Unit Quick Quick Pin On Pin On coupler coupler S1: Bucket tilt back angle (on ground) ° S2: Bucket tilt back angle (in transport °...
Page 50 Operating pressure of shift oil pump (gear 1.6~1.8MPa (232~261psi) 1.6~1.8MPa (232~261psi) pump) Manufacturer LiuGong LiuGong Model LiuGong 3T wet-type axle LiuGong 3T wet-type axle Type Wet-type alxe Wet-type alxe Drive axle Max. traction force 100kN (22480lbf) 104kN (23379lbf) Front & rear axle 20.267...
Page 51 Application and Specification January 12, 2018 Main Specifications CLG835H Main Components Specifications CLG835H T4f CLG835H T4f Item (with ZF158 gearbox) (with ZF160 gearbox) Steering hydraulic system Steering angle ° Steering pump Type Piston pump Piston pump Steering pump displacement ml/r (cc/rev)
Page 52 Note: 1. Continuing improvement and advancement 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...
Page 53: Operation Manual
Operation Manual January 12, 2018 Before Operation CLG835H 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. Inspect the area around the machine and under Mounting and Dismounting the machine.
Page 54: Operator Controls And Instrument Panels
Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Operator Controls and Disconnect switch--OFF Instrument Panels To shut down the electrical system, turn the battery disconnect switch key counterclockwise to OFF position. In this position, the battery Battery Disconnect Switch disconnect switch key will point to the OFF position.
Page 55 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Engine Start Switch The start switch (also called ignition switch) is If the engine fails to start, turn the start located on the right side of the steering column in...
Page 56 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Instrument Panels Most of the monitoring gauges, alert and turn indicators of the machine are integrated in the instrument assembly under the steering wheel and on the right front upright column.
Page 57 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Central Instrument Panel AdBlue gauge This gauge indicates the level of Central instrument panel consists of five pointer AdBlue. Green zone indicates the gauges, one LCD, status indicators and warning normal volume range, red zone indicates that the indicators, etc..
Page 58 4. System voltage display: 24.8 transmission gear and transmission fault code; right area can display the engine rotating speed, system voltage, engine fault code, LiuGong controller fault code and so on, which can show in turn by using the screen selector switch.
Page 59 3241 1. Parking brake indicator 2. Brake low pressure alert indicator 3. Main fault alert indicator 7. LiuGong controller fault code display: 1b45 Parking brake indicator When engaging parking brake, the red indicator turns on. It indicates the parking brake is working.
Page 60 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Transmission oil pressure alert indicator The red indicator will flash when 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.
Page 61 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Engine warning indicator Clutch cut-off indicator This indicator is used to warn operator The machine is at clutch cut-off state that the operating condition of the when the yellow indicator lights. The engine may result in engine damage.
Page 62 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Auxiliary Instrument Panel Hydraulic oil temperature alert indicator The red indicator will flash to alert when the hydraulic oil temperature is too high. Stop the engine to check. Centralized lubrication fault...
Page 63 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Front Switch Panel 12-16 1. Hazard flasher switch 2. Position light and front floodlight switch 12. Ride control indicator 3. Front work light switch 13. Centralized lubrication indicator 4. Rear work light switch 14.
Page 64 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Press the switch to the middle position, the four When the clutch cut-off switch is turned to ON position lights and license plate light (if equipped) (see following picture), the shift control valve will...
Page 65 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Front Right Upright Column Instrument Lighter Panel 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 out the lighter for smoking.
Page 66 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 4. Press the switch and release again after cleaning, the fan starts to reduce rotating speed and then returns to the mode before reversing. The fan reverse indicator on the auxiliary instrument panel will go out at the A lock buckle is provided on the lock switch;...
Page 67 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Screen switching switch Rear washer switch This switch is located on the right front The washer will work and spray water upright column in the cab, it is used for...
Page 68 1. LiuGong controller datalink connector 2. Engine datalink connector LiuGong controller datalink connector MANUAL This is the special datalink connector of LiuGong controller. It is able to calibrate the controller AUTO parameters, test the controller fault codes and update the controller program, etc. by linking to a computer through this connector and using LiuGong special software.
Page 69 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H A/C Panel If press this switch in the recirculating air model, it will not have any reaction. This function is only suitable for the following situation: rapidly cooling or warming air in cab, the outside air is dirty.
Page 70 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Temperature control switch Heating The temperature control switch is 1. Before starting the engine, set the warm used to set the temperature in water valve at engine coolant inlet and outlet the cab.
Page 71 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Backup Monitor System (Optional) A manual warm water valve is provided respectively for the water inlet and water outlet of the engine. (Note: some machines only have one Backup monitor system mainly includes screen for the water inlet of the engine).
Page 72 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Select ”COLOR” in the screen and press UP “+” The camera will work after the monitor system is and DOWN key ”-” to adjust the screen’s color. powered on. Ensure the operator has a good UP key for dark and DOWN key for blight..
Page 73 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Source/mute key FLAT——Original ● JAZZ——Jazz music ● Press to switch on the power. Press VOCAL——Speech this key for more than 2 seconds to ● switch off the power. Press this key shortly to POP——Pop music...
Page 74 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Radio Press ''AST''key to activate auto-store. Waveband Press BAND to select the desired band. USB interface is provided on this machine. Features: Support MP3 format only. ● Support 32Mbyte~4G memory disc.
Page 75 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 3. The display will show the album number Audible signal input before playing the songs. A 3.5 mm audible signal input interface 4. When playing, the display will show the is provided on the sound system, song's name and playing time.
Page 76 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Control Devices 1. Steering wheel 4. Service brake pedal 7. Parking brake button 2. Horn switches 5. Accelerator pedal 8. Work implement control lever 3. Shift control lever 6. Combination switch...
Page 77 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Steering Wheel Horn Switches There are three horn switches, one is located in the centre of the steering wheel, the second one is located at the end of the steering combination handle, the third one is on the work implement control lever.
Page 78 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Steering indication Horn control Push the combination switch forward when turning left, the left turn indicator will flash, and the front & rear left turn signal lights will also turn The horn will sound by pressing the horn button on simultaneously.
Page 79 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.
Page 80 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Push the shift control lever to NEUTRAL, and push the lock switch to position (N), the shift control lever will be locked at NEUTRAL position. Push the lock switch to position (D), the shift control lever will be unlocked, and the machine can be operated normally.
Page 81 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H When the machine exceeds the preset speed The KD key function and the direct forward/ (normally 2nd gear is set as the maximum driving reverse change function have supplied a...
Page 82 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 6. System self-protection function When abnormal information occurs (such as disconnected wiring, ground short-circuit of the A lock buckle is provided on the clutch cut electronic control box and odd signal) or power off switch.
Page 83 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Parking Brake Button If the clutch cut-off switch is turned on and the transmission is at first or second gear, depressing the brake pedal, then the transmission will shift to neutral automatically to cut off the power output.
Page 84 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Work Implement Control Lever The work implement control lever is located on the right side of the driver's seat. It is used to control the boom and bucket. Push the control lever forward and pull it backward to control the boom lowering and raising;...
Page 85 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 3. FNR function will stop when the shift control Pull the control lever to NEUTRAL position to lever is not at N position. Then the travel cancel FLOAT state.
Page 86 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Auxiliary Control Knob (Optional) Bucket positioning When the bucket is at DUMP condition, pull the The auxiliary control knob is located on the work control lever leftward to the limit position, then implement control lever.
Page 87 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H TILT BACK--Rotate the auxiliary SWING LEFT--Rotate the auxiliary control knob again, the bucket will tilt control knob again, the moldboard will back. The control knob will return to swing left. The control knob will return...
Page 88 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Other Devices 1. Rotate the adjusting handle counterclockwise for one quarter turn, the steering wheel will be unlocked and can be adjusted upward or Steering Column downward to desired position.
Page 89 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Pilot Shutoff Lever 1. Fore-and-aft adjustment. Hole the linkage under the seat, move the seat If the distribution valve of the machine hydraulic forward or backward to the desired position.
Page 90 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 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.
Page 91 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 seat belt for wear and fastness, replace if necessary. Contact your LiuGong dealer for the seat belt replacement.
Page 92 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Hand Pad Lights There is a hand pad beside driver's seat. The Lights of the machine consist of front work lights driver can place his right arm on it to reduce (left &...
Page 93 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H The front combination lights consist of front turn signal lights, front position lights, and front floodlights. 8. Rear position lights/ brake lights 9. Rear turn signal lights 10. Backup lights 5.
Page 94 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Door Lock Door Positioner The driver should enter the cab from the left door, which can be opened inside or outside the cab. The right door can not be opened.
Page 95 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Stay rod of left door When open the door, the pressurization in the cab will disappear. Before operating the machine, always close Extract the fixed pin to unlock the latch and then the right &...
Page 96 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Rear View Mirrors When open the right window completely, the position latch on the right window is locked by the buckle behind. Then the right window is Left and right rear view mirrors are separately locked in this position.
Page 97 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Engine Hood 2. Press the switch button on the rear lock handle to open the lock, hold the handle and open the engine hood by pulling it upward. The switch button of engine hood is located on the rear lock handle of the machine.
Page 98 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Steering Frame Lock Close the engine hood 1. Pull the rope downward to grab the engine hood lock handle, then pull the lock handle downward to lock the engine hood. The...
Page 99 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Backup Alarm System The backup alarm is located at the back of the machine. When the machine is reversing with shift control lever turned to REVERSE position, the backup alarm will sound automatically.
Page 100 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Centralized Lubrication System (Optional) Centralized lubrication system consists of pumps, controllers,circuits, connectors and brackets. This system can lubricate automatically when the bearing is working, which can reduce pollution, friction and abrasion, maintenance interval and lubricating effort.
Page 101 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Schematic of centralized lubrication system Motor pump Nozzle tip Piston pump Relief valve Note: The length of the pipe line connected to lubrication point 8 is: 635mm. The combination of numbers in the schematic indicates the combination of relative parts.
Page 102 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H VPKM in the schematic is the step-forward controller, which is composed of several modules. The locations of VPKM-3, VPKM-5 and VPKM-8 are as shown below.
Page 103 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Pump unit Relief valve The pump unit is located on the right side of the machine front frame. A---To pipe φ6 P---To pump unit R---Grease overflow The relief valve is installed at the end of the pump unit to protect the entire lubrication system from high-pressure.
Page 104 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Instructions and symbols on the adjusting Fh ..........Fault time timer panel: bLo....Indicates the fault time has exceeded three working periods of the pump. Symbol Name Function Adjusting Steps of the Electric Controller...
Page 105 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H LiuGong has set the running time for the Improper engagement of work attachment machine when manufacturing it. Make sure could result in injury or death. Do not operate that the lubrication is satisfactory if any this machine until you have positive change is needed.
Page 106 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 1. Install the Work Attachments Before using the quick coupler, please check the quick coupler carefully for a good connection. Improper engagement of work attachment could result in injury or death. Do not operate this machine until you have positive 1.
Page 107 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 5. If the machine is equipped with a pilot cut-off 7. Operate the machine to slightly tilt the quick lever, turn it to ON position. If the machine is coupler frame forwards.
Page 108 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 9. Pull the auxiliary control lever backward (to 4. Stop plate 5. Pilot control lever CLOSE position) to let the connecting pin of the quick coupler extends to connect with the 12.
Page 109 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 2. The diverter valve is located on the right side 4. Loosen nut of the auxiliary control lever lock of coupler frame. Firstly turn the handle of and pull the stop plate outwards to unlock the quick coupler to "Coupler"...
Page 110 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 6. Slightly push the auxiliary control lever 9. Press the quick coupler switch to LOCK forwards to let the connecting pin of the quick position. coupler retract inside. UNLOCK LOCK 10.
Page 111 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 1. Put the bucket gently on the trailer by using a lifting device. Try to keep the bucket parallel with the trailer body and move it to central part of the trailer. The width of the bucket can not exceed that of the trailer in order to avoid collision during transportation.
Page 112 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H Pallet Forks (Optional) The operator should be trained with professional techniques and have corresponding professional qualifications. The loading capacity of the fork should not exceed the specified value. The loading capacity of the pallet forks varies according to the lifting ability of boom and the tilting ability of pallet forks.
Page 113 Operation Manual January 12, 2018 Operator Controls and Instrument Panels CLG835H 2. Level the forks, slowly load the material and 4. Travel with the material as low as possible the forks should completely insert into the while you still maintain ground clearance.
Page 114: Engine Starting
Operation Manual January 12, 2018 Engine Starting CLG835H Engine Starting 1. Turn on the battery disconnect switch. After the battery disconnect switch is turned on, the key will point to ON position. Engine Starting 2. Mount and dismount the machine according Check Before Starting the Engine to the safety regulations.
Page 115 Operation Manual January 12, 2018 Engine Starting CLG835H 9. Slightly depress the accelerator pedal, and turn the start switch key clockwise to START Hydraulic lock switch position to start the start motor of the engine. In normal case, the engine will start within 10 seconds.
Page 116: Operation Techniques
Operation Manual January 12, 2018 Operation Techniques CLG835H Operation Techniques Driving Operation of the Machine Operation Information Follow these basic instructions when you are Before driving the machine on road, check operating the machine. whether the machine meets the requirements of the local road laws and 1.
Page 117 Operation Manual January 12, 2018 Operation Techniques CLG835H Steering 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 1. Release the accelerator pedal to slow down will travel forward or backward.
Page 118 Operation Manual January 12, 2018 Operation Techniques CLG835H Brake Operation of the Machine Operation during Cold Weather When performing brake, first release the accelerator pedal, then smoothly depress the brake pedal to perform the service brake If the ambient temperature is too low, the operation.
Page 119 Operation Manual January 12, 2018 Operation Techniques CLG835H 7. Due to the freezing point of Diesel Exhaust 1. Drive the machine at F2 speed to approach Fluid (DEF), the aftertreatment system is materials. Align the bucket middle with the equipped with electrically heated DEF lines.
Page 120 Operation Manual January 12, 2018 Operation Techniques CLG835H 1. The operation of the cutting in the material When transporting, make sure that the lower pile is the same as the common shoveling. articulated joint of the boom is at transporting position (about 500mm above the ground).
Page 121 Operation Manual January 12, 2018 Operation Techniques CLG835H Scraping Operation Lift the boom, tilt the bucket forward until the blade contacts the ground. The angle between Do not lower the boom when the bucket is at the blade and ground should be kept at about high dumping position with full load, 60°.
Page 122 Operation Manual January 12, 2018 Operation Techniques CLG835H Operation Method 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 1. V Type operation method machine from one side and stops.
Page 123 Operation Manual January 12, 2018 Operation Techniques CLG835H Parking 2. Apply down pressure to the bucket as the loader starts forward. Return the lift control to HOLD when sufficient penetration is Stopping the Machine obtained. 1. Park the machine on flat ground. If it is...
Page 124 Operation Manual January 12, 2018 Operation Techniques CLG835H Lowering the Work Implement with 3. Inspect the engine compartment for debris. Clean out any debris and paper in order to Engine Stopped avoid a fire. Make sure that no pesonnel is around the 4.
Page 125: Transportation Information
1. Chock the trailer wheels or the truck wheels before you load the machine. If the machine is not coated with antirust additive per month during storage, consult your LiuGong dealer. 2. When the machine is loading on the trailer or truck, it is forbidden to turn.
Page 126 Operation Manual January 12, 2018 Transportation Information CLG835H Driving the Machine 3. After the machine being parked, use the steering frame lock to lock the front frame and the rear frame. 1. Before operating the machine, consult your tire dealer for recommended tire pressure and speed limitations.
Page 127 Operation Manual January 12, 2018 Transportation Information CLG835H Towing Information 3. The length of the four ropes on the lifting device must be the same to ensure the four lifting eyes share the same pressure. Towing the Machine Personal injury or death could result when towing a disabled machine incorrectly.
Page 128 3. Do not allow riders on the machine that is It is impossible to list all the requirements for all being towed unless the operator can control different situations. Refer to liugong dealer for the steering wheel or the brake. more information of towing the disabled 4.
Page 129: Maintenance Manual
Proper sensors etc. maintenance will extend the service life of the 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.
Page 130 2. Check the circuits of the battery, starter motor and alternator. Avoid Mixing Oil 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.
Page 131: Run-In
Maintenance Manual January 12, 2018 Run-in CLG835H Preparation before Maintenance 4. Start the machine at low speed. Slowly increase speed. Always avoid starting, Park the machine as follows before speeding up, turning and braking suddenly maintenance: except for emergency cases.
Page 132: Maintenance Interval Schedule
(daily, weekly, it if it has been worn away, and exhaust air in monthly, etc). Liugong recommends that the clamp. Check once every 250 service maintenance should be performed according to hours later on.
Page 133 2. Tighten all connecting bolts on drive shafts at Use higher grade engine oil can prolong the the first 100 service hours, tighten them service hour of engine oil, contact LiuGong or every 2000 service hours later on. engine manufacturer for details.
Page 134 If the operating hours are less than specified, replace the coolant at 8. For the machine with LiuGong axle, ZF axle least every two years. or ZFAP axle, replace gear oil of the axles after the first 500 service hours, replace once 2.
Page 135 Maintenance Manual January 12, 2018 Maintenance Interval Schedule CLG835H 7. For the machine equipped with air conditioner, check the refrigerant level in the refrigerant receiver. 8. Check flexibility of the steering system. 9. Tighten all connecting bolts on drive shafts.
Page 136: General Torque Specifications
Maintenance Manual January 12, 2018 General Torque Specifications CLG835H 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...
Page 137: Tire Inflation Information
Low pressure will shorten the service life of the tires. Consult your Liugong dealer when you are not sure about the tire Training for using the equipment is inflation pressure.
Page 138: Lubrication Specifications
Maintenance Manual January 12, 2018 Lubrication Specifications CLG835H Lubrication Specifications Oil Change Interval and Refill Capacities Care must be taken in order to ensure that fluids are contained during the performance of inspection, maintenance, testing, adjusting and repair of the equipment.
Page 139 Maintenance Manual January 12, 2018 Lubrication Specifications CLG835H Oil Specifications Please use specified oil according to the following table when adding and replacing various oil for the machines to ensure the normal use of the machines. Type of oil Name of oil Position of use ★...
Page 140: Important Maintenance Procedures
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.
Page 141 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Engine System Maintenance Table Interval (Hours) Item 10hr or 50hr or 100hr 250hr or 500hr or 1000hr 2000hr every every or 2 every three or half a or one required week...
Page 142 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Coolant Level--Check Check the cooling system of the engine for leakage if it needs to add coolant everyday. If Hot coolant can cause serious burns. To leakage is found, eliminate the leakage and open the cap, stop engine until the radiator add coolant until it reaches the proper level.
Page 143 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Coolant must contain additive (SCA) to prevent Water used in coolant must be soft water or the engine parts which contact with coolant from distilled water, because ordinary fresh water and rusting, scaling, pitting, and corrosion.
Page 144 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Add coolant as follow: 6. Open the filler cap of the water radiator recovery tank, slowly add coolant until the 1. Mix the water and coolant completely level reaches the filler cap of the recovery according to desired density level of the tank and keeps stable within 10 minutes.
Page 145 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Coolant--Replace When coolant is polluted, engine overheated or bubbles appeared in radiator, test the freezing point of the additive and anti-freeze in the cooling system to determine whether the coolant must be replaced, replace the coolant if it exceeds any Hot coolant can cause serious burn.
Page 146 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Turn the manual valve on the water inlet hose 7. The water drain plug is located at the left side of the engine to ON position (The valve is at of the rear frame, near the rear left wheel, ON as shown).
Page 147 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Filter Elements of the Air Filter--Replace 11. Keep the water radiator filler cap open, start the engine, when the cleanser temperature reaches over 80°C, run the engine for 5~10 minutes again.
Page 148 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H The safety air filter element should be changed every third time the main air filter element is changed. 5. Check the new filter elements before installation to see if there is any cutting, tearing or indentation on the seal surface.
Page 149 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Fuel--Add If the air filter cover can’t be installed, remove it and check the locations of the filter No smoking and keep away from the flames elements again. It is difficult to install the air or spark area when adding fuel.
Page 150 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Add fuel. 2. Remove the flange cover in front of the fuel tank. Wash the inner surface of the tank with clean fuel. Don't take out the strainer of the fuel filler when adding fuel.
Page 151 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Filter Element of Fuel Water Separator-- 2. Before filling, screw out the drain plug at the bottom of the fuel tank to drain out water and Replace impurity deposited in the tank once every week.
Page 152 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Fuel Filter Element--Replace 3. Turn the drain valve counterclockwise to push the filter element of the fuel water separator upward slowly and then take it out. The fuel filter is located on the left side of the engine.
Page 153 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Engine Oil Level--Check 5. Install a new gasket onto the fuel filter. Apply a coat of engine oil on the seal surface of the filter. Fill the fuel filter with clean fuel.
Page 154 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 5. If the oil level is below L, add oil. If the oil 3. The engine oil drain plug is located at the left level is above the H, screw out the oil drain...
Page 155 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 5. Install a new O-ring, replenish the oil filter with clean engine oil, and apply a coat of clean engine oil on the gasket surface. Within 15 seconds after the engine has been started, check the reading of engine oil pressure gauge.
Page 156 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Engine Crankcase Breather Element-- Note: Excessive quantities of oil that enter the induction system of the engine can rapidly Replace increase the engine speed without control. Illustration 1 Hot oil and hot components can cause personal injury.
Page 157 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Gas-oil Dissociation System--Check 3. Note the orientation of the filter element. Remove the filter element. Illustration 2 4. Seal 5. Section Note: The cut away from section in the cap allows access to the seal.
Page 158 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Fuel Filter (In-Line)--Replace Replace steps are as follows: 1. Turn the fuel supply valve (if equipped) to the OFF position. Remove any brackets that hold the in-line fuel filter in place, refer to OEM information.
Page 159 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Post-processing System Description of T4F Engine Post-processing system of the T4F engine AdBlue supply pipes refers to AdBlue feed mainly includes the postprocessor, AdBlue tank& pipe, AdBlue return pipe and AdBlue AdBlue pump &...
Page 160 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H SCR System--Maintain DEF that has been split will crystallize when the water within the liquid evaporates. Split DEF will attack paint and metal. If DEF is split, wash the area with water.
Page 161 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 3. Fill the tank with the required amount of DEF. 1. Ensure that the area around cap on the Ensure that dirt is not introduced into the tank Diesel Exhaust Fluid (DEF) tank is clean.
Page 162 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Diesel Exhaust Fluid Filter--Clean/Replace 5. Diesel Exhaust Fluid Tank--Flush 1. Ensure that the area around the Diesel Clean the diesel exhaust fluid tank once every Exhaust Fluid (DEF) filter is clean and free 4000 service hours.
Page 163 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 2. If necessary, install the DEF filler screen. For more information, refer to this Operation and Maintenance Manual, “DEF Filler Screen-- Clean”. 3. Install the drain plug. Tighten the drain plug to a torque of 66 Nm (53 lb in).
Page 164 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Engine Valve Lash--Adjust Fan Belt Tension--Check/Adjust For more information on fan belt adjustment procedures, refer to the Operator and Maintenance Manual of the Engine. Adjustment of the engine valve lash must be performed by trained personnel with special tools.
Page 165 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Power Train System Maintenance Table Interval (Hours) Item 10hr or 50hr or 100hr 250hr or 500hr or 1000hr 2000hr every every or 2 every three or half a or one required...
Page 166 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Check the transmission hot oil level when the transmission oil temperature reaches 80~100°C. Unscrew the transmission oil filler cap and check the sight glass vertically. The oil level should be in the HOT zone. If the oil...
Page 167 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Transmission Oil--Replace Oil drain plug of ZF 160 gearbox 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...
Page 168 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 6. Replace the transmission secondary filter 10. When the transmission oil reaches 80~90 °C , and seal ring. Refer to section "Transmission check the oil level again. The level sho uld be Secondary Filter--Replace"...
Page 169 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Air Breather--Clean Transmission Primary Filter--Clean Care must be taken to ensure that fluids are Care must be taken to ensure that fluids are contained during performance of inspection, contained during performance of inspection, maintenance, testing, adjusting the product.
Page 170 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 3. Secure the primary filter, oil suction pipe, The secondary filter of ZF160 gearbox is located drain plug and oil drain plug of the torque in the accumulator box. converter oil radiator and seals.
Page 171 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Axle Oil Level--Check (LiuGong Wet 6. Check the oil level of another axle according to the previous operation steps. Axle) Axle Oil--Replace (LiuGong Wet Axle) Be careful of the splashing hot oil when adding, draining, or loosening the plug.
Page 172 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 3. Loosen the oil drain plug on the wheel end of 9. Start the engine, disengage the parking the front axle and the oil drain plug in the brake. Turn the shift control lever to the first...
Page 173 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Hydraulic System Maintenance Table Interval (Hours) Item 10hr or 50hr or 500hr or 1000hr or 1500hr or 2000hr or required every day every week three months half a year nine months...
Page 174: Hydraulic Oil--Add
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 5. Check the sight glass of the hydraulic oil tank 2. Refill the hydraulic oil tank and check the when there aren’t bubbles. The hydraulic oil sight glass. The hydraulic oil level should be...
Page 175 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Push the work implement control lever 6. Clean the oil drain outlet below the hydraulic rightward to let the bucket tilt forward by its oil tank, loosen the oil drain plug to drain out deadweight, and discharge the hydraulic oil the hydraulic oil and collect with a container.
Page 176: Serious Polluted Hydraulic Oil
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 8. Turn on the oil drain plug of the hydraulic oil 14. Remove the steering frame lock and start the cooler and drain residual hydraulic oil from engine. Operate the work implement control the cooler.
Page 177 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 2. Start and run the engine at idle speed for 10 6. Loosen the oil drain plug to drain out minutes. Operate the boom and tilt the hydraulic oil and collect with a container.
Page 178 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 11. Replace the polluted hydraulic oil according 1. Loosen the oil drain plug to drain out to the procedures described in section hydraulic oil and collect with a container. "Hydraulic Oil--Replace". Replace the return...
Page 179: Hydraulic Oil Tank--Clean
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Hydraulic Oil Tank--Clean 3. Remove the return oil filter end cap, take out the return oil filter element and O ring. Deal with them properly. Care must be taken to ensure that fluids are...
Page 180: Pilot Filter Element--Replace
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Pilot Filter Element--Replace 4. Remove the pilot filter from the mounting support with a spanner and take out the element from the pilot filter body. Dispose of The pilot filter is located on the right side of the the pilot filter element properly.
Page 181: Pre-Charge Pressure Of Pilot Oil Supply Valve Accumulator
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Pre-charge Pressure of Pilot Oil Supply 3. Move the pilot control lever to any directions continuously to discharge the high pressure Valve Accumulator--Check oil inside the accumulator. Check the accumulator pre-charge pressure at the first 50, 100, 250, 500, 1000 service hours of operation.
Page 182: Accumulator Of Pilot Oil Supply Valve--Charge
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Accumulator of Pilot Oil Supply Valve-- 4. Remove the protection cap of the charge valve from the accumulator. Charge 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.
Page 183 10. Apply a coat of engine oil to the top of the charge valve to check if any leakage occurs. There is a leak if air bubbles are found. Consult your LiuGong dealer to eliminate the fault. 11. Install the protection cap of the charge valve on the accumulator.
Page 184: Note: ★ ★ ★ Indicates The First Service Interval
Perform spot braking, the machine should stop immediately without deflection. If the brake distance exceeds 15m, consult your Liugong dealer for brake system checking. Before checking the service brake ability, Eliminate the problems before going on working. make sure the machine's parking brake system works normally in case of any emergency.
Page 185 Check to see if the machine has moved from its original location. If the machine moves while checking, consult your Liugong dealer for brake system checking. Eliminate the problems before going on working. Personal injury can result if the machine...
Page 186 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 1. Park the machine on flat ground, stop the 6. Operate the parking brake button repeatedly engine and install the steering frame lock. to check the parking brake ability by stopping the machine on a slope.
Page 187 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Parking Brake and Service Brake Accumulator Pre-charge Pressure --Check Check accumulator nitrogen precharge Check the accumulator pre-charge pressure at pressure according to the intervals specified the first 50, 100, 250, 500, 1000 service hours of in Maintenance Interval Schedule section to operation.
Page 188 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Parking Brake and Service Brake 5. Tighten the valve A (turn rightwards) on the 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.
Page 189 There should be a leak if air bubbles are 5. Tighten the valve A (turn rightwards) on the found. Contact your LiuGong dealer for repair accumulator charge tool, turn off the valve B. information.
Page 190 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 1. Park the machine on flat and open ground, pressure is higher than expected, adjust the and lower the bucket on the ground. Turn the exhaust valve B to get the desired pressure shift control lever to NEUTRAL position and reading.
Page 191 There should be a leak if air bubbles are When air is mixed into the system pipeline, found. Contact your LiuGong dealer for repair exhaust air as follows: information. (1) Disconnect the main pipeline from the pump 10.
Page 192 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 2. Check automatically 1. Pump grease through grease filling plug An automatic switch is provided for checking the Remove the red protection cap of the grease grease level. When the grease level falls below filling plug, pump grease by the grease gun.
Page 193 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Lubrication Diagram and Intervals If centralized lubrication system is not provided on this machine, add lubricant according to the lubrication diagram and intervals.
Page 194 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Electrical System B) Observe the reading on the multimeter. The voltage value should be lower than 12.5V (lower than 25V if two batteries are Battery--Check measured in series), charge the battery in time.
Page 195 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Battery--Install C) There are graduation lines for different capacity batteries on the battery testing gage board. Observe the relative graduation line and judge the battery condition. Make sure the battery terminals are clean before installing the battery.
Page 196 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H d) Connect the battery disconnect switch to A long-time use of the electric appliances without ground cable. starting the engine or a long-time stop, electricity leakage, or the alternator can not charge; all...
Page 197 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Connect the cables after finishing charging. Cennect the positive cable first. Wear safety goggles when charging. Keep ventilated when charging. Charge the battery under normal temperature. Do not smoke when charging the battery, keep any kindling away.
Page 198 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 1. Start the engine, and ensure that the battery Battery Voltage Charge Time charging system is in normal (observe the 11.95-11.80VDC battery voltage through gauge), keep the engine speed at second gear to charge the 11.80-11.65VDC...
Page 199 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Battery--Store/ Service Battery, Cable, Battery Disconnect Switch--Replace 1. Turn off the battery disconnect switch when storing the batteries being installed on a 1. Turm the engine start switch key to OFF machine, and check the battery voltage state position.
Page 200 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 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.
Page 201 The color of the fuses near the battery box is as It is recommeded to use fuse supplied by follows: LiuGong if it needs to replace the fuse when Model Color repairing. Do not buy the fuse randomly in...
Page 202 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Air Conditioning System Maintenance Table Interval (Hours) 10hr or 50hr or 100hr 250hr 500hr 1000hr 2000hr Item every every or 2 or every or three or half or one required week...
Page 203 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Compressor Belt Tension--Check/ Adjust/ Replace The compressor belt tension: apply(W=15N) R134a refrigerant is used in this air force in the center span of the pulleys conditioning system. Do not use other (compressor pulley and engine pulley).
Page 204 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Evaporator--Check Adjusting the air conditioner belt tension as follows: The fresh air strainer (fresh air vent) and recirculating air vent of the evaporator should be regularly checked and cleaned to avoid being blocked by accmulated dirt.
Page 205 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Condenser--Clean 5. Air conditioner system only can be used after the engine is started. Condenser is located between the heat 6. Set the temperature to a comfortable insulation supporter and the radiator under the temperature and turn on the air conditioner/ engine hood.
Page 206 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Cab Air Strainer--Clean and Replace The cab air strainers consist of the fresh air strainer and recirculating air strainer. The If the fresh air strainer is still blocked or blockage condition of the strainers is entirely...
Page 207 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Replace the recirculating air strainer every 2000 hours. Choose an air strainer which meets the standard of ISO10263-2. Other Maintenance Maintenance Table Interval (Hours) 10hr or 50hr or 100hr 250hr...
Page 208: Boom Lift Kickout--Adjust
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 4. Install the steering frame lock. 3. Turn the pilot shutoff lever (If equipped) to OFF position. Pilot shutoff lever at OFF 5. Loosen the bolts in following picture, adjust the bucket positioner switch in back and forth direction until it reaches proper position.
Page 209: Bucket Cutting Edges--Check
Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Bucket Cutting Edges--Check/Replace Bucket Teeth--Replace Check the bucket teeth for wear and for damage. Use the following procedure to service the bucket teeth: Personal injury or death can result from bucket falling. Chock the bucket before replacing bucket cutting edges.
Page 210: Backup Alarm--Test
For further information of the seat belt replacement, refer to your Liugong dealer. Windows--Clean WH EEL L OADER G u a n g x i L i u g o n g Ma ch i n e ry Co . , L t d .
Page 211 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 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.
Page 212 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H 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.
Page 213 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Appendix 1 LiuGong Controller Fault Code Fault Code Parameter Name Fault Description (hexadecimal) Transmission oil pressure Transmission oil pressure is low 1341 Transmission input rotating Transmission input speed sensor has 17C5...
Page 214 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Fault Code Parameter Name Fault Description (hexadecimal) Bucket tilt back proportional Bucket tilt back proportional valve has 6020 19E5 valve open circuit failure Bucket tilt back proportional Bucket tilt back proportional valve has...
Page 215 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H Appendix 2 Perkins Tier 4F 4cyl Diagnostic Code List Note: Column P highlights all diagnostic codes that if left active i.e. not rectified will lead to a Inducment escalation process initiating. In this case the J1939 SPN 5246 will be transmitted as well as the associated diagnostic code until the problem is fixed.
Page 216 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Oil Pressure : FALSE Low - most severe (3) Engine Oil Pressure : FALSE Voltage Above Normal Engine Oil Pressure : FALSE Voltage Below Normal Engine Oil Pressure :...
Page 217 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Coolant Temperature : Voltage FALSE Above Normal Engine Coolant Temperature : Voltage FALSE Below Normal Engine Coolant Temperature : High - FALSE least severe (1) Engine Coolant...
Page 218 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Number Of ECU Resets : Not FALSE Responding Properly Number Of ECU Resets : Abnormal FALSE Frequency, Pulse Width, or Period Number Of ECU Resets : Abnormal FALSE...
Page 219 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Injector Metering Rail #1 FALSE Pressure : Low - moderate severity (2) Battery Potential / Power Input #1 : FALSE Voltage Above Normal Battery Potential / Power Input #1 :...
Page 220 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Exhaust Gas Recirculation FALSE Differential Pressure : Voltage Above Normal Engine Exhaust Gas Recirculation FALSE Differential Pressure : Voltage Below Normal Engine Exhaust Gas Recirculation FALSE Differential Pressure :...
Page 221 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Calibration Memory : Erratic, Intermittent, or FALSE Incorrect Engine Timing Sensor : FALSE Other Failure Mode J1939 Network #1 : FALSE Abnormal Update Rate J1939 Network #1 :...
Page 222 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Injector Cylinder #02 : Current FALSE Below Normal Engine Injector Cylinder #02 : Current FALSE Above Normal Engine Injector Cylinder #03 : Erratic, FALSE Intermittent, or Incorrect...
Page 223 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Speed Sensor #2 : Abnormal FALSE Frequency, Pulse Width, or Period Engine Electric Lift Pump for Engine Fuel 1075 FALSE Supply : Current Below Normal Engine Electric Lift...
Page 224 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Turbocharger 1 Wastegate Drive : 1188 FALSE Current Above Normal J1939 Network #2 : 1231 TRUE Abnormal Update Rate J1939 Network #2 : 1231 14 TRUE Special Instruction...
Page 225 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Exhaust Gas Recirculation (EGR) 2791 FALSE Valve Control : Not Responding Properly Catalyst Tank 3031 12 TRUE Temperature : Failure Catalyst Tank Temperature : High - 3031 16...
Page 226 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Aftertreatment #1 Outlet NOx : Not 3226 TRUE Responding Properly Aftertreatment #1 Outlet NOx : Other 3226 TRUE Failure Mode Aftertreatment #1 3226 12 TRUE Outlet NOx : Failure...
Page 227 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Engine Exhaust Gas Recirculation Inlet 3358 13 FALSE Pressure : Out of Calibration Aftertreatment #1 DEF Controller : Voltage 3360 TRUE Above Normal Aftertreatment #1 DEF Controller : Voltage...
Page 228 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Sensor Supply Voltage 3 : Voltage Above 3511 TRUE Normal Sensor Supply Voltage 3 : Voltage Below 3511 TRUE Normal Sensor Supply Voltage 4 : Voltage Above 3512...
Page 229 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Aftertreatment #1 SCR Dosing Reagent 4334 TRUE Absolute Pressure : Voltage Below Normal Aftertreatment #1 SCR Dosing Reagent Absolute Pressure : 4334 16 TRUE High - moderate severity (2)
Page 230 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Aftertreatment #1 SCR Catalyst Reagent Line 4356 TRUE Heater #3 : Current Above Normal Aftertreatment #1 SCR Catalyst Intake Gas 4360 TRUE Temperature : Voltage Above Normal Aftertreatment #1 SCR...
Page 231 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Aftertreatment #1 Diesel Exhaust Fluid 4374 TRUE Pump Motor Speed : Voltage Above Normal Aftertreatment #1 Diesel Exhaust Fluid 4374 TRUE Pump Motor Speed : Current Below Normal...
Page 232 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Aftertreatment SCR Operator Inducement 5246 15 FALSE Severity : High - least severe (1) Aftertreatment SCR Operator Inducement 5246 16 FALSE Severity : High - moderate severity (2)
Page 233 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description DPF Active Regeneration Inhibited 5629 31 FALSE Due to Low Exhaust Gas Pressure Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve 5706 TRUE Actuator:Current Below Normal Aftertreatment #1 SCR...
Page 234 Maintenance Manual January 12, 2018 Important Maintenance Procedures CLG835H ET J1939 Description Aftertreatment #1 Diesel Exhaust Fluid Dosing Control Unit 6309 TRUE (KSW sinking dout) : Current Below Normal Aftertreatment #1 Diesel Exhaust Fluid Dosing Control Unit 6309 TRUE (KSW sinking dout) :...
Page 235: Index
INDEX January 12, 2018 CLG835H INDEX A/C Panel ............63 Cab Air Strainer--Clean and Replace ... 200 Accelerator Pedal ..........77 Cautions about Machine Maintenance ... 36 Accumulator of Pilot Oil Supply Valve -- Charge Cautions about machine operation ....29 ...............176 CE Marking, EMC Directive ......
Page 236 Lifting the Machine ........120 Filter Elements of the Air Filter--Replace ..141 Lights .............. 86 Fire &Explosion Prevention ......26 LiuGong Controller Fault Code ..... 207 Fire Extinguishers and First-aid Kit ....27 Lowering the Work Implement with Engine Front Right Upright Column Instrument Panel 59 Stopped ............
Page 237 INDEX January 12, 2018 CLG835H SCR System--Maintain ......... 154 Scraping Operation ........115 Seat ..............83 Pallet Forks ...........106 Seat Belt ............85 Parking ............117 Seat Belt--Inspect ......... 204 Parking Brake and Service Brake Accumulator Serious Polluted Hydraulic Oil--Replace ..170 Pre-charge Pressure--Check ......181...
Page 238 INDEX January 12, 2018 CLG835H Windows--Clean ..........204 Work Implement Control Lever .......78...

LiuGong CLG835H Operation And Maintenance Manual

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