Download
Share
Print this page
  1. Manuals
  2. Brands
  3. LiuGong Manuals
  4. Front End Loaders
  5. CLG842H
  6. Operation and maintenance manual

LiuGong CLG842H Operation And Maintenance Manual

Wheel loader
Hide thumbs

Advertisement

Quick Links

Download this manual
202311000
CLG842H
November 28, 2023

Advertisement

loading
Need help?

Need help?

Do you have a question about the CLG842H and is the answer not in the manual?

Questions and answers

Related Manuals for LiuGong CLG842H

Summary of Contents for LiuGong CLG842H

  • Page 1 202311000 CLG842H November 28, 2023...
  • Page 2 202311000 CLG842H WHEEL LOADER DCEC Power Tier 2/ LiuGong Dry Axle/ ZF200 Gearbox （英语） OPERATION AND MAINTENANCE MANUAL...
  • Page 4 Continuous improvements in the design of this machine may cause variations in some details, which may not be reflected in this manual. For the latest information on the machine, or for questions about the information in this manual, please contact LiuGong or a LiuGong distributor.
  • Page 5 CALIFORNIA Proposition 65 Warning WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.  Always start and operate the engine in a well-ventilated area. ...
  • Page 7 November 28, 2023 Contents CLG842H Contents Preface ..............................1 Machine Main Components and Direction ................... 3 PIN & Nameplates ........................... 4 Product Identification Number (PIN) ......................4 Machine Nameplate ..........................4 Engine Nameplate ............................ 4 Machine and Component Serial Numbers .................... 5 Safety Information ..........................
  • Page 8 Contents November 28, 2023 CLG842H Clean Cab Glass ............................ 33 Tire Information ............................33 Attachments and Options ........................34 Attachment Cautions ........................34 Storing Attachments ........................34 Crushing and Cutting Prevention ......................34 Steering Frame Lock ..........................35 Cautions when Running Engine inside Building ..................36 Cautions in Cold Areas ...........................
  • Page 9 November 28, 2023 Contents CLG842H Main Specifications ..........................51 Operation Manual ..........................58 Before Operation ............................ 58 Operator Controls and Instrument Panels ....................59 Battery Disconnect Switch ....................... 59 Start Switch ............................. 60 Instrument Panel ..........................61 Central Instrument Panel ......................62 Steering Column Instrument Panel ...................
  • Page 10 Contents November 28, 2023 CLG842H Attachment Transportation (Optional) ..................101 Machine Starting ..........................101 Check Before Starting the Machine ....................101 Machine Starting ..........................101 Operation Techniques .......................... 104 Operation Information ........................104 Driving Operation of the Machine ....................104 Steering Operation of the Machine ....................
  • Page 11 November 28, 2023 Contents CLG842H Break-in ..............................121 Maintenance Interval Schedule ......................122 General Torque Specifications ......................132 Tire Inflation Information ........................133 Fluids and Lubricants ........................... 135 Fluid Change Interval and Refill Capacities ................... 135 Fluid Specifications ........................136 Important Maintenance Procedures .....................
  • Page 12 Contents November 28, 2023 CLG842H Axle Oil--Change ........................165 Hydraulic System ........................... 166 Hydraulic System Oil Pressure -- Release ................166 Accumulator Precharge Pressure--Check/ Accumulator--Charge ........... 168 Hydraulic Oil Level--Check ..................... 168 Hydraulic Oil--Add ........................169 Hydraulic Oil--Change ......................169 Serious Polluted Hydraulic Oil--Change .................
  • Page 13 November 28, 2023 Contents CLG842H Windshield Washer Fluid Reservoir--Fill ................. 194 Window Wiper--Inspect/ Replace .................... 194 Bucket Blade--Replace ......................195 Bucket Teeth--Check and Replace ..................196 Bucket Positioner--Adjust......................197 Boom Lift Kickout--Adjust ......................198 Backup Alarm--Test ........................ 198 Seat Belt--Inspect ........................199 FOPS &...
  • Page 15 Do not use the machine for any purposes other This section includes information on than those described in this manual. LiuGong instrumentation, control equipment, control provides a full warranty for users who operate levers, as well as transport and towing. This...
  • Page 16 Otherwise, LiuGong will not bear any legal responsibility for the consequences. Maintenance Periods For convenience, you can use calendar time...
  • Page 17 November 28, 2023 Machine Main Components and Direction CLG842H Machine Main Components and Direction F: Front R: Rear LH: Left RH: Right Work lights Front combination light Tilting cylinder Rocker arm Bucket Boom Front wheel Front fender Ladder/ pedal Rear wheel...
  • Page 18 Outside the United States, engines may comply with other emission regulations. 1. LiuGong world manufacturer code (characters 1-3) 2. Machine description (characters 4-8) 3. Test letter (character 9) 4. Assembly year of the machine (character 10) 5.
  • Page 19 November 28, 2023 Machine and Component Serial Numbers CLG842H Machine and Component Serial Numbers Record machine information in the table below. Manufacturer Name Guangxi LiuGong Machinery Co., Ltd. Machine Model Machine Serial Number Engine Model Engine Serial Number Transmission Model...
  • Page 20 Safety Information November 28, 2023 Safety Warning Symbols CLG842H Safety Decals and Decal Safety Information Locations Safety decals can be found on the machine. Safety Warning Symbols This section describes the locations of these decals and explanations of the safety hazards Safety warning symbols are they indicate.
  • Page 21 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations Safety Decal Location (Suitable for other English speaking countries and regions) 1.WARNING DECAL 2.WARNING DECAL 3.DANGER DECAL 4.DANGER DECAL 5.INFORMATION DECAL 6.INFORMATION DECAL 7.WARNING DECAL 8.DANGER DECAL 9.INFORMATION DECAL 10.WARNING DECAL...
  • Page 22 Safety Information November 28, 2023 Safety Decals and Decal Locations CLG842H 18.INFORMATION DECAL 20.INFORMATION DECAL 21.INFORMATION DECAL 22.INFORMATION DECAL 32.INFORMATION DECAL...
  • Page 23 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 1.WARNING DECAL 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 24 Safety Information November 28, 2023 Safety Decals and Decal Locations CLG842H 3.DANGER DECAL CRUSH HAZARD Keep away from raised loader arm or bucket. 74A3153 4.DANGER DECAL CRUSH HAZARD Install arm support before maintenance or repair with loader arm raised. 74A3165 5.INFORMATION DECAL...
  • Page 25 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 6.INFORMATION DECAL Lifting point signs 74A2864 7.WARNING DECAL CRUSH HAZARD Keep clear. 74A3163 8.DANGER DECAL CRUSH HAZARD Install arm support before maintenance or repair with loader arm raised. 74A4509 9.INFORMATION DECAL...
  • Page 26 Safety warning for engine hood removal Improper handling of engine hood could result in injury. Please refer to operation manuals or consult LiuGong or local LiuGong dealers before handling engine hood or torsion bar and adjusting engine hood lifting force. Follow the instructions: To remove engine hood or torsion bar, first open rear hood 3 to maximum(55°...
  • Page 27 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 13.INFORMATION DECAL Control lever operation diagram. 74A3486 14.WARNING DECAL RUNOVER HAZARD Start engine from operator's seat, transmission in NEUTRAL. 74A3183 15.INFORMATION DECAL Control lever operation diagram 74A5884...
  • Page 28 Safety Information November 28, 2023 Safety Decals and Decal Locations CLG842H 16.CAUTION DECAL HOT SURFACE keep clear. 74A3168 17.DANGER DECAL Fumes given off by batteries are combustible. Keep flame and sparks away, do not store tools or metal objects near batteries.
  • Page 29 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 20.INFORMATION DECAL Drain water of air tank out every 50h or everyday. Operating procedure: Park machine on flat ground, apply the parking brake. Press down and loosen the brake pedal in...
  • Page 30 Safety Information November 28, 2023 Safety Decals and Decal Locations CLG842H 24.INFORMATION DECAL Emergency stop button indication decal. 74A2842 25.NOTICE DECAL Avoid damaging electronic components when welding: Position machine on level ground, engage parking brake. Shut off engine and turn off battery disconnect switch.
  • Page 31 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 27.WARNING DECAL Improper engagement of work tools could result in serious injury or death. Do not operate this machine until you have positive indication that: 1. Tool is firmly attached to coupler.
  • Page 32 Safety Information November 28, 2023 Safety Decals and Decal Locations CLG842H 28.INFORMATION DECAL Radiator cleaning procedure Clean the radiator according to the following steps Press the manual fan motor reverse switch, keep the engine at idle speed until the fan motor reverse...
  • Page 33 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 31.INFORMATION DECAL Battery disconnect switch position indication decal 74A2838 32.INFORMATION DECAL If the door of cab can not be opened, use the safety hammer to break the glass of the window, and leave the machine through the window.
  • Page 34 Safety Information November 28, 2023 Safety Decals and Decal Locations CLG842H 36.INFORMATION DECAL Coolant filler position indication decal 74A4459 37.WARNING DECAL HOT LIQUID UNDER PRESSURE Service when cool. 74A4512 38.INFORMATION DECAL Fuse position indication decal. 74A4772 39.INFORMATION DECAL Control lever operation diagram 74A4774 40.INFORMATION DECAL...
  • Page 35 November 28, 2023 Safety Information CLG842H Safety Decals and Decal Locations 41.INFORMATION DECAL Hydraulic oil detection instruction: 1.Park the machine on flat ground,ensure that the front and rear frames are on a straight line, the oil temperature is between 25-50℃.
  • Page 36 Safety Information November 28, 2023 General Safety Considerations CLG842H Do not wear loose-fitting clothing, jewelry, or General Safety have unsecured long hair. They may get caught Considerations in control systems or moving parts, causing severe injury or death. Please read these safety precautions carefully.
  • Page 37 It is prohibited to modify the machine without LiuGong's authorization, and LiuGong is not responsible for any consequences of such modifications. Understand the workplace hand signals and the Compressed Air and Water signal source.
  • Page 38 Safety Information November 28, 2023 Trapped Pressure CLG842H Even high-pressure fluid leaks the size of a Trapped Pressure pinhole may pierce flesh and cause loss of sight if it contacts your eyes directly, causing personal Pressure can be trapped in a hydraulic system.
  • Page 39 November 28, 2023 Safety Information CLG842H Burn Prevention Burn Prevention Hot oil and components can cause injury. Do not Some components may become hot after the let hot oil or hot components come into contact machine has been in operation for some time.
  • Page 40 Safety Information November 28, 2023 Fire & Explosion Prevention CLG842H Fire & Explosion Prevention Batteries Batteries produce combustible fumes, which are an explosion hazard. Keep batteries away from sparks and open flames. Do not touch batteries with metal objects, otherwise the batteries may explode due to a short circuit.
  • Page 41 November 28, 2023 Safety Information CLG842H Fire & Explosion Prevention Battery and Battery Cables Avoid static electricity risk when fueling. Ultra low sulfur diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations Do not operate a machine if battery cables or with a higher sulfur content.
  • Page 42 Safety Information November 28, 2023 Ether CLG842H (1) Fraying Ether (2) Abrasion Do not use ether to start the machine. Any (3) Cracking attempt to start the engine with ether may result (4) Discoloration in serious engine damage or personal injury.
  • Page 43 Promptly repair any loose or damaged fuel or lubricant lines and hydraulic system tubes and hoses. Leaks can cause fires. Contact LiuGong or a LiuGong authorized dealer for repairs or replacements. Fire Extinguisher If any of the following problems are found, replacement is necessary.
  • Page 44 Safety Information November 28, 2023 Fire Extinguisher and First Aid Kit CLG842H The fire will be fed from any damaged hoses Fire Extinguisher Location that are attached to the engine or pumps. If possible, turn the battery disconnect switch to Make sure that a fire extinguisher is available on the OFF position.
  • Page 45 & ROPS structure. Cab Protective Structures If the cab is to be modified in any way, consult LiuGong or LiuGong dealer to avoid damaging The rollover protective structure (ROPS) and the FOPS & ROPS structure. falling object protective structure (FOPS) of LiuGong products are located inside the frame structure of the cab.
  • Page 46 Safety Information November 28, 2023 Operator Station CLG842H Operator Station Emergency Hammer This machine is equipped with a cab that meets In cases of emergencies when the doors and with industry standard: ISO 3411, which windows of the cab cannot be opened, the driver specifies the requirements for the cab space.
  • Page 47 If the tire pressure drops abnormally or the wheel rim is not suitable for the tire, there may be a problem with the tire or wheel rim. Please contact your LiuGong dealer for repair. Dry nitrogen (N2) is recommended for inflation of tires.
  • Page 48 The working device could fall if the control mechanism moves, or if a hydraulic hose Without authorization, any modification of leaks. attachments is strictly prohibited. LiuGong is not responsible for any injuries, accidents, or damage to the machine caused by the use of unauthorized attachments.
  • Page 49 November 28, 2023 Safety Information CLG842H Steering Frame Lock Do not use twisted or worn cables. Wear gloves during use and transport. Make sure that no one is nearby when pressing out locking pins. Wear safety goggles to avoid eye injuries.
  • Page 50 Safety Information November 28, 2023 Cautions when Running Engine inside Building CLG842H Cautions when Running Cautions About Machine Engine inside Building Operation The engine exhaust gas contains substances Mounting and Exiting the that can be harmful to your health or even cause Machine death, can lead to illness or death.
  • Page 51 November 28, 2023 Safety Information CLG842H Cautions About Machine Operation  Buried or hanging electricity, gas, telephone, No People on Attachments water, sewage or other utility lines. If necessary, request the utility companies to Never let anyone ride on the work equipment or mark, shut off, or relocate these lines before other attachments.
  • Page 52 Safety Information November 28, 2023 Cautions About Machine Operation CLG842H Check that there are no persons or obstacles Visibility Information above, below, or in the area around the machine. Before you start the machine, perform a walk- Replace any damaged or missing parts and...
  • Page 53 November 28, 2023 Safety Information CLG842H Cautions About Machine Operation (8) Communication between signalmans and Starting the Machine operators before approaching the machine Optimize the machine configuration by Never start the engine if there is a “DO NOT evaluating the results of visibility restriction by OPERATE”...
  • Page 54 Safety Information November 28, 2023 Cautions About Machine Operation CLG842H Only start the machine from the operators seat Machine Operation in the cab. The transmission should be in the Neutral position before engine starting. Never Before driving on public roads, check that the...
  • Page 55 November 28, 2023 Safety Information CLG842H Cautions About Machine Operation When the machine is traveling on snowy ground, do not apply the foot brake suddenly, reduce the speed and apply the foot brake intermittently (hit the brake several times intermittently) while using the engine as the brake.
  • Page 56 Safety Information November 28, 2023 Cautions About Machine Operation CLG842H When building a dike or performing landfill, or When driving the machine on a slope, make it when unloading on a cliff, unload one pile and straight up and down and neither make turn on then push the first pile with the next pile.
  • Page 57 November 28, 2023 Safety Information CLG842H Cautions About Machine Operation 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.
  • Page 58 Safety Information November 28, 2023 Cautions About Machine Operation CLG842H Do not park the machine on a road that is under Cautions when Leaving the Driver construction. If it is necessary to park in such a Seat place, then according to local regulations, you...
  • Page 59 LiuGong for use on LiuGong machines. damaged, bent, or twisted. Never use if the element wire of wire rope is frayed, twisted or Use of work tools which are outside of LiuGong pinched. Never use bent or distorted hooks. recommendations or specifications may result in...
  • Page 60 When transporting the time. All workers must maintain contact with machine, consult your LiuGong dealer. the other workers. 4. Use the steering frame lock to lock the front 2.
  • Page 61 November 28, 2023 Safety Information CLG842H Cautions About Machine Maintenance Cautions when Loading and Lifting the Machine Unloading the Machine Refer to the machine nameplate for the machine mass. If handling is improper when loading or unloading the machine, it is dangerous that the Before lifting, secure the front and rear frames machine may tip over or fall.
  • Page 62 Safety Information November 28, 2023 Cautions About Machine Maintenance CLG842H During the towing operation, do not stand Regular Cleaning of the Machine between the towing machine and the machine being towed. Clean the machine regularly to avoid damage to the machine or possible injury. Remove all Welding Operation accumulated grease, oil, and debris.
  • Page 63 ISO 6396 meets the requirements of national laws and regulations for the cab offered by LiuGong. Vibration Level Whole body vibrations generated by construction machines are influenced by different factors such as working methods, ground conditions, and travel speed.
  • Page 64 Do not use the machine beyond the stipulated application scope. LiuGong is not liable due to operation beyond the stipulated application scope. Do not perform operations that are prohibited in this manual.
  • Page 65 The following tables list the specifications for the standard boom, longer boom and extra- long boom configurations. Refer to the appendix of this section or consult a LiuGong dealer for the modifications to the specifications for other special configurations (such as, a larger bucket, longer boom, log fork, pallet forks or side dump bucket).
  • Page 66 Applications and Main Specifications November 28, 2023 Main Specifications CLG842H Overall Dimensions Extra- Standard Longer Item Unit long boom boom boom 7572 8082 9100 L: Overall Length mm (In) (298.11) (318.19) (358.27) 3300 3300 3300 H: Overall Height mm (In) (129.92)
  • Page 67 November 28, 2023 Applications and Main Specifications CLG842H Main Specifications Extra- Standard Longer Item Unit long boom boom boom 3000 3000 3000 G: Wheel Base Distance mm (In) (118.11) (118.11) (118.11) 1950 1950 1950 J: Tread Width mm (In) (76.77) (76.77)
  • Page 68 Applications and Main Specifications November 28, 2023 Main Specifications CLG842H Extra- Standard Longer Item Unit long boom boom boom km/h (mph) 7 (4.35) 7 (4.35) 7 (4.35) km/h (mph) 13.2 (8.20) 13.2 (8.20) 13.2 (8.20) 27.1 27.1 27.1 km/h (mph) (16.84)
  • Page 69 November 28, 2023 Applications and Main Specifications CLG842H Main Specifications Powertrain System Extra- Standard Longer Item Unit long boom boom boom Transmission Manufacturer Transmission Model 4WG200 4WG200 4WG200 4 forward 4 forward 4 forward gears and gears and gears and...
  • Page 70 Applications and Main Specifications November 28, 2023 Main Specifications CLG842H Brake System Extra- Standard Longer Item Unit long boom boom boom Nitrogen Precharge Pressure of Service MPa (psi) Brake Accumulator Nitrogen Precharge Pressure of Parking MPa (psi) Brake Accumulator Single...
  • Page 71 DC 24 V Note: 1. Continuing updates and improvements are made to LiuGong products. All specifications are the latest product information accurate at the time of publication. LiuGong reserves the right to make changes without notice. 2. The above parameters are theoretical values. The tolerance ranges during testing are provided by LiuGong's...
  • Page 72 Operation Manual November 28, 2023 Before Operation CLG842H Daily Inspection Operation Manual For a maximum service life of the machine, complete a thorough walk-around inspection Before Operation before mounting the machine and before starting the machine. Inspect the area around and under the machine.
  • Page 73 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Disconnect switch--OFF Operator Controls and Instrument Panels To shut down the electrical system, turn the battery disconnect switch key counterclockwise to the O position. In this position, the battery...
  • Page 74 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Start Switch The start switch (also called ignition switch) is If the engine fails to start, turn the start located inside the cab and has three positions in switch to the OFF position before attempting clockwise direction.
  • Page 75 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Instrument Panel A) Central instrument panel B) Steering column instrument panel C) Steering column right instrument panel D) Front right column instrument panel E) A/C panel...
  • Page 76 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Central Instrument Panel Fuel level gauge The central instrument panel consists of gauges, a liquid crystal display (LCD), status indicators, The fuel level gauge represents the level of fuel and warning indicators.
  • Page 77 The LCD screen can display the following items: System voltage Engine rpm 1. Shift lever gear Travel speed 2. Controller output gear of LiuGong transmission Transmission gear Gear display under unlocked state Transmission fault code  System voltage displays 24.8 The shift lever is in gear F2, and the transmission controller output gear is in F2.
  • Page 78 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Gear display under locked state The display items can be switched by the screen selector switch on the front right column instrument panel, the display items are as follows:...
  • Page 79 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Parking brake alert indicator Alternator charge indicator The parking brake alert indicator illuminates The alternator charge indicator illuminates red if red when the parking brake is engaged. At the the alternator is not charging the battery.
  • Page 80 Park the machine in a safe, convenient place serious fault. It is necessary to contact LiuGong for repair when the transmission oil pressure dealer or service center in time and deal with it alert indicator is illuminated.
  • Page 81 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Heater working indicator Water-In-Fuel (WIF) indicator The heater working indicator illuminates yellow When the water in the fuel tank covers the WIF when the heater is on. sensor at the bottom of the fuel filter, the WIF indicator illuminates automatically.
  • Page 82 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Position light and front floodlight switch Rear work light switch This is a two-position switch. This is a three-position switch. POS3 is the default position of the switch, where In POS1, the switch is turned on and the front the lights are turned off.
  • Page 83 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Clutch cut-off switch Steering Column Right Instrument Panel The start switch and lighter are located on the right side of the steering column housing. A lock buckle is provided on the clutch cut- off switch.
  • Page 84 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Rearview mirror defroster switch Front Right Column Instrument Panel This is a two-position switch. In POS1, the switch is turned on and the defrosting device starts working. POS3 is the default position of the switch where the defrosting device is not working.
  • Page 85 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Rear windshield wiper switch Engine warm-up switch This is a three-position switch with the instantaneous reset function. A lock buckle is provided on the switch. In POS1, the switch is turned on, the wiper Slide the buckle toward the center of the works in high speed.
  • Page 86 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Rear windshield washer switch Air Conditioner (A/C) Panel This is a two-position switch with the The A/C panel is located on the top right inside instantaneous reset function. the cab.
  • Page 87 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Warm air/cool air/fresh air select switch Starting explanation of air conditioner This switch is used to shift warm air, After the engine is started, turn the warm air/cool cool air and fresh air.
  • Page 88 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Heating Warm water valve Before starting the engine, set the warm The heating function of the air conditioning water valve at engine coolant inlet and system can be realized by the engine coolant...
  • Page 89 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Control Devices A) Steering wheel B) Horn button C) Combination switch D) Shift control lever E) Service brake pedal F) Accelerator pedal G) Parking brake switch H) Work implement control lever...
  • Page 90 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Horn Button Steering Wheel The machine has three horn buttons. The horn button is located: in the center of the steering wheel at the end of the combination switch...
  • Page 91 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Front floodlight high/low beam shift Combination Switch The combination switch is located on the right of the steering wheel is a multi-function switch. The combination switch has the following functions: ●...
  • Page 92 Do not remove the transmission system if Front windshield washer control the shift control lever has a fault. Contact a LiuGong dealer or service company if the fault can not be eliminated. Slide the combination switch inward toward the steering column to spray washer fluid on the outside of the front windshield.
  • Page 93 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Service Brake Pedal Parking Brake Handle The service brake pedal is located at the front left side of the operator seat. Do not use the parking brake when the...
  • Page 94 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Boom control Work Implement Control Lever The work implement control lever is installed on the right side of the seat. The work implement control lever controls the boom and bucket.
  • Page 95 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Bucket control Float When the work implement control lever is moved to the full forward position, the work implement control lever will stay at that position (the work implement control lever will not return to a Neutral position after being released) and the boom is at float state.
  • Page 96 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Bucket auto-leveling Auxiliary Control Lever (Optional) When dumping is completed, pull the work An auxiliary control lever is located on the right implement control lever leftward to the limit side of the driver’s seat.
  • Page 97 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Quick coupler control (hydraulic controlled Other Devices quick coupler) The auxiliary control lever can be used to control Steering Column a quick coupler. The steering column of the machine can be Turn the diverter valve handle of the quick adjusted up, down, forward, and backward.
  • Page 98 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Pilot Cut-off Lever Mechanical Suspension Seat If the distribution valve of the machine hydraulic The seat is equipped with fore-and-aft system is the pilot valve, the work hydraulic adjustment, height direction, backrest angle...
  • Page 99 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels  Fore-and-aft adjustment The seat can be adjusted with a stroke of 170 mm (6.69 in) in the forward and backward direction. Pull the locking lever under the seat and move the seat forward or backward to the desired position.
  • Page 100 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H  Backrest angle adjustment  Headrest height adjustment The backrest can be adjusted with an angle of The headrest height can be adjusted separately. 90 ± 5° in the front, and 45 ± 5° in the rear.
  • Page 101 Replace the seat belt if necessary. Up/down adjustment Contact a LiuGong dealer for seat belt replacement. Press and hold the right bending plate of the Adjust the length of the seat belt before use in armrest box while pulling it up to adjust the order to ensure safety and comfort.
  • Page 102 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Fore/aft direction adjustment Press and hold the armrest, and push the armrest forward or backward to adjust it in the Connect the battery negative terminal only fore or aft direction.
  • Page 103 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels VOL+/VOL- M4/RDM Press the VOLUME+/- key to adjust Press the key M4 < 2 seconds, to the volume up or down. load corresponding stations from memory. Press the key M4 > 2 seconds, to store corresponding stations to memory.
  • Page 104 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Rear combination lights Lights The rear combination lights consist of backup The machine lights consist of: signal lights, rear turn signal lights, rear position lights/ brake lights, reflectors. Front work lights (2 used)
  • Page 105 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Rotating beacon light (optional) Door Lock The machine cab only has one door on the left, and right side is window, the left door is installed with a door lock.
  • Page 106 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Door Shock Emergency Exit The driver should enter and exit the cab from the The window of the cab can be used as an left door, which can be opened from inside or emergency exit if the door cannot be opened.
  • Page 107 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels Latch unlocking handle Adjustment of Interior Rearview Mirrors Sliding Window (Left and Right) The angle of the interior rearview mirror can be adjusted up, down, left, and right directly by a The window of the cab left door is a sliding universal ball.
  • Page 108 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Engine Hood Quick Coupler (Optional) Safety label instruction and location Be cautions when opening the engine hood, Read and be familiar with all safety the operator may be injured by the hood.
  • Page 109 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels 1. Install the Work Attachments When installing and removing the quick coupler or attachments, do not close to the machine to avoid personal injury or death. Before using the quick coupler, please carefully check that the connections of the quick coupler are secure.
  • Page 110 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H 5. If the machine is equipped with a hydraulic lock switch, press it to the UNLOCK (POS1) position. 1. Diverter valve 2. Handle 3. COUPLER position 4. AUX position Operate the auxiliary control lever (auxiliary 6.
  • Page 111 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels 8. Tilt the quick coupler frame back until the 11. If the machine is equipped with a pilot cut- connecting pin aligns with pin hole on the off lever, turn it to the OFF position.
  • Page 112 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H 1. Lock nut 1. Diverter valve 2. Stop plate 2. Handle 3. Auxiliary control lever 3. COUPLER position 4. AUX position 14. Turn the diverter valve handle to the AUX position.
  • Page 113 November 28, 2023 Operation Manual CLG842H Operator Controls and Instrument Panels 9. If the machine is equipped with a hydraulic lock switch, press it to the LOCK (POS3) position. 1. Lock nut 2. Stop plate 3. Auxiliary control lever 6. Slowly operate the auxiliary control lever forward so the connecting pin of the quick coupler retracts inside.
  • Page 114 Operation Manual November 28, 2023 Operator Controls and Instrument Panels CLG842H Backup Alarm System Steering Frame Lock The backup alarm is located at the back of the machine. When the shift control lever or the FNR switch is in the REVERSE position, the backup alarm will sound automatically.
  • Page 115 November 28, 2023 Operation Manual CLG842H Machine Starting Attachment Transportation (Optional) Machine Starting The following table is the reference weight of Check Before Starting the each component of the attachment, refer to this table for lifting tool selection when using lifting Machine equipment.
  • Page 116 Operation Manual November 28, 2023 Machine Starting CLG842H 9. Turn the hydraulic lock switch (if equipped) to the POS1 position. 3. Open the left door of the cab. Sit in the driver’s seat. Check the seat belt (if equipped) for normal condition. Adjust the driver’s seat to the proper position.
  • Page 117 November 28, 2023 Operation Manual CLG842H Machine Starting 13. During the warm-up process, listen closely to the normal running of the engine and confirm that the transmission does not sound abnormal noises. When the steering wheel is stopped due to low temperature, there is a time interval 14.
  • Page 118 Operation Manual November 28, 2023 Operation Techniques CLG842H Operation Techniques Driving Operation of the Machine Operation Information Follow these basic instructions when you are Before driving the machine on the road, operating the machine : check whether the machine meets the...
  • Page 119 November 28, 2023 Operation Manual CLG842H Operation Techniques The machine starts to travel only when it is in gear F1, F2, R1, or R2. 6. Drive the machine to open and flat ground; Turn the steering wheel to check the ability of the machine to turn right and left.
  • Page 120 Operation Manual November 28, 2023 Operation Techniques CLG842H (d) Based on the machine characteristics, the 6. Depress the accelerator pedal to get the fully automatic speed shift control system desired engine rpm to control the machine and the semi-automatic speed shift control driving speed.
  • Page 121 November 28, 2023 Operation Manual CLG842H Operation Techniques 3. The machine is equipped with an electronic Downhill Operation transmission. When performing the service brake, two operating modes are available. Select a proper speed before going down a hill. One by disconnecting the transmission power...
  • Page 122 Operation Manual November 28, 2023 Operation Techniques CLG842H After the weather turns warm, change fuel, hydraulic oil, and lubricant with half viscosity. Refer to the “Fluid Specifications” section. When the bucket touches the ground, too When operating machine in cold weather,...
  • Page 123 November 28, 2023 Operation Manual CLG842H Operation Techniques Excavation Lower the bucket to the ground and position the bucket for a slight digging angle. When the bucket is operated, the boom oil circuit is cut off, and the boom will stop While moving forward, depress the operating;...
  • Page 124 Operation Manual November 28, 2023 Operation Techniques CLG842H Transportation of Materials Dumping Operation The machine can be used for transporting 1. Dumping materials into a truck or hopper material under the following conditions: 1. Reduce speed when the machine is 15 m ...
  • Page 125 November 28, 2023 Operation Manual CLG842H Operation Techniques 5. After dumping, operate the work implement Scraping Operation control lever to tilt the bucket backward continuously and retract the bucket until it Position the boom and bucket so the blade reaches the limit position. Release the work contacts the ground with an angle of about 60°...
  • Page 126 Operation Manual November 28, 2023 Operation Techniques CLG842H Shuttle operation method Operation Method The shuttle operation uses the machine and V Type operation method multiple trucks. Maintain a 60° angle between the machine After loading, reverse the machine so a and the truck.
  • Page 127 November 28, 2023 Operation Manual CLG842H Operation Techniques Turning off the Engine Parking Stopping the Machine 1. Park the machine on flat ground. If it is Do not turn off the engine when the machine necessary to park the machine on a slope, is working with a load.
  • Page 128 If the machine is not coated with anti-rust is difficult to start. additive per month during storage, consult your LiuGong dealer. During Storage 1. Start the machine once every month and run every system. Lubricate all parts of the moving pins and shafts.
  • Page 129 November 28, 2023 Operation Manual CLG842H Transportation Information Transportation Information Loading of the Machine Obey all local laws governing weight, width, and length of a load. 8. Chock the wheels of the machine and fasten Investigate the travel route for overpass the chocks with steel wires or chains to avoid clearances.
  • Page 130 Operation Manual November 28, 2023 Transportation Information CLG842H Lifting the Machine Use suitable lifting device and shackles when lifting a machine to avoid damage or falling of the machine. Improper lifting or securing could cause the machine to move accidentally and cause machine damage, personnel injury or death.
  • Page 131 Before releasing the parking brake, chock It is impossible to list all the requirements for all the wheels to prevent movement. Remove different situations. Contact a LiuGong dealer for the wedge before starting the machine. more information on towing the disabled 2.
  • Page 132 Operation Manual November 28, 2023 Transportation Information CLG842H Towing with a Running Machine If the machine 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.
  • Page 133 Clean Lubricating Oil and Grease machine has a problem, perform maintenance or Use clean lubricating oil and grease, and keep contact a LiuGong dealer before operating the the lubricating oil or grease container clean, and machine. don't let debris mix into the lubricating oil or Daily Checks grease.
  • Page 134 Check the gauges, lighting, indicators, horn, and wipers to make sure they are working properly. Do not Mix Oils Contact a LiuGong dealer if any problem is Do not mix different brands of oil. If necessary, found. change the oil to remove the old oil prior to using a different brand of oil.
  • Page 135 November 28, 2023 Maintenance Manual CLG842H Break-in Preparation before Maintenance Break-in Park the machine as follows before maintenance: The break-in of a new machine is an important procedure for prolonging the service life of the 1. Park the machine on flat ground.
  • Page 136 Maintenance Manual November 28, 2023 Maintenance Interval Schedule CLG842H 5. Check the electrical system connectors Maintenance Interval including the alternator and all lights. Schedule Check oil level according to the relevant operation regulations. Read and understand all the safety After Break-In Inspection instructions, warnings and indications before any operations or maintenance.
  • Page 137 November 28, 2023 Maintenance Manual CLG842H Maintenance Interval Schedule 16.★ Maintain the A/C compressor. Every 50 service hours or every week 17.★ Replace the bucket blade. 1.★ Check coolant level. 2.Check the cooling fan. 18.★ Check and replace the bucket teeth.
  • Page 138 Maintenance Manual November 28, 2023 Maintenance Interval Schedule CLG842H First 100 service hours 25.Check the compressed air pipeline of the brake system for looseness. 1.★ Clean the fuel tank. 26.★ Check the air reservoir water drain valve. 2.★ Check the accumulator precharge pressure/ charge the accumulator.
  • Page 139 15.★ Change the engine oil. Use higher grade 39.★ Test the backup alarm. engine oil can prolong the service hour of engine oil, contact LiuGong or engine manufacturer for 40.Check the work implement, and each stress details. weld and mounting bolts of the front & rear frames for cracks and looseness.
  • Page 140 45.Check the qualification of brake fluid, if not, engine oil can prolong the service hour of engine change or replenish it. oil, contact LiuGong or engine manufacturer for 46.Check the compressed air pipeline of the details. brake system for looseness.
  • Page 141 25.★ Change the engine oil. Use higher grade prevent wear, scald, excessive bending and joint engine oil can prolong the service hour of engine looseness. oil, contact LiuGong or engine manufacturer for details. 65.★ Test the backup alarm. 26.★ Replace the engine oil filter.
  • Page 142 Maintenance Manual November 28, 2023 Maintenance Interval Schedule CLG842H 47.Check the steering gear, priority valve and 71.Check the fixing bolts of the A/C compressor steering cylinder oil pipes for looseness. and the compressor bracket for looseness. 48.Check the front and rear pin shaft fixing bolts 72.★...
  • Page 143 45.Check the fixing bolts of the parking brake engine oil can prolong the service hour of engine flexible shaft for looseness. oil, contact LiuGong or engine manufacturer for 46.★ Check the booster oil level. details. 47.Check the qualification of brake fluid, if not, 23.★...
  • Page 144 50.Check the fixing bolts of the hydraulic system 27.★ Change the engine oil. Use higher grade control flexible shaft for looseness. engine oil can prolong the service hour of engine oil, contact LiuGong or engine manufacturer for 51.Check flexibility of the steering system. details.
  • Page 145 November 28, 2023 Maintenance Manual CLG842H Maintenance Interval Schedule 52.Check airtight condition of the control valve 75.Check the cab air filters (the recirculating air and work cylinders by measuring natural filter and fresh air filter), and replace it if it is sediment of the cylinders.
  • Page 146 Maintenance Manual November 28, 2023 General Torque Specifications CLG842H General Torque Specifications Tighten the bolts used in the machine according to the torque requirements shown in the following tables unless otherwise specified. Metric System Standard Torque Thread 8.8 Grade Strength 10.9 Grade Strength...
  • Page 147 Tire Inflation Information Tire Inflation Information LiuGong recommends the use of dry nitrogen for tire inflation and tire pressure adjustments on all machines with rubber tires. Nitrogen is an inert gas that reduces the risk of combustion inside the tire.
  • Page 148 18—21° C (65—70° F). If the tire is inflated to the correct pressure under normal temperature, the tire will be under inflated in colder temperatures. Low pressure will shorten the service life of the tires. Consult your LiuGong dealer when unsure about the tire inflation pressure.
  • Page 149 November 28, 2023 Maintenance Manual CLG842H Fluids and Lubricants Fluids and Lubricants Fluid Change Interval and Refill Capacities Care must be taken in order to make sure that fluids are contained during inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluids with suitable containers before opening any compartment or disassembling any component.
  • Page 150 Used for transmission and 8# hydraulic torque converter. -15~50℃ (5~122° F) transmission oil LiuGong transmission & torque converter: use 8# hydraulic transmission oil in normal and high CH-4 15W-40 ★ temperature areas. -15~50℃ (5~122° F) ZF transmission & torque...
  • Page 151 November 28, 2023 Maintenance Manual CLG842H Fluids and Lubricants Fluid Recommended Ambient Fluid type Note viscosity & grade brand temperature HM46 anti-wear -5~40℃ (23~104° F) hydraulic oil ★ Used for work equipment HV46 -15~40℃ (5~104° F) hydraulic system, steering hydraulic system, hydraulic brake system.
  • Page 152 SAE 85W- 90 gear oil in normal and GL-5 / LS 75W - 90 -40~50℃ (-40~122° F) high temperature areas. LiuGong limited slip wet- type axles and Kessler axles: use SAE 80W-90 gear oil in normal and high temperature areas.
  • Page 153 November 28, 2023 Maintenance Manual CLG842H Fluids and Lubricants 1. Do not mix different brands of oils even if they have the same specifications. Clean the system before refilling with a different brand of oil. 2. If the machine is used at low temperatures in severe cold areas for a long period of time, use HV-32 low temperature anti-wear hydraulic oil and ATF330 or DEXRON-III or Donax TC transmission oil.
  • Page 154 9. Check the FOPS & ROPS for visible damage. Consult your LiuGong dealer for repair information if there is damage. 10. Check all the lighting equipment and replace cracked bulbs and glass if...
  • Page 155 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Checking method for coolant level： Power System 1. The coolant level sight glass is on the recovery tank. Coolant Level--Check The working coolant has high pressure and temperature. Hot coolant can cause serious burns.
  • Page 156 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Anti-freeze density and coolant additive Coolant--Add density-check The working coolant has high pressure and Antifreeze, which resists freezing at temperature. Hot coolant can cause serious temperatures down to -30° C (-22° F), has been burns.
  • Page 157 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures If the machine is located in an area where the temperature may drop below 0° C (32° F), add antifreeze suited to local climatic conditions to the coolant. Some antifreeze is sold as concentrate and must be mixed before adding to the machine.
  • Page 158 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Before reaching maintenance interval of replacing coolant and cleaning the cooling system, if the coolant is contaminated, the engine is overheating, or bubbles appear in the Adding coolant when the engine temperature radiator, clean the cooling system as soon as is high could cause damage to the engine.
  • Page 159 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Battery disconnect switch-ON 8. After draining out coolant, reinstall the 3. Turn on the warm air switch of the air coolant drain hose and the clamp. conditioner (if equipped). 9. Check all water lines and clamps of the 4.
  • Page 160 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 14. Keep the recovery tank filler cap open and Air Filter Element--Replace start the engine. When the coolant temperature reaches over 80° C (176° F), continue to let the engine run for an additional 5-10 minutes.
  • Page 161 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures 3. Along the housing direction, rotate to remove the main (outer) filter element and the safety filter element. If the air filter cover can not be installed, remove the air filter cover and check the locations of the air filter elements.
  • Page 162 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 3. Take out the strainer from the oil pan and put 6. Install the oil seals to the clean strainer in it into a wash tub. position and air-dry it in a vented place.
  • Page 163 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Add clean engine oil (about 3.8L) to the clean oil pan until the oil level reaches the top of the oil pan. 9. After cleaning, air-dry the oil pan in a vented place.
  • Page 164 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 2. Carefully remove the dust and dirt around the fuel filler. Pull up the lock plate of the fuel filler cap, turn the cap counterclockwise to the next position and move it outwards, and then remove the fuel filler cap.
  • Page 165 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures 3. Carefully remove the dust and dirt around the Fuel Tank--Clean flange cover on the side of the fuel tank. Remove the flange cover. Wash the inner surface of the tank with clean fuel.
  • Page 166 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Fuel Strainer--Clean Water and Impurity--Remove The fuel pump and fuel injection nozzle are precision devices. If water or impurities are in the fuel, the fuel pump and fuel injection nozzle cannot work properly and will wear out quickly.
  • Page 167 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Drain plug on the fuel and water separator The fuel primary filter is located on the rear right side of the machine. 1. Park the machine on flat ground, lower the work implement onto the ground.
  • Page 168 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 6. Install a new fuel primary filter to the support. Do not refuel the machine until the fuel primary filter is installed. Fuel contamination will quicken damage of the fuel system parts.
  • Page 169 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures 3. Remove the fuel fine filter from the support Fuel Fine Filter--Replace with a wrench. Dispose the used filter properly. Do not allow foreign material to enter the fluid circulation system when checking the fluid level, adding fluid, changing fluid or replacing the fluid filter.
  • Page 170 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 5. If the oil level is below the (L) mark, add oil. If Engine Oil Level--Check the oil level is above the (H) mark, loosen the oil drain plug to drain some oil. After draining, tighten the oil drain plug.
  • Page 171 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Engine Oil--Change Make sure that fluids are contained during inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before removal or disassembly of any parts.
  • Page 172 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 4. Clean the gasket surface of the support with Engine Oil Filter--Replace a clean cloth. If the old O-ring adheres to the support, remove the old O-ring. Do not allow foreign material to enter the...
  • Page 173 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Engine Surface--Clean Cooling Package--Clean 1. Park the machine on flat ground, lower the work implement onto the ground. Straighten the machine direction, turn the work implement control lever to the Neutral...
  • Page 174 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Engine Air Intake System--Check Fan Belt Tension--Check/Adjust Check the air intake system for cracked hoses, For more information on the fan belt adjustment loose clamps, and holes. Tighten or replace procedures, refer to the Operation and parts to make sure the air intake system is Maintenance Manual of the Engine.
  • Page 175 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Turn the oil dipstick counterclockwise and take it Powertrain System out. Wipe off the oil with a clean cloth. Insert the oil dipstick into the end of the oil filler pipe and Transmission Oil Level--Check then take it out again (repeat at least twice).
  • Page 176 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Transmission Oil & Torque Converter Oil--Change Make sure that fluids are contained during inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before removal or disassembly of any parts.
  • Page 177 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Transmission Oil Filter--Replace Make sure that fluids are contained during inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before removal or disassembly of any parts.
  • Page 178 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H The secondary filter of the transmission is on the Breather--Clean right side of the box housing. Make sure that fluids are contained during inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before removal or disassembly of any parts.
  • Page 179 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Clamp breather If the oil level is lower than the lower edge of the oil port, refill with clean axle oil. Observe the oil level for about 5 minutes after adding the oil, the oil level should remain stable.
  • Page 180 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 3. Carefully remove the dust and dirt around the Hydraulic System plug on the wheel end of the axle and the plug in the middle of the axle housing. Hydraulic System Oil Pressure --...
  • Page 181 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures 8. If the machine is equipped with a ride control switch, turn the ride control switch to the POS1 position (M position), and then operate the work implement control lever to set the...
  • Page 182 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Accumulator Precharge Pressure-- Hydraulic Oil Level--Check Check/ Accumulator--Charge 1. Make sure that the hydraulic oil tank, hydraulic lines, radiator and other hydraulic parts are full of hydraulic oil before checking the hydraulic oil level.
  • Page 183 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures 6. When checking the oil level, if the oil level is Hydraulic Oil--Change higher than the normal range of the sight glass (when there are bubbles visible in the sight glass), do not drain the oil even when the level is above the MAX marking (highest oil level line).
  • Page 184 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 4. Operate the work implement control lever to tilt the bucket forward under its own weight, discharging the hydraulic oil in the tilt cylinder. After the bucket tilts to the limit The hydraulic oil will be hot.
  • Page 185 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Serious Polluted Hydraulic Oil--Change Refer to the section “Hydraulic Oil--Change” to change the hydraulic oil twice. Hydraulic Oil Tank Oil Filler Strainer-- Clean/Replace Do not allow foreign material to enter the...
  • Page 186 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Return Oil Filter Element of Hydraulic Oil Tank--Replace Do not allow foreign material to enter the fluid circulation system when checking the fluid level, adding fluid, changing fluid or replacing the fluid filter.
  • Page 187 2. Start and drive the machine at 32km/h (20mph). Perform spot braking. The machine should stop immediately without deflection. If the brake distance exceeds 15m(49 ft), consult a LiuGong dealer for brake system checking. Eliminate any problems before continuing to work.
  • Page 188 The machine should not move from the original location. If the machine moves while the parking brake is engaged, consult a LiuGong dealer. Eliminate 1. Front booster 2. Rear booster any problems before continuing to work.
  • Page 189 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures 1. Park the machine on flat ground, lower the Air Reservoir Water Drain Valve--Check work implement onto the ground. Straighten the machine direction, turn the work 1. Park the machine on flat ground, lower the implement control lever to the Neutral work implement onto the ground.
  • Page 190 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 5. Cooperation of two operators are needed to Clamp--Exhaust finish this step. One operator presses the service brake pedal and hold it on in the cab. If air enters the oil line of brake system, the The other one unscrews the exhaust nozzle braking performance of clamp will be effected.
  • Page 191 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Lubrication System Lubrication Diagram and Intervals If centralized lubrication system is not provided on this machine, add lubricant according to the lubrication diagram and intervals.
  • Page 192 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Lubrication points of work implement Manual Lubrication System When the machine is engaged in frequent heavy-duty operation and long-time operation, the lubrication intervals for adding grease specified in the section “Maintenance Interval Schedule”...
  • Page 193 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Lubrication point of rear drive axle swing Electrical System frame Battery--Check Cut off the power supply of the machine before working with batteries. 1. The machine is equipped with a battery with hydrometer.The battery is located in the...
  • Page 194 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H The battery clamp plate, battery terminals, and cable leads will loosen due to machine vibration after operating the machine for a period of time. In order to prevent the batteries from loosening, always check...
  • Page 195 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Battery--Charge The machine is equipped with a battery with hydrometer. Obey the following instructions When removing a battery with low power when dealing with the battery. before charging, first disconnecting the negative terminal of the battery.
  • Page 196 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Battery Voltage Charge Time (HR) 12.55-12.45V 12.45-12.35V 12.35-12.20V If the hydrometer is black, check for loose 12.20-12.05V cable and clean connecting terminal. 12.05-11.95V Check whether the voltage has come to 11.95-11.80V 16VDC.
  • Page 197 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Battery--Store/ Service Battery, Cable, Battery Disconnect Switch--Replace 1. Turn off the battery disconnect switch when storing the batteries installed on the machine 1. Turn the engine start switch to the OFF and check the battery voltage state at least position and remove the key.
  • Page 198 When replacing the fuses, it is recommended to use fuses supplied by LiuGong. Other fuses on the market can often be poor quality and could damage the machine or cause a fire.
  • Page 199 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Fuse box (in the cab)
  • Page 200 Note: The fuse decal and the fuse function shown in the above figure and table are for reference only. Correspond to the fuse according to the actual configuration of the machine. If in doubt, contact the designated dealers of LiuGong.
  • Page 201 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures The box with fuses of 30A or above is located in Fuse in the cab the battery box. Open the cover to access the Part no. Model Fuse Rating (A) fuses.
  • Page 202 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 1. Turn the engine start switch to the ON Alternator--Maintain position with the engine off. Observe the reading of the voltmeter. Start the engine and observe reading of the voltmeter again. The voltage reading should be higher when the engine is running.
  • Page 203 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Air Conditioning System Refrigerant Level--Check R134a refrigerant is used in this air conditioning system. Do not use other refrigerants or low quality refrigerants to avoid damaging the compressor. Do not overfill the refrigerant. Insufficient...
  • Page 204 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H A used air conditioner belt tension should Compressor Belt Tension-- be 400 ± 44 N•m (90 ± 10 lb-ft) when the Check/Adjust/ Replace belt has run for more than 30 minutes at the rated speed.
  • Page 205 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Evaporator--Check Condenser--Clean The evaporator is located on the right side of the The condenser is located near the radiator. cab. Open the hood to access the condenser. The fresh air filter and recirculating air filter on Clean the condenser fins regularly.
  • Page 206 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Clean /replace the recirculating air filter Cab Air Filter--Clean and Replace Open the clip, remove the ventilation grille The cab air filters consist of the fresh air filter in the cab, and remove the recirculating air and recirculating air filter.
  • Page 207 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures R134a can dissolve rubber hoses and Compressor--Maintain seals designed for use in R12 systems. Rubber materials designed for R134a refrigerant, such as polyethylene-propylene rubber, EPDM, etc. should be used. R134a refrigerant is used in this air R134a refrigerant can not use the same conditioning system.
  • Page 208 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Other Maintenance Windows--Clean Check the windshield washer fluid reservoir frequently to make sure that there is enough water in it. A dirty windshield may impact the visibility of the operator. Using the wiper on a dry window may damage the wiper motor.
  • Page 209 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Bucket Blade--Replace 4. Clean the bucket blade, bolts, washers and nuts. Remove the nuts, washers and bolts from the bucket blade, then remove the bucket blade. 5. Install the bolts, washers, nuts and new bucket blade.
  • Page 210 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 3. Remove the nuts and the bolts connecting Bucket Teeth--Check and Replace the bucket teeth. Remove the old bucket teeth from the bucket. Clean the front cutting Check the bucket teeth for wear or damage. Use edge of the bucket.
  • Page 211 November 28, 2023 Maintenance Manual CLG842H Important Maintenance Procedures Bucket Positioner--Adjust 1. Park the machine on flat ground, lower the work implement onto the ground. Straighten the machine direction, turn the work implement control lever to the Neutral position, turn the shift control lever to the...
  • Page 212 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H 4. Loosen the bolt (3) and turn the proximity Boom Lift Kickout--Adjust switch quickly to let the proximity switch (2) align with the magnet (1). The electromagnetic force will disappear and the boom control lever will return to the Neutral position automatically.
  • Page 213 FOPS & ROPS, refer to the  Electronic parts section “FOPS & ROPS”, and contact a LiuGong  Other possible parts on the machine dealer for more information.
  • Page 214 Maintenance Manual November 28, 2023 Important Maintenance Procedures CLG842H Keep any flammable and explosive materials away from the welding site, protect any cables, and do not allow sparks and solders produced during welding to splash onto the cables, thus causing a fire and resulting in loss and injury.
  • Page 215 November 28, 2023 Troubleshooting CLG842H Appendix 1 Powertrain System Troubleshooting Troubleshooting Appendix 1 Powertrain System Troubleshooting Power Train System Troubleshooting Item Features Causes Troubleshooting 1. Oil level of the transmission oil sump is too low. 2. Leakage in main oil passage.
  • Page 216 Troubleshooting November 28, 2023 Appendix 2 Work Hydraulic System Troubleshooting CLG842H Appendix 2 Work Hydraulic System Troubleshooting Work Hydraulic System Troubleshooting Item Features Causes Troubleshooting 1. Cylinder seals worn or damaged. 1. Replace the seals. 2. Distribution valve is excessively worn.
  • Page 217 November 28, 2023 Troubleshooting CLG842H Appendix 3 Steering Hydraulic System Troubleshooting Appendix 3 Steering Hydraulic System Troubleshooting Steering Hydraulic System Troubleshooting Item Features Causes Troubleshooting 1. Oil temperature is too low. 2. Pilot oil line is blocked. 1. Operate after the oil temperature rises.
  • Page 218 Troubleshooting November 28, 2023 Appendix 3 Steering Hydraulic System Troubleshooting CLG842H Steering Hydraulic System Troubleshooting Item Features Causes Troubleshooting 3. Metering holes on both ends of the flow amplifying valve rod are blocked or the hole positions are improper. 1. Air in the steering oil lines.
  • Page 219 November 28, 2023 Troubleshooting CLG842H Appendix 4 Brake System Troubleshooting Appendix 4 Brake System Troubleshooting Brake System Troubleshooting Item Features Causes Troubleshooting 1. Exhaust air. 1. Air in brake hydraulic lines. 2. Check the brake valve, measure the pressure of 2.
  • Page 220 Troubleshooting November 28, 2023 Appendix 5 Electrical System Troubleshooting CLG842H Appendix 5 Electrical System Troubleshooting Electrical System Troubleshooting Item Features Causes Troubleshooting 1. Clean it with gasoline by using a piece of clean 1. Commutator has oil smear or is cloth or planish it with 00 sandcloth.
  • Page 221 November 28, 2023 Troubleshooting CLG842H Appendix 5 Electrical System Troubleshooting Electrical System Troubleshooting Item Features Causes Troubleshooting Instrument indicates the Instrument grounding wire is loose. Tighten or connect the grounding wire again. max. range...
  • Page 222 Troubleshooting November 28, 2023 Appendix 6: Transmission Fault Code Index CLG842H Appendix 6: Transmission Fault Code Index Fault Code Index of ZF200 Gearbox FAULT CODE MEANING OF THE FAULT CODE Invalid Controller input-line combination Short circuit of an output against ground...
  • Page 223 November 28, 2023 Troubleshooting CLG842H Appendix 7 Transmission Oil Suppliers Appendix 7 Transmission Oil Suppliers Transmission oil suppliers List of licensed suppliers ZF approval Manufacturer (03B) Trade name (03B) number FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN UNIVERSAL HD SAE 10W...
  • Page 224 Troubleshooting November 28, 2023 Appendix 7 Transmission Oil Suppliers CLG842H ZF approval Manufacturer (03C) Trade name (03C) number CHEVRON LUBRICANTS, SAN RAMON, DELO TORQFORCE SAE10W ZF001904 CA/US CHEVRON LUBRICANTS, SAN RAMON, URSA TORQFORCE SAE 30 ZF001905 CA/US CHEVRON LUBRICANTS, SAN RAMON,...
  • Page 225 November 28, 2023 Troubleshooting CLG842H Appendix 7 Transmission Oil Suppliers ZF approval Manufacturer (03C) Trade name (03C) number GS CALTEX CORPORATION,SEOUL/KR KIXX GEARTEC TO-4 10W ZF002237 GS CALTEX CORPORATION,SEOUL/KR KIXX GEARTEC TO-4 30 ZF002238 HITACHI CONSTRUCTIONMACHINERY HITACHI GENUINE TRANSMISSION OIL 10W...
  • Page 226 Troubleshooting November 28, 2023 Appendix 7 Transmission Oil Suppliers CLG842H ZF approval Manufacturer (03C) Trade name (03C) number REPSOL LUBRICANTES Y ESPECIALIDADES, REPSOL TRANSMISSIONSTO-4 SAE 30 ZF003472 S.A, MADRID/ES REPSOL LUBRICANTES Y ESPECIALIDADES, REPSOL NAVIGATOR TO-4 SAE 10W ZF008277 S.A, MADRID/ES...
  • Page 227 November 28, 2023 Troubleshooting CLG842H Appendix 7 Transmission Oil Suppliers ZF approval Manufacturer (03C) Trade name (03C) number WOLF OIL CORPORATION N.V., WOLF TDTO SAE 10W ZF003582 HEMIKSEM/BE WOLF OIL CORPORATION N.V., WOLF TRACTOFLUID 500 ZF003583 HEMIKSEM/BE ZF approval Manufacturer (03D)
  • Page 228 Troubleshooting November 28, 2023 Appendix 7 Transmission Oil Suppliers CLG842H ZF approval Manufacturer (03D) Trade name (03D) number LIQUI MOLY GMBH, ULM/DE LIQUI MOLY MARINE ATF ZF004927 LIQUI MOLY GMBH, ULM/DE LIQUI MOLY ATF III ZF004928 MEGUIN GMBH & CO. KG, SAARLOUIS/DE...
  • Page 229 November 28, 2023 Troubleshooting CLG842H Appendix 7 Transmission Oil Suppliers ZF approval Manufacturer (03D) Trade name (03D) number SYN GARD™ ATF ES VALVOLINE, LEXINGTON/US ZF003710 VIBRA ENERGIA S.A., DUQUEDE CAXIAS/BR LUBRAX ATF HD ZF002120 ZF approval Manufacturer (03E) Trade name (03E)
  • Page 230 Troubleshooting November 28, 2023 Appendix 7 Transmission Oil Suppliers CLG842H ZF approval Manufacturer (03E) Trade name (03E) number EXXONMOBIL CORPORATION, HOUSTON, MOBILFLUID 424 (*) ZF004764 TX/US EXXONMOBIL CORPORATION, HOUSTON, MOBILFLUID 428 ZF005939 TX/US EXXONMOBIL CORPORATION, HOUSTON, MOBILFLUID 428 ZF008221 TX/US...
  • Page 231 November 28, 2023 Troubleshooting CLG842H Appendix 7 Transmission Oil Suppliers ZF approval Manufacturer (03E) Trade name (03E) number PETROLUBE OILS COMPANY, JEDDAH/SA PETROMIN MP TRACTOR 10W30 ZF002009 PETRONAS LUBRICANTS INTERNATIONAL AMBRA MULTI G (SAE 10W-30) ZF000544 SDN BH, KUALA LUMPUR/MY...
  • Page 232 Troubleshooting November 28, 2023 Appendix 7 Transmission Oil Suppliers CLG842H ZF approval Manufacturer (03E) Trade name (03E) number SHELL INTERNATIONAL PETROLEUM SHELL SPIRAX S4 TXM ZF000359 COMP.LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM SHELL SPIRAX S6 TXME ZF001295 COMP.LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM...
  • Page 233 November 28, 2023 Troubleshooting CLG842H Appendix 7 Transmission Oil Suppliers ZF approval Manufacturer (03G) Trade name (03G) number SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL HD DRIVE AXLE OIL ZF002162 ZF FRIEDRICHSHAFEN AG, ZF POWERFLUID C-PLUS ZF002087 FRIEDRICHSHAFEN/DE ZF FRIEDRICHSHAFEN AG,...
  • Page 234 Troubleshooting November 28, 2023 Appendix 7 Transmission Oil Suppliers CLG842H ZF approval Manufacturer (03L) Trade name (03L) number SHELL INTERNATIONAL PETROLEUM SHELL SPIRAX S4 TXM ZF003325 COMP.LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM SHELL SPIRAX S4 TXM ZF005938 COMP.LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM...
Save PDF