202006005

CLG856H WHEEL LOADER

GCIC II POWER / LIUGONG SPLIT AXLE / BS306 GEARBOX
( 英语 )

OPERATION AND
MAINTENANCE MANUAL
 Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

CALIFORNIA PROPOSITION 65

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.
 1
June 1, 2020 CONTENTS
CLG856H

CONTENTS

Preface Operation Manual

Before Operation ............................................. 41
Safety Information
Operator Controls and Instrument Panels ....... 42
Safety Decals and Decal Locations ...................5
Engine Starting ................................................ 71
General Hazard Information .............................16
Operation Techniques ..................................... 72
Crushing and Cutting Prevention .....................20
Transportation Information .............................. 81
Burn Prevention ...............................................20

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

Fire Extinguishers and First-aid Kit ..................22 Maintenance Guidance .................................... 86

Electrical Storm Injury Prevention ....................23 Run-in .............................................................. 88

Tire Explosion Prevention ................................23 Maintenance Interval Schedule ....................... 89

ROPS/FOPS ....................................................24 General Torque Specifications ........................ 93

Operator Station ...............................................24 Tire Inflation Information .................................. 94

Steering Frame Lock ........................................24 Lubrication Specifications ................................ 95

Attachment Cautions ........................................24 Important Maintenance Procedures ................ 96

Cautions about Machine Operation .................25

INDEX
Cautions about Machine Maintenance .............32

Sound and Vibration ........................................34

Key Spare Parts to be Periodically Changed ..35

Application and Specification

Applications ......................................................36

Main Specifications ..........................................37

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CONTENTS June 1, 2020
CLG856H
 1
June 1, 2020 Preface
CLG856H

Preface Safety

The safety section lists basic safety precautions.

In addition this section identifies the text and
This manual includes important instructions locations of warning signs and labels used on the
concerning operation, lubrication, checking machine.
testing, adjusting the machine and permanent
key components. Read and understand the basic precautions
listed in the safety section before operating or
This manual should always be kept safe, clean performing lubrication, maintenance or repairs
and with the machine where it is convenient to on this machine.
find for operators to use. This manual should not
be separated from the machine even when Operation
reselling or leasing.
Some photographs and illustrations in this The operation section is a reference for the new
manual show details of attachments those may operator and a refresher for the experienced
be different from your machine. Guards and operator. Read, understand and reference it
covers may have been removed for the purpose whenever necessary. This section includes a
of illustration. description of gauges, machine controls,
switches and other controls at the operators’
Read this manual carefully and follow all station. It also provides transportation and towing
instructions for proper operation and information.
maintenance of this machine. Instructions in this
manual should help the reader avoid possible Photographs and illustrations guide the operator
personal injury or damage to the machine. The through correct procedures of checking, starting,
operator should proficiently and correctly operate operating and stopping the machine.
the machine to ensure safety. Operating techniques outlined in this publication
Use this machine only for the purpose described are basic. Skill and techniques develop as the
in this manual. Contact your Liugong dealer for operator gains knowledge of the machine and its
approval before making any modifications or capabilities.
adding attachments to the machine. The addition
of any unauthorized attachment may cause Maintenance
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi The maintenance section is a guide for
Liugong accepts no liability for any damage equipment care. The illustrated, step-by-step
resulting from the use of unapproved instructions are grouped by servicing intervals.
attachments or working practices. Items without specific intervals are listed under
the "When Required" service interval. Items in
Only trained or experienced personnel should be the "Maintenance Intervals" are referenced to
allowed to operate or maintain this machine. detailed instructions that follow.
Correctly record the machine type, serial
number, engine serial number and all major For the replacement of environment-friendly key
component serial numbers for your reference parts and components when maintaining an
when ordering parts or in the event of theft. engine, please use the OEM parts and
Record the correct numbers to both the components of the same type and the same
operator’s manual and a secure place outside specifications. Otherwise, LiuGong accepts no
the machine. legal liability for any consequence resulting from
the use of unapproved parts.
2
Preface June 1, 2020
CLG856H

Maintenance Intervals

Use the service hour meter to determine

servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 10 service hours or daily.
All the information, figures, tables and
specifications are the latest product information
obtainable at the time of publication. Guangxi
Liugong Company will reserve the right to make
change without notice.
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June 1, 2020 Preface
CLG856H

Main Components

1
2
3
4
5
6

8
9
10
11
12
13
14
15

16
17
FRONT 18
RIGHT

19

LEFT
21
REAR
20

1. Front work light 7. Counterweight 13. Front fender 19. Rear combination light-RH
2. cab 8. Rear wheel 14. Front wheel 20. Rear frame
3. Front combination light-LH 9. Rear fender 15. Boom 21. Rear combination light-LH
4. Tilting cylinder 10. Ladder 16. Rear work light
5. Lever 11. Front combination light-RH 17. Hydraulic oil tank
6. Bucket 12. Front frame 18. Engine hood
4
Preface June 1, 2020
CLG856H

Type and Serial Number of the Machine and Parts

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

Type of the Machine

Serial Number of the Machine

Type of Engine

Serial Number of Engine

Type of Transmission

Serial Number of Transmission

Type of Front Axle

Serial Number of Front Axle

Type of Rear Axle

Serial Number of Rear Axle

Type of Hydraulic Pump

Serial Number of Hydraulic Pump

Cab Manufacturer

Serial Number of Cab

Note: After receiving the machine the user should fill out the above table according to the specific configuration.
 5
June 1, 2020 Safety Information
CLG856H Safety Decals and Decal Locations

Safety Information "Caution" is also used to indicate safety

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

● Caution: this word denotes potential danger,

failure to observe instructions could result in
minor to medium degree of injury.
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Safety Information June 1, 2020
Safety Decals and Decal Locations CLG856H

Decal Location

1. WARNING DECAL 7. NOTICE DECAL 15. WARNING DECAL 32. WARNING DECAL
2. DANGER DECAL 8. CAUTION DECAL 16. DANGER DECAL 33. WARNING DECAL
3. DANGER DECAL 9. WARNING DECAL 20. NOTICE DECAL 36. DECAL
4. WARNING DECAL 10. NOTICE DECAL 25. NOTICE DECAL 38. DECAL
5. WARNING DECAL 12. NOTICE DECAL 26. WARNING DECAL
 7
June 1, 2020 Safety Information
CLG856H Safety Decals and Decal Locations

Decal Location

VIEW B

VIEW A

1. WARNING DECAL 15.WARNING DECAL

2. DANGER DECAL 30. WARNING DECAL
3. DANGER DECAL 33. WARNING DECAL
9. WARNING DECAL
8
Safety Information June 1, 2020
Safety Decals and Decal Locations CLG856H

Decal Information

Fig.1 WARNING DECAL

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

74A3167

Fig. 2 DANGER DECAL

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

74A3153
 9
June 1, 2020 Safety Information
CLG856H Safety Decals and Decal Locations

Decal Information

Fig. 3 DANGER DECAL

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

74A3165

Fig. 4 WARNING DECAL

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

74A3163
10
Safety Information June 1, 2020
Safety Decals and Decal Locations CLG856H

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. Operate only from
operator's seat. Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral. Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator's compartment, park on level
ground, lower attachments to ground, make
sure hydraulic control lever is in lockout
position. All control levers are in neutral.
Engage parking brake. Never operate
machine downhill with stalled engine and
gear in neutral. Avoid contacting overhead
obstacles when operating or hauling
machine. 74A4777
Fig. 7 NOTICE DECAL
(Located in the cab)
Do not clean inside of cab with water under
pressure, electrical component damage will
result. Prevent loss of electrical power, turn
battery disconnect switch to off position when
machine not in use or being parked overnight. 74A4780
 11
June 1, 2020 Safety Information
CLG856H Safety Decals and Decal Locations

Decal Information

Fig. 8 NOTICE DECAL

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

Fig. 9 CAUTION DECAL

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

74A3168

Fig. 10 WARNING DECAL

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

74A3183
12
Safety Information June 1, 2020
Safety Decals and Decal Locations CLG856H

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

Fig. 15 WARNING DECAL

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

74A3161
Fig. 16 DANGER DECAL
(Located near the battery)
Fumes given off by batteries are combustible.
Keep flame and sparks away, do not store
tools or metal objects near batteries. Risk of
explosion if metal objects cause a short
circuit. Sulphuric acid contained in batteries is
poisonous, do not allow acid to contact skin,
clothing or your eyes. If you spill acid on
yourself, immediately:
● Flush your skin with water.
● Apply a neutralizing agent such as lime.
● Flush eyes with water for 10-15 minutes.
Immediately seek medical attention. 74A4506
 13
June 1, 2020 Safety Information
CLG856H Safety Decals and Decal Locations

Decal Information

Fig. 20 DANGER DECAL

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

74A4509

74A2868

Fig. 25 NOTICE DECAL

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

74A2863

Fig. 26 WARNING DECAL

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

74A4512
14
Safety Information June 1, 2020
Safety Decals and Decal Locations CLG856H

Decal Information

Fig. 30 WARNING DECAL

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

74A3178
Fig. 32 WARNING DECAL
(Located in the cab)
Improper engagement of work tools could
result in serious injury or death. Do not
operate this machine unitl you have positive
indication that:
1. Tool is firmly attached to coupler.
2. Handle of diverter valve is in Aux position
as picutured.
3. Mechanical lock on control lever of
coupler is in locked position.
Never operate machine without locks in
locked position. To change tool, turn hydraulic
diverter valve to Coupler position. Ensure that
work area is clear of personnel.Tool must be
in rolled back position and indicators visible to
operator. Release mechanical interlock on
control lever and withdraw locking pins.
Lower tool to ground and roll forward to
release. When attaching tool, roll back fully
and extend locking pins. Check attachment
by rolling tool forward against ground. Tool
should remain attached. Bucket engaged,
indicators point towards each other at top.
Bucket disengaged, indicators point away
from each other at top.Relock the mechanical
interlock on the coupler control lever and
reset the hydraulic diverter valve to Aux
position. Do not operate machine with a faulty
coupler or with the mechanical interlock on
the control lever not engaged at all times. 74A4779
 15
June 1, 2020 Safety Information
CLG856H Safety Decals and Decal Locations

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

Fig. 38 DECAL
(Located in the cab)

74A2875
16
Safety Information June 1, 2020
General Hazard Information CLG856H

General Hazard Information

Be familiar with all safety cautions, failure to

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

Wear relevant personal protective equipment

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

Do not operate the machine if you feel sick,

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

Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high
G

pressure liquids, when maintaining storage

IN
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AR
W

batteries, by flying scraps when the engine is in

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op o n

e
at

operation or you are using tools. When you

d

remove springs or resilient parts, add acid/

r:
te
ra
pe

electrolyte to batteries, you should wear a full

O

:
ate
D

face protective mask. When carrying out welding

Do not wear loose fitting clothing, dangling operations or gas cutting operations with a
jewelry or long hair that can catch on controls or welding torch, wear specific safety goggles
in other moving parts of the machine. suitable for the task being performed. Consult
your welding equipment dealer for more
information.
 17
June 1, 2020 Safety Information
CLG856H General Hazard Information

Pay attention when opening fluid compartments

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

When working under high noise conditions, wear

appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high Know the appropriate worksite hand signals and
noise on your hearing. who gives them. Accept signals from one person
only.
Do not smoke or allow open flames near the
machine while performing maintenance on the
air conditioner or if refrigerant gas is present.
Refrigerant gas coming in contact with a burning
cigarette or open flame could produce toxic
vapors that must not be inhaled. Inhaling these
toxic vapors can cause serious injury or death.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
Make sure all protective guards and covers are
handling harmful articles such as lubricants,
secured in place on the machine. Always replace
fuels, coolants, solvents, filters, batteries and
protective guards and covers removed for
other materials.
servicing or maintenance. Repair damaged
guards and covers before operation. Use all cleaning solutions with care. Do not use
any flammable material to wash components, for
Keep the machine, especially the panels,
example, diesel oil or gasoline. They may easily
accesses, step and ladders, free of foreign
catch fire.
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.
18
Safety Information June 1, 2020
General Hazard Information CLG856H

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

Compressed Air

Compressed air can cause personal injury. When

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

High-pressure Fluid

Avoid injury from high-pressure oil. When

repairing hydraulic lines, ensure that
system pressure is completely released Disposal of Waste Fluids
before beginning the repair. Hydraulic oil
under pressure contacting the skin could Improper handling of the waste fluid will cause
cause serious injury or damage. pollution of the environment. Obey all local
regulations for disposal of waste fluids.
Use caution before disconnecting hydraulic lines
or connectors. High pressure oil that is released Collect all waste fluids when performing
can cause a hose to whip. inspections, maintenance, testing, adjusting and
repairs to the machine.
Always support attachments and release
residual pressure before attempting to Prepare to collect fluids with suitable containers
disconnect hydraulic lines. Pressure applied by before opening any compartment or
loads on attachments could cause hydraulic oil to disassembling any component that contains
spray when lines are removed. fluids.
 19
June 1, 2020 Safety Information
CLG856H General Hazard Information

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

Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
● Never use compressed air to clean up
asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.
Cautions about Accumulators ● A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
High-pressure nitrogen is contained in the can also be used.
accumulators making them dangerous articles.
Read the following requirements and pay ● Do not grind materials that contain asbestos.
attention to the proper use of accumulators. ● Operate the machine on the windward side of
Check accumulators before charging with the asbestos as far as possible.
nitrogen. Safe use cannot be guaranteed if there ● Obey environmental regulations for the
is not a nameplate attached to the accumulator. disposal of asbestos.
Never charge accumulators that have an
incomplete nameplate or that are of an ● Shower after contact with asbestos.
unidentified type. ● Wear an approved respirator if there is no
Accumulators are charged with nitrogen. The other way to control the dust.
use of oxygen, compressed air or other
flammable air in the accumulator could cause an
explosion and possible injury, death and damage
to the machine.
When charging accumulators with nitrogen, care
should be taken not to damage the diaphragm.
The accumulator's valve should be installed
facing vertically upward. Do not attempt to fix
accumulators by welding them.
Do not drill any hole in the accumulator or close
a hole by welding.
Do not weld a boss on the accumulator.
Accumulators are high-pressure vessels and
should be repaired only by trained specialized
personnel.
20
Safety Information June 1, 2020
Crushing and Cutting Prevention CLG856H

Crushing and Cutting If the machine must be repaired with engine

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

Burn Prevention

Some parts of the machine become hot during

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

Keep hands and objects away from moving fan

blades. They can throw or cut any object that
contacts the moving blades.
Check the coolant level only after the engine has
Never attempt adjustments while the machine is been stopped and the coolant filler cap is cool
moving or the engine is running unless otherwise enough to remove with your bare hand.
specified.
Remove the cooling system filler cap slowly to
relieve pressure.
 21
June 1, 2020 Safety Information
CLG856H Fire & Explosion Prevention

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

Oil

Hot oil and components can cause personal

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

Fire & Explosion Prevention

All fuels, most lubrication and some coolant

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

Batteries
Clean and tighten all electrical connections.
Batteries give off flammable fumes which can Check daily for loose or frayed electrical wires.
explode. Have all loose or frayed electrical wires
Batteries and battery terminals may contain lead; tightened, repaired or replaced before operating
do not touch batteries with your bare hands. the machine.
Always wash your hands right after maintaining a Check the electric circuit periodically to avoid fire
battery. caused by overload or short circuit.
Do not smoke when observing the battery Keep all fuels and lubrications stored in properly
electrolyte levels. marked containers and away from all
Electrolyte is an acid and causes personal injury unauthorized persons.
if it contacts skin or eyes. If contact occurs flush Store all oily rags or other flammable materials in
with water and seek medical attention right away. a protective container away from naked flames
or other sources of ignition.
Do not weld or flame cut pipes that contain
flammable fluids. Clean the flammable fluids
before welding or flame cutting on them.
22
Safety Information June 1, 2020
Fire Extinguishers and First-aid Kit CLG856H

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

A fire extinguisher that meets with all local fire

extinguisher laws and regulations should be
available on the machine.
Maintain the fire extinguisher in accordance with
all local laws and regulations. Contact your local
fire department for further information.
Know how to use the fire extinguisher and first-
Cautions Concerning Lines, Tubes and
aid kit.
Hoses
A first-aid kit should be available at the work site.
Do not bend or strike high-pressure lines. Do not Periodically check the contents of the kit and
install bent or damaged tubes or hoses. replace used medical supplies as necessary.
Tighten any loose fuel or oil pipes, hydraulic Keep telephone numbers of doctors, first-aid
system tubes or hoses. Repair any damaged fuel centers or fire stations etc with you so you can
or oil lines, tubes or hoses. Leaks can cause contact them in case of an emergency. Post the
fires. Contact Liugong or your Liugong Dealer for contact telephone numbers in regulated places.
factory authorized replacement parts. Ensure that all persons know where the
telephone numbers are located and know the
If you see evidence of any of the following
correct contact method.
situations, replace the part before using:
● Connectors damaged or leaking.
● Outer covering frayed or cut and reinforcing
wire exposed.
● Outer covering ballooning.
● Evidence of kinking or crushing.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
 23
June 1, 2020 Safety Information
CLG856H Electrical Storm Injury Prevention

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

Tire Explosion Prevention

Maintenance, removal, repair and installation of

Dry nitrogen is recommended for inflation of
the tires and wheel rims must be performed with
tires. If the tires were originally inflated with air,
special equipment and a trained repairer.
nitrogen is still preferred for adjusting the
Therefore, it is better to repair and maintain the
pressure. Nitrogen mixes properly with air.
tires in a tire service shop.
Nitrogen inflated tires reduce the potential of a
tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation
of the rubber, deterioration of rubber, and
corrosion of rim components.
Avoid over inflation. Use proper inflation
equipment, and training for using the equipment
is necessary. Improper equipment or using will
result in tire break or rim damage.
Inproper tire and rim maintenance may cause tire
explosion, and such explosion can lead to
serious personal injury or death. Only trained
personnel with proper tools and correct
procedure can maintain the tires and wheel rims.
24
Safety Information June 1, 2020
ROPS/FOPS CLG856H

ROPS/FOPS Any modifications or aditional equipment added

to the inside of the operator station should not
project into the operator space. The addition of a
Roll-Over Protective Structure / Falling Object radio, fire extinguisher and other equipment must
Protective Structure (ROPS/FOPS) of Guangxi be installed so that the defined operator space is
LiuGong Machinery Co., Ltd are located above maintained. Any item that is brought into the cab
the operator's compartment and secured to the should not project into the defined operator
machine. space. A lunch box or other loose items must be
The strength of the structure will be reduced if it secured. Objects must not pose an impact
is damaged due to a rollover. ROPS are certified hazard during travel over rough terrain or in the
structures and cannot be repaired. Any damage event of the machine tipping.
to the ROPS structure will require replacement of
the structure to retain the certification. Steering Frame Lock
Always fasten your seat belt when you operate
the machine.
Connect steering frame lock when the machine
It is forbidden to drill holes or weld inside or is being lifted and shipped. Also connect the
outside or change anything of the cab. This will steering frame lock when performing repairs
damage the integrity of the ROPS structure. near the articulation joint.
If the cab is to be modified in any way, contact Disassemble the steering frame lock before
your local LiuGong dealer to avoid damaging the operating the machine.
ROPS structure.
More information refers to Steering Frame Lock
in Operation Manual.

Attachment Cautions

Attachments should only be installed by

authorized people who have been trained to
operate and maintain the attachment according
to the operator’s manual.
Refer to the instructions in the operation manual
and any other related information when installing
and using attachments.
Operator Station
Incorrect installation of attachments or optional
parts not only will result in safety problems, but
This machine is equipped with a cab that meets also will negatively influence the operation and
with industry standard: ISO 3411. service life of the machine and the attatchments.
It is forbidden to modify the machine or any
attachments without permission from your
LiuGong dealer.
LiuGong bears no responsibility for injuries,
accidents or machine damage resulting from the
use of unauthorized attachments.
 25
June 1, 2020 Safety Information
CLG856H Cautions about Machine Operation

Cautions about Machine Understand the rated load, speed range, the
characteristics of braking and steering, turning
Operation radius and the space clearance for operation.
Remember that rain, snow, ice, gravel and soft
Mounting and Dismounting earth may change the performance of the
machine.
Before mounting or dismounting the machine,
check the condition of handrails, ladders and Understand the safety signs on the machine
steps. Clean them of grease, lubricants and dirt (Danger, Warning, Caution) and any other signs.
before use. Repair any damaged parts and
tighten loose bolts. Understand Your Working Area

Mount and dismount the machine only where Before starting, inspect the area where you will
there are handrails, steps or ladders. be working. You should check: adequate
Face the machine when getting on or off, grab ventilation, the position of any slopes, visible
the handrails with both hands and step onto the ditches, falling or hanging objects, conditions of
steps or ladders. Touch three points soils (soft or hard), accumulated water and
simultaneously (two feet and one hand or two swamp areas, rocks or stumps, hidden
hands and one foot) to ensure stability of the groundwork, posts or the outer limits of walls, the
body. outer limits of the areas where garbage is buried
or that are filled in with earth, holes or openings,
obstacles, mud or ice, traffic, heavy dust, heavy
smoke, heavy fog, the exact locations of cables
or pipes for power supply, gas supply, phone
service, water supply, sewage disposal and other
utilities that are hidden or hung. If necessary
before starting work you should ask the utility
companies to mark out, close or move out these
utilities.

Never jump off the machine. Before Starting the Engine

Never get on or off a moving machine. Inspect the machine carefully before starting the
Be careful not to touch any control levers when engine, ensure all systems are in good
getting on or off the machine. operational condition. Make sure nobody is on or
around the machine before starting the engine.
Do not try to climb on or off the machine when
carrying tools or supplies. Use a rope to pull Keep the steps and handrail clean. Clear any dirt
equipment up onto the platform or have an and sand from your shoes before mounting the
assistant pass them to you. machine.
Check all structural members, covers and
Understand Your Machine fenders for deformation or damage.

Be able to operate all the equipment on your Check the condition of safety items such as
machine. doors, guards and covers. Repair any damage
as necessary.
Understand the purpose of all control systems,
instruments and indicators. Check the hydraulic system for oil leakage.
Check the condition of hoses and pipes.
Check all fasteners for security.
26
Safety Information June 1, 2020
Cautions about Machine Operation CLG856H

Check the condtion of the electrical wiring Engine Starting

harness and fuses, replace or repair as
neccessary. Also check the connectors for good Do not start the engine if there is a DO NOT
connection. OPERATE or similar tag attached to the start
switch or control levers.
Check the fuel level and fuel system for normal
condition, drain any water or sediment in the
water/fuel separator. Dispose of fluids in
accordance with local regulations.

G
IN
N
Replace all damaged or lost parts and carry out

AR
W

er ot
!
lubrication according to the maintenance interval

op o n

e
at
d
schedule.

r:
Remove all loose objects from the cab. Loose

te
ra
pe
O

:
ate
D
objects may affect the operation and cause
accidents.
Do not start the engine until seated in the
Make sure that all the windows, if fitted, are clean operators seat and the seat belt is firmly
and the screenwiper works normally. fastened.
Adjust the operators seat to a position that is
most comfortable and provides for easiest
operation of the machine. Check the seat belt
and the condition of mounting hardware. Repair
or replace any items that are damaged. Replace
the seat belt after three years of use or any time
the belt shows signs of wear or damage.
Adjust the seat to ensure that you can depress
the pedals fully when your back is against the
seat. Ensure the hydraulic control levers are all in the
Check all the illumination equipment before NEUTRAL position and the shift control lever is
operation in low light, and ensure that the in the NEUTRAL position before starting the
illumination system is in good condition. engine.

Check to make sure the steering frame lock is in Sound the horn to alert personnel before starting
the RELEASED position. the engine.

Beep
 27
June 1, 2020 Safety Information
CLG856H Cautions about Machine Operation

Only start the engine from the operators seat in Keep all the windows, lightshades and rearview
the cab. The transmission should be in mirrors clean. Secure doors and windows in
NEUTRAL position before engine starting. Never either the open or close position.
start the engine by short-circuiting the starter
Adjust the rearview mirrors for best vision,
motor terminals. Starting the engine by short-
especially close to the machine.
circuiting could result in damage of the electrical
system, personal injury or death. Clear all obstacles from where the machine will
be working. Be aware of hazards such as high
After the engine is started, you should observe,
voltage wires, ditches, etc.
instruments and warning lights, and make sure
that they work and every reading is within Make sure the horn, backup alarm (if equipped)
working range. and all other alert devices are working properly.
Observe machine movements and listen
Machine Operation
carefully for unusual noises. If there is any fault
or abnormality, you should stop the engine
Before operating the machine on roads, check
immediately. Locate the source of the problem
whether the machine meets the requirements of
and repair before further operation.
the local laws and regulations for road operation.
Make sure that you get the road operating
permission from relevant road administration
offices. Observe the local traffic regulations when
driving the machine on roads.
Before driving the machine, you should carefully
observe the surroundings, and find out the
relations between the direction that you want to
go in and the pedal/operating lever.
Do not allow another person to sit on the
Never run the engine in a closed or poorly machine unless equipped with an additional
ventilated environment. If working inside a seat, seat belt and Rollover Protective Structure
building, open the doors and windows to ensure (ROPS).
enough ventilation and try to prevent exhaust
gas poisoning. Use a power exhaust system
when working in an enclosed area.

Before working the machine, you should operate

the machine slowly to an open area, check for
proper operation of all control levers and all
protective devices.
Before Operating the Machine
Note any needed repairs during machine
Make sure the machine is clear of personnel and operation such as an abnormal noise, vibration,
fasten the seat belt before operation. smell, wrong reading of gauges, gas or oil
leakage, etc., stop what you are doing and report
any needed repairs.
28
Safety Information June 1, 2020
Cautions about Machine Operation CLG856H

Dust, heavy rain, and heavy fog will blur your Never undercut a high bank. The bank edges
vision. You should keep windows, mirrors and could collapse causing severe injury or death.
lights clean and in good condition. When the Avoid working at the base of a bank or under
visibility decreases, you should decrease the overhanging structures. Overhanging ground
speed and apply the proper lights. and structures could collapse. Extreme caution
should be used when working in such areas.
Stay away from overhanging banks and
structures.

If driving or operating the machine with a bad

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

Avoid bumping the obstacles on top of the

machine when operating it.
 29
June 1, 2020 Safety Information
CLG856H Cautions about Machine Operation

Consider filled or unstable ground. Be certain the Avoid operating the machine across the slope. If
condition of the work site is stable and capable of possible, drive the machine in reverse when
supporting the machine during operation. Do going down the slope with a load, and drive
operate the machine close to an unstable drop forward when going up the slope. The machine
off. Operation of the machine on shoulders, drop may turn over if do not drive the machine in
off's, or filled areas could cause the machine to reverse when going down the slope with a load.
become unstable, presenting a work hazard.

When driving the machine on a slope, make it

straight up and down and neither make turn on
the slope nor drive it transversely on the slope to
prevent tipping. The distance between bucket
and ground should be 200-300mm (7-12in).
If the engine stops accidentally when operating
the machine across the slope, depress the
service brake pedal immediately and lower the
bucket to the ground, then pull up the parking To prevent the machine from tipping over or
brake button (or parking brake handle) to stop damaging the attachment due to overloading,
the machine from moving. never exceed the machines rated capacity.
If the machine begins to sideslip on a slope,
immediately remove the load and turn the
machine downhill.
When going down a slope, use the brake power
of the engine and drive in low speed. At the
same time, use the service brake to control the
travel speed if necessary. Do not shut down the
engine or push the lever to NEUTRAL position
when machine goes down the slope, so as to
prevent serious accident or personal injury. Do not use the bucket or boom for lifting. The
machine can only be used within its capability.
Any operation beyond its capability will bring
damage to the machine. Refer to the
Applications and Specifications section for the
specific capacities.
Never hoist heavy articles by directly hanging
slings on the bucket teeth.
30
Safety Information June 1, 2020
Cautions about Machine Operation CLG856H

Never use the loader to lift people. Do not use Transportation

the bucket as a work platform for people. Never
allow people to ride in the bucket. When transporting, make sure that the hooks
and the towing devices are adequate. Connect
Be careful when working beside high voltage
tie down equipment to a drawbar or hook only.
wire. If it is possible to contact the electrical wire
Never straddle a wire rope cable or similar
while working, consult the Electricity Company
device, nor allow others to do so.
before working.
Before transporting, ensure that no personnel
The contact with electrical wire may cause
stays between the machine and tie down
accidents, such as injury or death, do not allow
equipment. The towing bracket or drawbar pin of
any part of the machine to come close to or
the tie down equipment should be centering
contact an electrical wire. Check the area above
connected with the drawbar or hook of the
the machine, and learn about the exact distance
machine.
between electrical wire, machine and ground. If
possible, you’d better cut off the power supply. If
Parking the Machine
it is impossible to cut off the power supply, you
should ask a signalman to guide you.
When possible choose flat level ground to park
the machine, apply the parking brake, always
lower any attachment to the ground and ensure
the machine will not move, possibly causing
damage or injury.
Consider any overhead hazards such as the
posibility of falling rocks, any powerlines or any
other overhead hazards that may exist.
Consider the ground conditions. Do not park the
If the machine has contacted the high voltage machine near the edge of a cliff, close to an open
wire: excavation or pit.

● Alert all personnel to keep away from the Consider environmental conditions such as the
machine. posibility of flooding, heavy snow fall, electrical
storms and exposure to wind and cold. Any of
● If you can, drive the machine away to these conditions may cause damage to the
disconnect the contact point and separate machine.
the high voltage wire from the machine and
leave. Do not cause an obstruction, consider the site
access and other emergency conditions the
● If you can not disconnect the contact point, machine may obstruct.
stay inside the cab until the Electricity
Company cuts off the power and you are
informed to go out.
● If a fire occurs, hold your feet as close as
possible and jump off the machine without
touching ground with your hands. Try to jump
into a safe place.
 31
June 1, 2020 Safety Information
CLG856H Cautions about Machine Operation

If it is necessary to park the machine on a slope When leaving the machine lock all equipment
or incline, lower the implement to the ground, covers and doors with the key. Remove the key
engage the parking brake and shut off the and keep it with you.
engine. Place chocks under the wheels at the
downhill side on both sides to prevent the
machine from moving.

Lowering the Attachment/ Implement with

Engine Stopped

Understand and obey all regulations relating to

public roads, if the machine is parked on a public
road. Additional signal or flasher may be For a machine controlled by electro-
required. hydraulically control lever, in order to lower
Always lower attachments or other equipment the implement, the engine start switch must
before leaving the machine, apply the parking be on ON position. Turn the engine start
brake. switch to OFF position after lowering the
implement.
If the machine is equipped with a pilot cut-off
lever, turn it to OFF position. If the machine is
equipped with a hydraulic lock switch, press it to In order to lower the implement to the ground or
LOCK position. Put the work implement control trailer, move all control levers to DOWN position.
levers and shift control lever to the NEUTRAL When release them, they will return to HOLD
position. position.

Engage the parking brake.

Keep the engine running at idle speed for five
minutes to let the engine cool down gradually.
Stop the engine, and take out the key from the
switch.
Turn the battery disconnect switch to OFF
position to avoid battery discharge.
32
Safety Information June 1, 2020
Cautions about Machine Maintenance CLG856H

Store Accessories Safely Transportation Information

Store accessories and tools safely so as to Obey the appropriate laws that govern the
prevent them from falling and causing serious parameters of the load (weight, length, width,
injury or death. Keep playful children and and height).
bystanders away from the storage area or any
Understand the correct procedures for loading
area accessories are being stored while in use.
and unloading.
Carry out the loading and unloading operations
on flat ground.
Chock the wheel of the trailer to make it unable
to move.

Cautions about Machine

Maintenance
1. Wedge
Prepare the Working Area 2. Block
3. Angle (Max. angle is 15°)
Please choose a clean and flat area with 4. Distance between the ramps
adequate space, enough light, and good 5. Ramp
ventilation to carry out any repair work. Clean the Use loading ramps appropriate for the machine
ground surface, wipe up fuel, lubricating oil and being moved. Consider: size, strength, departure
water, and spread sand or other absorptive angle and proper height. Make sure that the
materials on the slippery ground. Keep the work loading ramp is anti-slip and free of mud and
area clean and dry. snow.
Use chains and blocks to secure the machine to
Support the Machine Correctly
the trailer.
Lower to the ground or support any attachments Keep the bystanders away.
with stands or other methods. Ensure that any
Place all the working equipment in the
attachment can not move during maintenance or
transportation position, secure all the equipment
repair work, use wheel chocks or other devices
and attachments or additional equipment with
to prevent machine movement.
chains or other secure methods to prevent
Do not work under any part of the machine or accidental movement.
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use Lifting the Machine
stands or other measures that are secure and
can support the weight being applied to them. Refer to the machine nameplate for the machine
mass.
 33
June 1, 2020 Safety Information
CLG856H Cautions about Machine Maintenance

Before lifting, secure the front and rear frame Remove all the flammable materials, supply the
with the steering frame lock so that the machine work area with a fire extinguisher.
can not move.
Use proper rated cables and lifting device, keep
levelling in lifting.
Lifting device should be big enough to prevent
the machine from being damaged in lifting.

Clean the Equipment Periodically

To avoid possible injury or damage to the

machine, all the oil and scraps accumulated
should be removed. The engine, radiator,
storage battery, hydraulic hose, fuel tank and cab
should be kept clean.
Welding Operation
When carrying out the cleaning operation, wear
Any personnel engaging in welding operations suitable PPE. Consider exposure to: chemicals,
must have occupational certificates and carry out slippery surfaces, high pressure water spray and
the operation at a place with appropriate devices material splash.
equipped, When carrying out the welding
operation, the personnel must follow the
instructions below:
Before carrying out the welding operation, turn
off the battery isolator switch, disconnect the
battery, disconnect the controllers, GPS and
other electrical parts.
Remove all paint from the place to be welded, so
as to prevent harmful gas from being produced.
Do not inhale smoke produced by burning paint.
Never weld pipes, close to rubber hose and Do not spray the water directly onto sensors,
electrical wires. connectors or instruments of the electrical
Always remove residual pressure from the system. If water enters the electrical system
machine. Never weld pipes that are fitted to the malfunction may occur.
machine.
Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
of the operation being performed.
Ensure good ventilation.
34
Safety Information June 1, 2020
Sound and Vibration CLG856H

Sound and Vibration

Sound

The sound performance offered for this machine

is the standard in European Union countries and
in countries that adopt the EU Directives.
A-Weighted emission sound pressure level, L at
the operator's position measured according to
work cycle procedures specified in "ISO 6396" is
76dB(A), for the cab offered by LiuGong.
A weighted sound power level of the cab
measured according to work cycle procedures
specified in "ISO 6395" is 106dB(A).

Vibration Level

Whole body vibrations generated by

construction machines, are to a high degree,
influenced by different factors, e.g. working
methods, ground conditions and traveling
speed selected by the operator.

This machine is equipped with an operator's

seat, which meets the criterion in standard ISO
7096. This seat is tested with the input spectral
class EM6 and has a Seat Amplitude
Transmissibility factor SEAT=0.95.
The hands and arms are exposed to a weighted
root mean square acceleration that is less than
2.5 m/s2.
The whole body is exposed to a weighted root
mean square acceleration that is less than
0.5 m/s2.
Mesurements are obtained on a representative
machine using the procedures in the following
standards:
"ISO 2631-1"
"ISO 5349-1"
"ISO 5349-2"
 35
June 1, 2020 Safety Information
CLG856H Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically

No. Q'ty Change Intervals
Changed
Every year or every 2000h (To see which one
1 Hydraulic oil tank filter element 1
comes earlier)
2 Fuel hose (fuel tank--fuel pre-filter) 1
3 Fuel hose (fuel pre-filter-fuel lift pump) 1
4 Fuel hose (fuel lift pump-fuel filter) 1
5 Fuel hose (fuel filter-high pressure pump) 1
6 Fuel hose (fuel return hose) 1
7 Return hose of turbocharger 1
8 Hose assembly (pump-flow amplifying valve) 1
Hose assembly (flow amplifying valve-steering
9 2
cylinder)
10 Steering cylinder seals 2 Every two year or every 4000h (To see which
one comes earlier)
11 Hose assembly (air compressor to air reservoir) 1
Hose assembly (air reservoir to air connection
12 1
block)
Hose assembly (air connection block to service
13 1
brake valve)
14 Hose assembly (air connection block to assistor) 2
15 Assistor seal 2 sets
16 Hose (assistor-axle) 1
17 Hose (air connection block-parking brake valve) 2
18 Hose (parking brake valve-air brake chamber) 1
Every three year or every 6000h (To see
19 Air reservoir 1
which one comes earlier)

1. To ensure the safety of the wheel loader during usage, the user must adhere to replace the parts listed in the above
table regularly due to the important of these parts in the security and fire prevention.
2. The materials of these parts will degenerate along with the passage of time, or more easy to wear, corrosion.
Moreover, it is very difficult to determine the state of these parts simply according to the regular maintenance.
Therefore, no matter what usage state they are, it is necessary to change these parts regularly in order to ensure their
performance.
3. If the parts not work properly even less than the time for replacement, they should be repaired or replaced immediately.
4. If the pipe folder of the fixed hose has any damage, such as distortion or cracks, it should be replaced together with the
hose.
5. Please replace the O-ring, seals and other parts like these at the same time when replace the hose.
6. Please contact the designated dealer of LiuGong Machinery Co., Ltd. to replace the safety key parts.
36
Application and Specification June 1, 2020
Applications CLG856H

Application and
Specification

Applications

This loader is a kind of engineering machinery

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

Requirements of Work Environments

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

Preventive measures for operation,

maintenance and safety rules outlined on this
manual are only suitable for the stipulated
applications of the machine. Do not use the
machine beyond the stipulated application
scope, Guangxi LiuGong Machinery Co., Ltd
will not bear any safety liability, and these
safety liabilities will be born by users. Under
any cases, do not use the forbidden
operation outlined in this manual.
 37
June 1, 2020 Application and Specification
CLG856H Main Specifications

Main Specifications

All rated lift capacities are based on the criteria of the machine being levelled on a hard and flat ground.
When the machine is operated in conditions that deviate from these criteria (e. g. on soft or uneven
ground, on a slope or when subject to slide loads), these conditions shall be taken into account by the
operator.
The following table lists the specifications in standard collocation, please refer to the appendix of this
section for the specification change parts of the other special collocations (such as larger bucket, longer
boom, and side dump bucket).
Exterior drawing
38
Application and Specification June 1, 2020
Main Specifications CLG856H

Machine Specification
Rated bucket capacity m3 3
Rated load kg 5000
Boom lifting time (under full load) s ≤5.7
Total time s ≤10
Forward II speed km/h 39.68
Max. traveling speeds Forward I speed km/h 12.14
Reverse I speed km/h 16.34
Max. traction force kN 171±10
Max. breakout force (bucket tilting) kN 173±10
Max. gradeability ° 27
A: Height to hinge pin, fully raised mm 4159±50
B:Dumping height mm 3100±50
C: Reach, fully raised mm 1126±50
D: Digging depth mm 85±10
E: Ground clearance mm 431±20
F: Distance from swing pivot axis to front
mm 1660
wheel center
G: Wheel base mm 3320±20
Overall dimensions H: Overall height (top of cab) mm 3450±50
J: Tread width mm 2150±10
K: Overall width (outside of wheel) mm 2750±50
L: Overall length(with bucket) mm 8253±100
M: Max. turning angle ° 38±1
W: Bucket width mm 2976±30
R1: Turning radius with bucket in
mm 6914±140
carrying position
R2: Min. turning radius(tire center) mm 5896±50
Operating mass(with cab) kg 17200±200
Work implement Single bucket lever reversal Z-bar Mechanism
Driver's seat Above articulation frame
 39
June 1, 2020 Application and Specification
CLG856H Main Specifications

Appendix: Special Specificaion

Specifications in special Standard Larger bucket Larger

V-rock bucket
collocation bucket (movable blade) bucket
Rated Bucket Capacity m3 3.0 3.3 4.5 2.7
Max. Breakout Force (Bucket
KN 172 167 135 162
Tilting)
B:Dump Height mm 3100±50 3072±50 2882±50 3057±50
C: Reach, fully raised (Dumping
mm 1126±50 1156±50 1346±50 1170±50
distance)
L:Overall length (with bucket) mm 8253±100 8319±100 8330±100 8340±100
R1:Turning radius with bucket in
mm 6914±50 6935±50 7002±50 6824±50
carrying position
W: Bucket width mm 2976±30 2976±30 3150±30 2887±30
Operating Mass kg 17200±200 17200±200 17200±200 17200±200

Main Components Specification

Model GCIC 6LT9.3 engine

Rated fuel consumption g/kWh 215
No. of cylinder and
Straight-six cylinder
arrangement
Cylinder bore × stroke mm Φ116.5X144.5
Total displacement L 9.3
Compression ratio 18:1
Ignition sequence 1-5-3-6-2-4
Intake type Turbocharged
Power system Engine
Rated power KW 162
Rated speed r/min 2200
Maximum speed(without
r/min 2376±100
load)
Minimum speed(without load) r/min 800±50
Maximum torque N.m 910
Speed at maximum torque r/min 1400
Start motor 24V-7.8 KW
Alternator 28V- 70A
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Application and Specification June 1, 2020
Main Specifications CLG856H

Model Double turbine, four members

Torque converter
Cooling type Air cooled, forced circulation type
Model Planetary hydraulic shift
Two forward speed, one reverse
Speed
Transmission speed
Power train Shift pump(gear pump) work
MPa 1.1~1.5
system pressure
Main drive type Spiral bevel gear single reduction
Drive axle Final decelerate type Spur gear planetary reduction
Reduction rate 22.547
Model Four wheel drive
Wheel
Tire 23.5-25PR16
Model Hydraulic power steering system
Steering cylinders--
mm 2-φ90×465
bore×stroke
Steering pump displacement ml/r 90.5
Steering hydraulic
Rated speed of steering
system r/min 2200
pump
System flow L/min /
System work pressure MPa 18±0.3
Hydraulic Steering angle 38°±1°each
system Doulbe pump junction hydraulic
Model
system
Boom cylinder--bore×stroke mm 2-φ160×745
Tilting cylinder--bore×stroke mm 1-φ180×571
Work hydraulic
Pilot control, double spools, three
system Control valve
spools
Work pump displacement ml/r 83.9
Rated speed of work pump r/min 2200
System work pressure MPa 20.7±0.3
Single line air over hydraulic, disc
Model
type
Service brake
System air pressure MPa 0.71~0.784MPa
Brake system
System oil pressure MPa 12.3MPa
Flexible shaft control, internal
Parking brake Model
expanding brake
Heating capacity W 5800

Air Warm air flow m3/h 900

Air conditioner
conditioning Working medium Engine coolant
(Heating-only)
system
Total power W 250
Voltage V 24
Electrical System voltage V 24
system Battery V 24
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June 1, 2020 Operation Manual
CLG856H Before Operation

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

Never jump off the machine.

Never get on or off a moving machine.
Be careful not to touch any control levers when
getting on or off the machine.
Do not try to climb on or off the machine when
carrying tools or supplies. Use a rope to pull
equipment up onto the platform or have an
assistant pass them to you.

Daily Inspection

For a maximum service life of the machine,

complete a through walk-around inspection
before you mount the machine and before you
start the engine.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Operator Controls and Disconnect switch--OFF

Instrument Panels To shut down the electrical system, turn the

battery disconnect switch key counterclockwise
to O position. In this position, the battery
Battery Disconnect Switch disconnect switch key will point to the O position.

The battery disconnect switch is located in the

battery box at the rear left side of the machine, it O I
can be seen only open the cover.

The battery disconnect switch and the engine

start switch perform different functions. To
disable the entire electrical system, turn the
battery disconnect switch to the OFF position.
The battery remains connected to the electrical
system when you just turn off the engine start
switch key.

Disconnect switch--ON

Turn the battery disconnect switch key clockwise Do not turn off the battery disconnect switch
to I position before you start the engine. In this while the engine is running, otherwise it may
position, the battery disconnect switch key will damage the electrical system.
point to the I position.

O I
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Engine Start Switch

The start switch (also called ignition switch) is

located inside the cab and it has four positions in The battery disconnect switch must be at I
clockwise direction. position and the shift control lever must be
in NEUTRAL before starting the engine.

If the engine fails to start, turn the start

switch to the OFF position before restart or
the start switch could be damaged.
Do not engage the start switch for more
than 15 seconds at one time. Wait at least 30
seconds before restarting. Do not exceed
three consecutive attempts before allowing
the starter motor and choke solenoid to cool
AUX——The first position when insert the start down. Failure to comply could result in a
switch and turn it counterclockwise. The start reduction of the service life of the battery as
switch key will reset to OFF position well as damage to the starter motor and
automatically after being released. This position choke solenoid.
is not available at present.
OFF——The oil passage of the engine is cut off
at this position. The power of the machine is
turned off. All of the other electrical appliances
can not be turned on except the turn signal lights,
rotating beacon and dome light.

The start switch key can only be inserted or

taken out in OFF position.

ON——The first position when insert the start

switch key and turn it clockwise. The electrical
system of the machine can turn on and work
normally.
START——The second position when insert the
start switch key and turn it clockwise. The engine
will be turned on and work. Release the start
switch key after starting the engine. This position
can not hold on automatically and the key will
reset to the ON position automatically after being
released.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Instrument Panel

Most of the gauges, alert and steering indicators are integrated in the instrument panel in the front of the
steering wheel and on the right front upright column. There are eighteen items showed on the
instrument, namely, service brake air pressue alert, fuel level, speed meter, service hour meter, engine
coolant temperature, torque converter oil temperature, left and right turn indicators, parking brake, brake
low pressure alert, status indicator, engine intake air filter alert indicator, transmission fault, engine oil
pressure alert, charging indicator, voltage indicator, transmission oil alert and front floodlight high beam
indicator.

C
A

A. Central instrument panel D. Front upright column instrument panel-RH

B. Front left instrument panel E. Heating-only air conditioner panel
C. Front right instrument panel
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Central Instrument Panel Service hour meter

Central instrument panel consists of five pointer Service hour meter indicates the total
gauges, a service hour meter, status indicators work hours of the machine, unit in
and warning indicators, etc.. hour. The time range of the hour meter is 0 to
9999.99 hours. When starting engine, the
6 7 service hour meter starts to time. The display
shows the accumulated work hours of the
machine. The recording value by the service
hour meter can be used to determine the
machine maintenance intervals.

Engine coolant temperature gauge

This gauge shows the coolant

temperature of the engine. The green
zone (55~101 °C) shows normal work
temperature; the yellow zone (40~55 °C) shows
low temperature and the red zone (101~120 °C)
1 2 3 4 5
shows high temperature.
1. Service brake air pressure gauge
2. Fuel level gauge
3. Service hour meter
4. Engine coolant temperature gauge
5. Torque converter oil temperature gauge Stop the engine and park the machine on a
6. Left turn indicator convenient place to check when the gauge
7. Right turn indicator
points to red zone. Check the engine fan,
Service brake air pressure gauge belts and the radiator coolant level. Never
go on working until the trouble is
This gauge indicates the pressure eliminated.
value of the compressed air in the
brake system. The green zone indicates the
service brake air pressure is in the range of the
normal work pressure. The red zone indicates When checking the engine fan, belt and
lower or higher brake pressure. The service water tank level, be extremely careful to
brake low pressure alert indicator on the avoid injury. Keep away from the moving
instrument panel illuminates when the gauge parts to avoid being injured and keep away
points at the left of the red zone, and the status from hot parts to avoid being burnt.
indicator flashes at the same time. At this time, if
the engine is running, the buzzer alerts.

Fuel level gauge

This gauge indicates the fuel level of

the machine. Green zone indicates the
high fuel level. Red zone indicates the low fuel
level. Add fuel in time when the pointer points at
the red zone.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Torque converter oil temperature

gauge
8 9 10 11
This gauge is used to indicate the oil
temperature of the torque converter. The green
zone (60~116 °C) shows normal work
temperature; the yellow zone (40~60 °C) shows
low temperature and the red zone (116~140 °C)
shows high temperature.
12
13 15
14
8. Parking brake indicator
When the pointer of the torque converter oil 9. Brake low pressure alert indicator
temperature gauge points to the red zone, 10. Status indicator
park the machine on a safe and convenient 11. Engine intake air filter alert indicator
place for repair. Check the transmission and 12. Engine oil pressure alert indicator
13. Generator charge indicator
transmission oil level. Never go on working 14. Voltage indicator
or operate the machine before eliminating 15. Transmission oil pressure alert indicator
the problem.
Parking brake indicator
Turn indicators
When engaging parking brake, the red
The left indicator flashes when the indicator turns on. It indicates the
machine turns left, the front & rear left parking brake is working.
turn signal light will also flash
simultaneously. Brake low pressure alert indicator

The right indicator flashes when the The illumination of this red alert
machine turns right, the front & rear indicator indicates the hydraulic oil
right turn signal light will also flash pressure of the brake (including parking brake
simultaneously. and service brake) is too low. Stop the machine
to check.

Status indicator

When illuminates any one of the

following alert indicators: parking
brake, brake low pressure, engine oil pressure,
engine air filter blocked, centralized lubrication
fault, transmission oil pressure, and transmission
fault alert indicator, the status indicator flashes; If
illuminates one of the following alert indicators:
parking brake, brake low pressure and engine oil
pressure alert indicator, at the same time, the
engine is running, the buzzer will alert.
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Engine intake air filter alert indicator

When the air filter is blocked, this 16 17

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

Engine oil pressure alert indicator

Engine oil pressure alert indicator will

flash to alert when the engine oil
pressure is too low, and the buzzer will sound at
the same time (the buzzer alerts only in the
situation that the engine is running). Stop the 16. Front floodlight high beam indicator
engine to check. 17. Preheat indicator (Optional)

Generator charge indicator Front floodlight high beam indicator

The indicator indicates if the generator The blue indicator indicates the front
is charging the battery. Turn the start floodlight is at high beam.
switch to ON position, it will light. Aafter starting
engine, the indicator will go out and the Preheat indicator (Optional)
generator starts charging the battery.
The yellow indicator shows that the
Voltage indicator engine grid preheater is working when
it turns on.
When the yellow indicator lights, it
indicates the voltage of the machine is
out of the range of 24.8-29.5V. If the voltage of
the machine exceeds 31.5V, the voltage indicator
and status indicator will light, the buzzer will
sound at the same time.

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. Check the
transmission and transmission oil level.
Never go on working or driving the machine
before correcting the fault.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Front Left Instrument Panel Hazard flasher switch

After turning on the hazard flasher

switch, all the turn signal lights (four
lights) will flash simultaneously. They function as
warning lights when the machine stops in case of
11 danger and emergency.

22
The left and right turn lights switch will not
work after turning on the hazard flasher
33
switch. Therefore, turn off the hazard flasher
switch before starting the machine.
1. Position light and front floodlight switch
2. Hazard flasher switch
3. Front work light switch Front work light switch

Position light and front floodlight The front work light switch controls on
switch or off of two front work lights on the top
of the cab simultaneously.
This switch controls the on and off of the
Turn on the position light switch first when
position lights and front floodlights.
operating, and then turn on the front work light
When press the upper of the switch, the four switch. The front work light can not be turned on
position lights and front floodlights of the and off by just turning on the front work light
machine will be turned on. At the same time, the switch only.
backlight lamp and the relevant switch indicator
will be turned on.
Press the switch to the middle position, the four
position lights of the machine will be turned on
and the front floodlights will be turned off. At the
same time, the backlight lamp and the relevant
switch indicator will be turned on.
Press the switch to the inferior position, the four
position lights and the front floodlights of the
machine will be turned off.
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Front Right Instrument Panel Front Right Upright Column Instrument

Panel

1
1

1. Lighter
2. Rear work light switch
1. Engine start switch
Lighter Engine start switch
Push down the lighter, the lighter will For more information about engine start switch,
be turned on and begins to heat. The refer to "Engine Start Switch" on page 43.
lighter will spring out when it is hot enough. Pull
out the lighter for smoking. Return the lighter to
socket after use.

The lighter will automatically spring out in 10-

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

The socket of the lighter can be used as a power

supply interface of 24 volts DC, the maximum
power supply current is 10 Amp.

Rear work light switch

The rear work light switch controls on or

off of two rear work lights on the top of
the cab simultaneously.
Turn on the position light switch first when
operating, and then turn on the rear work light
switch. The rear work light can not be turned on
and off by just turning on the rear work light
switch only.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Heating-only Air Conditioner Panel Fan speed switch is also the power switch of the
air conditioner. Turn this switch to either H, M or
Two types of heating-only air conditioner panels L with engine starting to turn on the air
are available for this machine. The control panel conditioner.
is located under the left side of the driver’s seat. Turn the fan speed switch to O or OFF position to
turn off the air conditioner.

Starting explanation of air conditioner

After the engine is started, turn the fan speed

switch to either H, M or L with engine starting to
turn on the air conditioner.
Turn the fan speed switch to O or OFF position to
turn off the air conditioner.

2 During winter, turn on the air conditioner for

20 minutes to run the compressor to avoid
leakage of coolant. This keeps the
1 compressor in best condition.

Heating

1. Before starting the engine, set the warm

water valve at engine coolant inlet and outlet
to ON position(warm water valve direction is
same with the hoses).
1
2
3 2

1. Fan speed switch

2. Indicator
3
When the A/C system is working, the vent will
send out warm air or natural air, the air direction
can be adjusted according demand. 1. Warm water valve
2. Warm water valve ON
Fan speed switch 3. Warm water valve CLOSE

Three positions are available: high(H),

medium(M), low(L). Turning the switch to O or
OFF position will turn off the fan.
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

2. After the engine is started, adjust the fan During heating operation, the manual warm
speed switch to the desired position. water valve should be at ON position (the warm
water valve direction is the same with the hoses).

At the beginning when the engine is started,

the air temperature is low due to the low If it is necessary to repair the air
coolant temperature, but the air temperature conditioning system due to fault, first close
will raise after coolant temperature is the manual warm water valve (the warm
getting high. water valve direction is vertical to hoses) to
prevent coolant loss.
Warm water valve When replacing the engine coolant, open
the warm water valve and set the selector
The heating function of the air conditioning switch to warm air position to replace the
system can be realized by the coolant flows coolant inside the evaporator together.
through the evaporator of the air conditioning Make sure the engine coolant level is
system to release heat. correct.
A manual warm water valve is provided
respectively for the water inlet and water outlet of
the engine.(Note: some machine only has one
for the water inlet of the engine). The water radiator should be emptied or filled
with antifreeze and the selector switch
3 2 should be set to warm air position when the
ambient temperature is below 0°C and the
engine stops running, otherwise the radiator
lines will be damaged by being frozen.

1. Warm water valve

2. Warm water valve ON
3. Warm water valve CLOSE
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Control Devices

1 3
8
2

5
7 6

1. Steering Wheel 6. Parking Brake Handle

2. Horn Switches 7. Accelerator Pedal
3. Combination Switch 8. The Work Implement Control Lever
4. Shift Control Lever 9. Fan
5. Service Brake Pedal
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Steering Wheel Horn Switches

There are two horn switches, one is located in

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

Articulate full-hydraulic power steering is

provided on this machine, the steering wheel is
in the cab and it is connected to the full-hydraulic
metering pump. In normal operation, turn the
steering wheel clockwise, the machine will turn
right; turn the steering wheel counterclockwise,
the machine will turn left.
The characteristics of the full-hydraulic power Combination Switch
steering are as follows:
1. The steering angle of the steering wheel is The combination switch located on the right of
not the same with the turning angle of the the steering wheel is an integrated type switch. It
machine, turn the steering wheel has the following functions: steering indication,
continuously to increase the turning angle of front floodlight high beam / low beam shift, horn
the machine until the desired position is control, windshield wiper control, windshield
obtained. washer control etc.
2. The faster the steering wheel turns, the faster Steering indication
the machine turns.
3. The steering wheel can not reset
automatically after being released, and the
machine steering angle will not change.
Therefore, turn the steering wheel
counterclockwise to let the machine travel in
straight direction after finishing turning.

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
on simultaneously. Pull it backward when turning
right, the right turn indicator will flash, and the
front & rear right turn signal lights will also turn
on simultaneously. When the hazard flasher
switch is on, the turn signal lights will not work.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

High beam/ low beam shift Front windshiled wiper control

The high beam/ low beam can be achieved by

the up and down movement as per the arrow
direction. Front windshield wiper switch is located on the
combination switch. There are four positions:
If the front floodlight is at low beam state, push
OFF (O), intermittent (J), low velocity (I), high
the combination switch up and down to change
velocity (II). The position J is not available at
the light to high beam and the blue front
present. Rotate the switch to I position, the
floodlight high beam indicator on the central
windshield wiper works at low velocity, rotate it to
instrument panel turns on. Push the combination
II position, it works at high velocity.
switch up and down again, the front floodlight
high beam will change to low beam.
Front washer control
Horn control

The washer will work by pressing the washer

control switch inwards. The water from reservoir
The horn will sound by pressing the horn button will be sprayed to windshield window glass.
at the end of combination switch.
The washer will reset to natural position and stop
spraying after being released.
Refer to section “Window Washer Reservoir--Fill”
for the location and maintenance of the washer
reservoir.
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Shift Control Lever Service Brake Pedal

The shift control lever is located under the

steering wheel. Push the shift control lever
forward to get the forward 1st speed (the lever on
position 1), the forward 2nd speed (the lever on
position 2) and push rearward to get reverse
speed. When push the shift control lever to
NEUTRAL position, the machine should not
move.

The service brake pedal is located at the front left

side of the driver’s seat. The service brake
system has single brake pedal and single circuit.
Depress the service brake pedal, the front and
rear axle will brake and the brake lights will turn
on simultaneously. Repair the brake system in
time if it has fault to ensure the machine has
enough brake power.
If the clutch cut-off switch is turned on and the
transmission is at first and second position,
When the shift control system has a fault,
depressing the brake pedal, then the
never remove the transmission system
transmission will shift to neutral automatically to
without authorization. Consult LiuGong
cut off the power output. If the transmission is at
dealer or Service Company if the fault can not
the third and fourth position, the transmission will
be eliminated.
not shift to neutral even if the brake pedal has
been depressed.
If the clutch cut-off switch is turned off, the
transmission will not shift to neutral even if the
brake pedal has been depressed.
Release the service brake pedal to disengage
the serviced brake.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Parking Brake Handle Accelerator Pedal

The parking brake handle is located on the floor

inside the cab, on left side of the driver's seat.
Pull it up to engage and press it down to
disengage the parking brake.

The accelerator pedal is located at the front right

side of the driver's seat. Naturally, the engine is
at idle state. The diesel engine oil supply and the
Ways to disengage the parking brake handle: engine speed will increase by depressing the
Press the button on the top of the parking brake pedal while the oil supply and the engine speed
handle to unlock the positioning plate, then push will reduce by releasing it.
down the handle slowly until the handle reaches
the horizontal position. Pull up the handle when Work Implement Control Lever
engaging the parking brake.
The work implement control lever are located on
the right side of the driver's seat. They are used
to control the boom and bucket. Push the boom
control lever forward and pull it backward to
control the boom lowering and raising; push the
bucket control lever forward and pull it backward
to control the bucket dumping and tilting back.
The two control levers are naturally at the
NEUTRAL position when the engine stops.

1
2
2

1. Boom control lever

2. Bucket control lever
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

When the engine is running, push the bucket Boom lift kickout: pull the control lever backward
control lever forward to tilt the bucket forward; until it reaches to the limit position, then the
pull the bucket control lever backward to tilt the control lever will stay at this position (it will not
bucket backward. reset after being released); when the boom
reaches its maximum height, the boom lift
Push the boom control lever forward to lower the
kickout switch works and the control lever will
bucket and backward to raise the boom.
return to the NEUTRAL position, the boom will
Move the two control levers forward or backward not raise any more.
slightly can control the opening of the main valve
port, and cooperate with the throttle opening of Lower
the diesel engine, which can control the moving
position and speed of the implements more Push the control lever forward, the
accurately. boom will lower. The control lever will
return to NEUTRAL position after being
See the following picture for the operation
released.
positions of boom control lever and bucket
control lever.
Float
Control lever operation positions
Push the control lever forward until it
4 reaches the limit position, then it will
5 stay at that position (the control lever will not
1 reset after being released) and the boom is at
6 FLOAT state.
2 When scraping or loading, push the control lever
7 to the FLOAT position, then the bucket will raise
3 or lower along with the ground condition to avoid
damaging the road surface.
When lowering the boom, push the control lever
to FLOAT position, and then the boom will lower
slowly due to its dead weight.
1. Tilt back
2. Bucket control lever (NEUTRAL) Pull the control lever to NEUTRAL position to
3. Dump cancel FLOAT state.
4. Float
5. Lower
6. Boom control lever (NEUTRAL)
7. Raise
Do not use FLOAT when lowering the boom
Boom control with a loaded bucket. The quick lowering
speed of the boom will damage the
Raise machine.
Pull the control lever backward, the
boom will raise. Hold

The control lever will return to the

NEUTRAL position after being
released from RAISE or LOWER position, the
boom will stay at the position that is selected.
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Operation Manual June 1, 2020
Operator Controls and Instrument Panels CLG856H

Bucket control Then lower the boom, when the bucket

contacting with the ground, the bucket bottom
Dump should align with the ground.

Push the control lever rightward

(forward), the bucket will dump
forward.

Hold

The control lever will return to the

NEUTRAL position after being
released from DUMP or TILT BACK position, the
bucket will stay at the position that is selected.

Tilt back

Pull the control lever leftward

(backward), the bucket will tilt back.
The control lever will hold at the maximum tilting
position till the bucket reaches the positioning
position. Then the control lever will return to the
NEUTRAL position.

Bucket positioning (indicator type) Push the control levers to LOWER position
to lower the work implement onto ground or
When the bucket is at DUMP condition, pull the trailer if the engine flames out.
bucket control lever backward and check the
indicator position on the bucket cylinder at the
same time. When the indicator reaching the
desired position, turn the bucket control lever to Before lowering the work implement, make
NEUTRAL position. sure that no obstacles or personnel is around
the machine to avoid machine damage or
personnel injury or death.
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Auxiliary Control Lever

The auxiliary control lever is located on the right

side of the driver’s seat. It is used to control the Do not operate the auxiliary control lever
operation of attachments. Naturally, the auxliary during loading, otherwise the side dump
control lever is at NEUTRAL position when the cylinder will be damaged, the bucket will
engine stops. loose and dump accidently, serious accident
will be caused.
Auxiliary control lever

Logging fork

CLOSE--Push the auxiliary control lever forward,

the logging fork will close. The control lever will
return to NEUTRAL position after being
released.
NEUTRAL--The logging fork will stay at this
position after releasing the auxiliary control lever.
OPEN--Pull the auxiliary control lever backward,
the logging fork will open. The control lever will
return to NEUTRAL position after being
Side dump bucket released.

DUMP--Push the auxiliary control lever Snow plow moldboard

forward, the bucket will dump by side.
The control lever will return to SWING RIGHT--Push the auxiliary
NEUTRAL position after being control lever forward, the moldboard
released. will swing right. The control lever will
return to NEUTRAL position after
NEUTRAL--The side dump bucket will being released.
stay at this position after releasing the
auxiliary control lever. NEUTRAL--The moldboard will stay at
this position after releasing the
TILT BACK--Pull the auxiliary control auxiliary control lever.
lever backward, the bucket will tilt
back. The control lever will return to SWING LEFT--Pull the auxiliary control
NEUTRAL position after being lever backward, the moldboard will
released. swing left. The control lever will return
to NEUTRAL position after being
released.

After finish dumping, do not operate other

control levers until the side dump bucket is
lowered to ground.
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Other Devices

Seat The maximum supporting capacity of the

armrest is 50KG.
The seat provided for this machine can be
adjusted in the aspects of fore-and-aft direction,
3. 3-step height adjustment by lifting the
height, backrest angle, armrest angle, headrest
seat top
height and weight to meet the needs of different
drivers in various working conditions.

1. Fore-and-aft adjustment.

Hole the linkage under the seat, move the seat

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

Three increment are available. When lifted to the

max. height, the seat will get back to the min.
height automatically.

Do not adjust the seat while the machine is

running, otherwise a serious accident could
result!
2. Armrest angle adjustment

Adjust height and angle of the armrest through 4. Headrest adjustment

roller. The adjustment range of armrest angle is
40°and height is 40mm. Headrest height adjustment 157mm.
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CLG856H Operator Controls and Instrument Panels

7. Nonretractable seat belt

Before taking off the headrest, raise the

headrest and remove the spring under the
bush cover first.

5. Backrest angle adjustment

Backrest angle adjustment min.90°. It can be

adjusted to meet the need of different operators.

8. Document box

The document box is located at the back of the

backrest.

6. Weight adjustment and suspension

function

Two stroke options are available for this weight

adjustment: 60mm and 80mm. Adjust according
to the operator's weight. Weight adjustment is
infinite from 50 kg to130 kg.
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Seat Belt A red button is provided by side of the buckle.

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

The machine is equipped with a seat belt by

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

The seat belt used in this machine can not retract

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

3 4 5 6 7 8 9 10 11 12

1. Source/mute key
2. SRC/SOUND
3. Volume key
4. Menu key
5. Preset key 2
6. Preset key3
7. Preset key4/last menu
8. Preset key 5/next menu
9. SCAN key
10. Search station forward/last song/hour
11. Auto store station/exit
12. Search station backward/next song/minute
13. Audible signal input
14. USB
15. Waveband key
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June 1, 2020 Operation Manual
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1. Press SRC/SOUND key for 2 seconds to

enter BASS-TRE.

Connect the battery negative terminal only

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

Source/mute key

Press to switch on the power. Press

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

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

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

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

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

A 3.5 mm audible signal input interface

is provided on the sound system,
which can be used to connect other music
players. Press SRC key and select AUX IN
3. The display will show the album number mode. The volume can be adjusted under AUX
before playing the songs. IN mode.
4. When playing, the display will show the
song's name and playing time. After finishing,
it will continue to play the next one.
5. Press or to select the last song or the
next song to play.
6. Press SCAN key during playing, each song in Small Tool Kit
the same album will play for 10 seconds in
sequence, press SCAN key again to make it There is a small tool kit under the driver's seat,
return to normal playing state. which is used to store some common small tools.

7. During playing, press MENU key to show the

the song sequence in the album, after 2
seconds, it will return to normal playing state.
8. In playing state, press 3||, playing will
pause, press this key again to continue
playing.

Do not take out the memory disc when

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

floodlight high/low beam, front position lights,
Lights of the machine consist of front work lights front turn signal lights.
(left & right each), front combination lights (left &
right each), rear work lights (left & right each),
rear combination lights (left & right each) and 7
dome light.

6
1

2 5

5. Front left turn signal light

6. Front floodlight high/low beam
7. Front position light
8. Front right turn signal light
1. Front work light The rear combination lights consist of rear
2. Front combination light position lights, brake lights, backup signal lights
3. Rear work light
4. Rear combination light and rear turn signal lights .The turn signal lights
are controlled by the combination switch.

10

11
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June 1, 2020 Operation Manual
CLG856H Operator Controls and Instrument Panels

Door Lock

The key for the right inferior & left door of the cab
9 is different.
Insert the key and rotate it clockwise for 180
12 degrees then take it out. Push the lock with your
thumb, then open the door by pulling the door
outward.
11 Before locking the door, first close it. Insert the
key and rotates counterclockwise to 180
degrees, then take it out. After the door is locked,
9. Backup signal light the lock can't be pressed.
10. Rear left turn signal light
11. Service light
12. Rear right turn signal light

13

Door Positioner

13. Dome light 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.
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Latch

The right window of the cab can be a spare exit.

If the left door can not be opened at the
emergent situation, leave the machine from the
right window of the cab.
Open the right window from the driver’s cab. Pull
the latch handle and then push it outward to
open the right window partly.
Latch handle
After the left door is opened to a particular
opening, it can be opened completely and
positioned automatically by an air spring, which
is located on the top of the left door. Pull the
inner handrail backward to close the left door.
If it needs to open the left door partly, push the
left door outward and fix it with the stay rod.
Remove the stay rod to close the left door.

Stay rod of left door

When open the door, the pressurization in

the cab will disappear.

Before operating the machine, always close

the right & left doors and right window first to
ensure safety.
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June 1, 2020 Operation Manual
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Extract the fixed pin to unlock the latch and then Pull the latch unlocking handle to unlock the
open the right window completely. window, and then pull the inner handrail
Fixed pin backward to close the right window.
Latch unlocking handle

Rear View Mirrors

When open the window, the pressurization
in the cab will disappear. Left and right rear view mirrors are separately
located at the top of the cab. Before operating
When open the right window completely, the the machine, adjust the rear view mirrors and
position latch on the right window is locked by make sure the driver has a good rear view when
the buckle behind. Then the right window is sitting on the seat.
locked in this position.
Buckle
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Operator Controls and Instrument Panels CLG856H

Adjustment of Rear View Mirrors Pull the cable downwards to grab the engine
hood lock handle, then pull the lock handle
1. Loosen the connecting bolts between the downwards to the lock the engine hood. The
rear view mirror brackets and the cab, turn engine hood was locked when there is a click.
the brackets to adjust the rear view mirrors to
proper position. Steering Frame Lock
2. Loosen the connecting bolts between rear
view mirrors and the brackets, adjust the rear
view mirrors to desired angles.
3. After completing the above-mentioned No clearance for person in this area when
adjustment, tighten the bolts. machine turns. Injury or death from crushing
could result.
Engine Hood

The switch button of engine hood is located on

the rear lock handle of the machine. Press the To connect the steering frame lock, the
button to open the lock, then hold the handle and machine must be in the straight ahead
open the engine hood by pulling it upward. direction.

The steering frame lock is located at the left or

right side of the machine.

Open the engine hood in steps through the cable

2
on the right of engine hood. Buckle the free end
of the cable on the hook of frame.
1. Pin
2. Steering frame lock
Connect the steering frame lock when the
machine is being lifted and transported. Also
connect the steering frame lock if you are
performing service work near the articulation
joint.
Separate the steering frame lock before
operating the machine. Move the steering frame
lock to the rear frame and install the pin.
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June 1, 2020 Operation Manual
CLG856H Engine Starting

Engine Starting 2. Mount and dismount the machine according

to the safety regulations.

Check Before Starting the Engine

Check the engine coolant level.

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

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

6. Insert the key to the start switch and turn

clockwise to turn on the power. Sound the
O I horn to warn that the machine is going to
start, keep away from it.
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Operation Techniques CLG856H

7. Turn the fan speed switch and wind mode 14. If there are no obstacles around the machine,
switch of the air conditioner system (If slowly turn the steering wheel and observe
equipped) to OFF position. for left and right turning.
8. Slightly depress the accelerator pedal, and
turn the start switch key clockwise to START Operation Techniques
position to start the start motor of the engine.
In normal case, the engine will start within 10
seconds. Release the start switch at once to Operation Information
let it reset.
Follow these basic instructions when you are
operating the machine.
1. To prevent injury, make sure that no one
Start motor operation should not exceed 15
works on the machine or near the machine.
seconds. If the engine doesn't start after 15
Always keep control of the machine.
seconds, release the start switch at once.
Wait 30 seconds before trying to start again, 2. Raise the bucket or the implement high
If the engine can not be started for three enough to go over any obstacle.
times, wait for at least three minutes before
3. Before disengaging the parking brake,
trying again to prevent damage to the start
depress the service brake pedal in order to
motor.
prevent the machine from moving.
9. Warm up the engine at idle speed of 4. Drive the machine forward for best visibility
700~850 rpm after the engine is started. and the best stability.
Check the coolant temperature gauge. Run
the engine with full speed only after the 5. Reduce the engine speed when turning and
coolant temperature of the engine reaches go over a hill.
green zone.
10. The warning indicators on the central
instrument panel will turn off in sequence.
Falling objects can cause personal injury or
Disengage the parking brake handle, the
death. Remove any hanging objects and
parking brake low oil pressure indicator and
watch out for rolling objects.
P light will turn off.
11. Check the readings of all the gauges to make
sure they are in the normal range. Check that
all the lights, indicators, horn, windshield Never allow the bucket in the float position
wiper and brake lights work normally. to avoid bucket damage.
12. During severely cold weather, preheat the
hydraulic oil. Pull the control lever backward
and hold for about 4-5 minutes, depress the
accelerator pedal and let the bucket
positioner stop on the boom to make the
hydraulic oil flow out, which can increase the
hydraulic oil temperature rapidly.
13. Check the service brake and parking brake
systems for normal condition.
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CLG856H Operation Techniques

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

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

1. Shift control lever

1. Turn the pilot control lever to tilt the bucket F: Forward
backward to limit position. Raise the boom to N: Neutral
the transportation position. Keep a clearance R: Reverse
of approximately H=500~600mm between
the lower articulation point of the boom and
the ground.

The machine can start only when the F1, F2

or R1, R2 is selected.
4. Drive the machine to open and flat ground;
turn the steering wheel to check whether the
machine has spot right and left turn ability.

H
5. Check the brake performance of the
machine. Drive the machine at F1 or F2,
release the accelerator pedal, smoothly
2. Depress the service brake pedal and press
depress the service brake pedal, the
the parking brake button to disengage the
machine should obviously reduce speed and
parking brake. Slowly release the service
stop.
brake pedal and observe the machine for
movement.

After depressing the service brake pedal, if

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

Steering Operation of the Machine Brake Operation of the Machine

1. Release the accelerator pedal to slow down When performing brake, first release the
the engine running speed. accelerator pedal, then smoothly depress the
brake pedal to perform the service brake
2. Depress the service brake pedal to slow
operation.
down the driving speed.
The machine will cut off the oil line of the shift
3. Push the combination switch forward when
control valve automatically at the same time
turning left; pull the combination switch
when performing the service brake, therefore, it
backward when turning right. Then the turn
is unnecessary to turn the shift control lever to
signal lights on both the front and rear of the
NEUTRAL position before braking. After
machine and the turn indicators on the
releasing the bake, the machine will return to the
central instrument panel will light to warn the
gear automatically used before braking.
neighboring vehicles and passerby that the
machine is going to turn.

When the machine runs at high speed, do not

rapidly depress the brake pedal unless an
emergency occurs, so as to avoid accidents
and damage to the machine.
When the machine is traveling or working on
a slope, do not cut off the transmission
power output when performing the service
brake to ensure safety.

4. Turn the steering wheel for turning. Turn the

Downhill Operation
steering wheel oppositely for straight driving
after steering operation is finished. Select a proper speed before going down a hill.
5. After the steering is finished, turn the Do not change gears during the downhill
combination switch to NATURAL position. process. Most of time, the speed for downhill
The turn signal lights and the turn indicators operation is the same.
will go out. Maintain a proper speed that is slow enough for
6. Depress the accelerator pedal to get a the conditions. Use the service brake to control
desired running speed of the engine. the travel speed. Using service brake when the
machine runs at a high speed may result an
overheating of the brakes and driving axle oil.
These will bring serious abrasion or damage to
the brakes.
Never turn the machine on a slope. Drive the
machine to flat ground before turning. Drive the machine reversely when going down a
hill with a load. Drive forward when going up the
hill.
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June 1, 2020 Operation Manual
CLG856H Operation Techniques

Operation during Cold Weather Machine Operation

Preparation before Operation

Before operation, first level the work site with this

If the ambient temperature is too low, the machine. Remove bulges, fill in the pits and
engine can't be started easily, and the shovel away the operational barriers on the wet
radiator will be frozen. and slippery ground. Clean up large, sharp rocks
on the work site to avoid damaging the
machine's tires.
1. Use fuel, hydraulic oil and lubrication with low
viscosity. Refer to section “Oil Specifications” If this machine is used to load or unload a truck
for particular oil brands. or hopper, adjust the limit height of the boom lift
kickout according to the height of the truck or the
2. Add anti-freeze to coolant.
hopper to allow the bucket to go in and out of the
truck or hopper safely.
For information about how to use the work
Keep antifreeze away from an open fire. Do implement control lever, refer to section “Wok
not smoke when adding antifreeze. Implement Control Lever”.

3. In severe cold areas, use anti-cold batteries. Shoveling

As the ambient temperature drops, the
electrolyte may be frozen. In order to prevent 1. Common Shoveling
battery capacity loss, cover the battery or
move it to a warm place and install it the next Common shoveling is suitable for loading loose
day, then the engine can be started easily at materials.
the next day.
1. Drive the machine at F2 speed to approach
4. Thoroughly clear sludge, water or frozen materials. Align the bucket middle with the
snow from the machine to avoid them materials, lower the boom to transportation
entering into the seams and damaging position.
sealing performance.
2. At the distance of about 3' (one meter) from
5. Park the machine on dry and hard ground. If the material, lower the boom, let the bucket
impossible, park the machine on wooden contact the ground and keep the bucket
boards. The wooden boards can prevent the bottom parallel with the ground. Operate the
machine from being frozen. machine to change the speed of the machine
6. After the weather turns warm, change fuel, from F2 speed to F1 speed.
hydraulic oil and lubricant with half viscosity.
Refer to section “Oil Specifications” for
particular oil brands.
When the bucket touches the ground, too
much pressure to the ground should be
avoided, so as to avoid the unnecessary
resistance to go forward. Moreover, the front
and rear frames of the machine should be
aligned, and no included angle between
them.
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Operation Techniques CLG856H

3. Depress the accelerator pedal to force the 2. Raise the boom to a certain height to keep
bucket to cut into the material with full power. the machine away from the material when
When the machine can't advance any more, reversing. Then operate the machine
tilt the bucket backward, then release the backward.
work implement control lever back to the
3. After the machine retreats from the material,
NEUTRAL position. The machine will
lower the boom to the transportation position.
advance and continuously cut in the material.
Repeat cut in material and tilting the bucket
until the bucket is completely filled.
Excavating With Bucket

1. Lower the bucket to the ground and position

for a slight digging angle.

2. Combination Shoveling

Combination shoveling is mainly used for hard

and viscous materials. 2. Apply down pressure to the bucket as the
loader starts forward. Return the lift control to
1. The operation of the cutting in the material
HOLD when sufficient penetration is
pile is the same as the common shoveling.
obtained.
2. When the bucket can't advance after cutting
in the material, tilt the bucket upward, then
the bucket cuts in forward for some
distances. Then tilt the bucket backward so
as the bucket can continue to cut in the
material.
3. Repeat cutting in material and tilting the
bucket until the bucket is completely filled.

3. Maintain level cuts while moving forward, by

raising and lowering the bucket.

3. Retreating from the material

1. After the bucket is filled fully, tilt the bucket

backward until the bucket block contacts the
boom.
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CLG856H Operation Techniques

4. When the bucket is loaded, tilt it back against Dumping Operation

the stops. Carry the loaded bucket
approximately 40 cm (15 inches) above the 1. Dumping materials into a truck or hopper
ground when moving to the dump area.
1. Release the accelerator pedal to let the
machine approach the truck or hopper at a
low speed when the machine is at a distance
of 15 meters from the truck or hopper with a
full load.
2. Let the boom raise to its limit position, the
boom will not raise up any more once it
reaches its limitation.
3. When the bucket is on the top of the truck or
hopper, depress the brake pedal to stop the
Transportation of Materials machine. Then tilt the bucket forward and
dump the materials.
The machine can be used for transporting
material under the following conditions: 4. If the body length of the truck is over two
times than the bucket width, dump the
● When the ground is too soft or the ground is materials from the front part to the rear part.
not leveled, a truck can not be used.
● When transporting distance is less than 500
meters, using trucks for transportation is not
economical.
When transporting, make sure that the lower
articulated joint of the boom is at transporting
position (about 500mm above the ground). Tilt
the bucket back to its limit position (the bucket
block contacts the boom) in order to ensure
safety and stability when transporting.

When dumping, it is advisable not to bump

the bucket block with the boom repeatedly
Never raise the bucket to a higher position
so as to avoid damaging the machine.
for transporting, otherwise the machine
could tip over.

Do not lower the boom when the bucket is at

high dumping position with full load,
otherwise the machine may tip over.

5. After dumping, tilt the bucket backward until it

reaches the positioning position.
6. Then push the shift control lever to the
REVERSE position so that the machine can
leave the truck or hopper reversely.
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Operation Techniques CLG856H

7. After the machine leaves the truck or hopper, Scraping Operation

the driver could drive the machine with
lowering the boom for next operation. Lift the boom, tilt the bucket forward until the
blade contacts the ground. The angle between
2. Dumping at low position the blade and ground should be kept at about
60°.
When carrying materials among the work sites,
sometimes you may need to dump at a lower The work implement control lever should be set
position, that is, the machine dumps materials to the float position for hard road surface, and it
near the ground. After dumping, first tilt the should be pushed to the NEUTRAL position for
bucket to the level position, then lift the boom. soft surfaces.
Pull the shift control lever to REVERSE speed
Shoving Operation and depress the accelerator pedal to operate the
machine backward. Scrape the ground evenly by
Place the bucket on the ground, push the shift the bucket blade.
control lever to the F1 or F2 and depress the
accelerator pedal to drive the machine forward.
During the shoving operation, slightly lift the
boom and continue the shoving operation if the
machine meets an obstacle.
To ensure shoving safety, operate the work
implement control lever slowly and smoothly
when lifting or lowering the boom.

Towing Operation

The machine can be towed by a 20T trailer.

Operate as follows:
1. Secure the trailer firmly to the traction pin of
the towed machine.
2. The trailer should be equipped with a brake
system of strong brake ability.
3. Set the bucket to transportation position.
4. Start and stop the towed machine slowly.
Engage brake before going down a hill.

When braking, engage the brake of the

trailer first, then the towed machine.
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June 1, 2020 Operation Manual
CLG856H Operation Techniques

Operation Method 2. Shuttle operation method

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

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

angle between the machine and the truck.
Stop the machine at 12~15m(39'4"-49'3")
away from the truck.
2. After the machine is loaded fully, drive the
machine to 12~15m(39'4"-49'3") from the 2. If the truck is not completely filled with
material, then drive the machine towards the materials, drive the truck forward for one
truck with bucket lifted while it is turning. After position. After the machine performs the
dumping, return the machine to the original second loading, it will return to the original
position for next loading. position. Then the truck returns to the front of
the machine for dumping.
3. Repeat the operation until the truck is filled
with material. The machine then goes on
loading the next truck.
4. This operation requires skillful cooperation
between the machine and the truck drivers.
They communicate with each other by using
the horn, lights, or hand signals.
80
Operation Manual June 1, 2020
Operation Techniques CLG856H

Parking Lowering the Work Implement with

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

Leaving the Machine

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

2. Use the ladder and the handrail when you get
off the machine. Face the machine and use
both hands. Make sure that the steps are
2. Use the service brake to stop the machine. clear of debris before you dismounting.
3. Turn the shift control lever to NEUTRAL 3. Inspect the engine compartment for debris.
position. Clean out any debris and paper in order to
4. Pull up the parking brake button (or parking avoid a fire.
brake handle). 4. Remove all flammable debris in order to
5. Lowering all the implements to the ground reduce a fire hazard. Dispose all debris
and press the bucket downwards slightly. properly.
5. Turn the battery disconnect switch to the “O”
Turning off the Engine position.
6. If the machine is not filled with anti-freeze,
after the machine parks in winter, open all
water drain valves of the engine in time to
Do not turn off the engine when the machine discharge coolant in the cooling system and
is working with a load. Otherwise, the air conditioner system so as to prevent the
engine parts will be worn quickly due to machine from being cracked by frost. If the
overheating. machine has been filled with anti-freeze at
ex-factory, refer to the instructions of the anti-
freeze labels.
1. Let the engine run at idle speed for 5min to
cool down the parts. 7. Fix all covers, lock all equipment and remove
the key.
2. Turn the start switch of the engine to OFF
position and take out the key.
3. Turn all the switches to NEUTRAL or OFF
position.
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June 1, 2020 Operation Manual
CLG856H Transportation Information

Storage 2. Lubricate all moving pins and shafts.

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

1. Clean and dry every part of the machine and

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

To avoid personal injury or death, when

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

Before Reuse

1. Change lubricant of the engine, transmission,

axles lubrication and hydraulic oil, brake oil
and anti-freeze of the engine.
82
Operation Manual June 1, 2020
Transportation Information CLG856H

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

11. Cover the exhaust outlet to prevent the

turbocharger from rotating during
2. When the machine is loading on the trailer or transportation. Damage to the turbocharger
truck, it is forbidden to turn. can result.
3. After the machine being parked, use the
steering frame lock to lock the front frame Driving the Machine
and the rear frame.
1. Before operating the machine, consult your
tire dealer for recommended tire pressure
and speed limitations.
2. Stop for 30 minutes after every 40km or after
every hour when driving the machine for a
long distance in order to cool down the tires.
3. Inflate the tires to the correct pressure. Refer
to the maintenance section for tire inflation
information.
4. Travel at a moderate speed. Observe all
4. Lower the bucket to the floor of the trailer. speed limitations when you drive the
Turn the shift control lever to the NEUTRAL machine.
position.
5. Push the pilot cut-off lever to the OFF
position (If equipped).
6. Engage the parking brake.
7. Stop the engine, turn every switch to
NEUTRAL or OFF position and remove the
key.
8. Lock the door and remove the key.
9. Turn the battery disconnect switch to the
OFF position.
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June 1, 2020 Operation Manual
CLG856H Transportation Information

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

Improper lifting or securing could cause the

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

1. Lift the machine by professional personnel.

2. Calculate the maximum lift weight of the
crane and loading capacity of the lifting 7. Before lifting, secure the front and rear frame
device to ensure the lift safety. with the steering frame lock so that the
machine can not move.
3. Lift the machine by the lifting device with
frame to avoid damaging the machine. The
length and width of the frame are 2.5-4m and
1.8-2.2m. The 6.3t D type or bow shackle will
22
be preferred (reference standard: JB8112- 11
1999).

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

4. The length of the four ropes on the lifting

device must be the same to ensure the four
lifting eyes share the same pressure.
5. Turn the battery disconnect switch to OFF
position.
84
Operation Manual June 1, 2020
Transportation Information CLG856H

Towing Information

Towing the Machine Before releasing the parking brake, chock the
wheel to prevent movement. Remove the
wedge before starting the machine.
2. The towing machine should be equipped with
Personal injury or death could result when protective guard to protect the towing
towing a disabled machine incorrectly. Chock operator once the towing ropes or towing bar
the wheels before disengage the brake to cracks accidentally.
prevent the machine from moving.
3. Do not allow riders on the machine that is
being towed unless the operator can control
Do not tow the machine unless the loader has a the steering wheel or the brake.
severe trouble. The machine can only be towed
for a short distance for repair. Never tow the 4. Before you towing the machine, make sure
machine for a long distance. The towing distance that the towing ropes or the towing bar are
should not exceed 10Km and towing speed strong enough for towing the machine. The
should not exceed 10km/h; otherwise, the gear towing ropes or towing bar must have a
box will be damaged due to insufficient strength that is 1.5 times of the gross weight
lubrication. If the machine needs to be of the machine that is being towed.
transported for a long distance, a truck and trailer 5. Do not use a chain for pulling. A chain link
should be used. may break. This can cause personal injury.
Use a wire rope that has cable loops or end
Do the following steps: rings. Position an observer at a safe location.
The observer should stop the pulling
1. If the machine doesn’t move due to machine procedure if the cable starts to break or the
brakes caused by an engine fault or a brake cable starts to loose. If the towing machine
system fault. Remove the connecting shaft moves without the pulled machine, stop the
between the parking brake flexible shaft and pulling procedure.
the parking brake rod to disengage the
parking brake by force. 6. The minimum angle between the towing
ropes and straight direction should not
exceed 30°.
7. Quick machine movement could cause the
towing ropes or the towing bar overload. This
could cause the towing ropes or the towing
bar to break. A smooth machine movement
helps towing operation easier.
8. Normally, the towing machine should be as
large as the disabled machine. The towing
machine must have enough brake capacity,
weight, and power for the grade and distance
that is involved.
9. During towing, all personnel should keep
away from the both sides of the towing ropes
so as to avoid injury caused by break.
 85
June 1, 2020 Operation Manual
CLG856H Transportation Information

10. It may be necessary to connect a large

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

Towing with a Running Engine

If the engine is running, the machine can be

towed for a short distance under certain
conditions. The power train and the steering
system must be operable. Tow the machine for a
short distance only. For example, pull the
machine out of mud or to the side of the road.
The operator on the towed machine must turn
the machine in the direction of the towing ropes.
Turn the shift control lever to NEUTRAL position,
lift all implements and strictly observe all the
instructions that are outlined in this topic.
86
Maintenance Manual June 1, 2020
Maintenance Guidance CLG856H

Maintenance Manual Maintenance Suggestions

1. Use only recommended fuels and lubricants.

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

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

Learn how to maintain your machine correctly. Clean Engine Oil

Follow the instructions of this manual, if your
machine has troubles, you must maintain or Use clean engine oil and keep the engine oil
contact your dealer before operating. clean. Ensure no foreign matter mixes with the
engine oil.
Daily Checks
Check Discharged Oil or Used Filter Element
1. Check the gauges.
After replacing the oil or filter element, check the
2. Check the coolant, fuel and oil level.
discharged oil or filter element for iron particles
3. Check hoses and tubes for leakage, wear and foreign matter. If any iron particles or foreign
conditions and damage. matter is found, report this immediately and take
preventive measures.
4. Perform a walk-around inspection of the
machine.
Welding Cautions
5. Check for loose or missing parts.
1. Turn off the engine.
Check Service Hour Meter
2. Do not keep using voltage above 200V.
1. The service hour meter determines when 3. Keep the welding area and earth cables
your machine needs to be maintained. The within 1m. If the earth cable is close to
time in the maintenance table is basically gauges or connectors, failure could result.
given for normal operation. If the machine is
4. Protect the seals and bearings located
operated in severe conditions, you must
between the welding area and earth cables.
maintain the machine more frequently.
5. Never use the surrounding area of the work
Maintain Machine on Schedule implement pin or cylinder as an earthing
point.
Follow the maintenance methods listed in this
maintenance manual.
 87
June 1, 2020 Maintenance Manual
CLG856H Maintenance Guidance

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

Dusty Environment

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

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

Install Hydraulic Hoses

1. If components equipped with O-rings or Before starting the engine, make sure
gaskests need to be removed, clean the nobody is on or near the machine. Keep the
mounting surfaces. Do not forget to install machine controlled by the operator.
new O-rings and gaskets.
88
Maintenance Manual June 1, 2020
Run-in CLG856H

Preparation before Maintenance Run-in

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

5. It is better to load with loose material during

AR
W

er not
!

run-in period. Do not operate rushly and

e
at
do

exceed its rating load capacity and travel

op

speed by 70%.
r:
te
ra
pe
O

:
ate
D

6. Check the lubricant periodically. Replace or

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

The following must be done after the first 8

hours of operation during the run-in period.

1. Check the tightness of all the bolts and nuts

especially the bolts of the engine cylinder
cover, exhaust pipe, front and rear axles,
drive shaft, diesel engine, transmission, front
and rear frames joint, and wheel rim nuts etc.
 89
June 1, 2020 Maintenance Manual
CLG856H Maintenance Interval Schedule

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

belt and air conditioner compressor belt.
Schedule
3. Check the oil level of the transmission, drive
axle and diesel engine.
4. Check the hydraulic system and brake
system for oil leakage.
5. Check the connections of all control levers, Read and understand all the safety
throttle linkage (if equipped) and flexible instructions, warnings and indications before
shaft. any operations or maintenance.
6. Check temperatures and connections of the
electrical system, power supply of the The maintenance intervals stated in this manual
alternator, lights and the turn signal lights. are determined according to the service hour
meter or calendar intervals shown (daily, weekly,
monthly, etc). Liugong recommends that
maintenance should be performed according to
Check oil level according to the relevant whichever of the above-mentioned intervals
operation regulations. occurs first.
Under extremely severe, dusty or wet operating
Work should be done after the finish of run-in conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart
1. Check the tightness of all the bolts and nuts may be necessary.
especially the bolts of the cylinder head, Perform service on items at multiples of the
exhaust pipe, front and rear axles, drive original requirement. For example, at every 500
shaft, diesel engine, transmission, front and service hours or 3 months, also service those
rear frames joint, and wheel rim nuts etc.. items listed under every 250 service hours or
2. Check the tightness of the fan belt, engine monthly, every 50 service hours or weekly and
belt and air conditioner compressor belt. every 10 service hours or daily.
3. Check the hydraulic system and brake Every 10 Service Hours or Every Day
system for oil leakage.
4. Replace the transmission oil and axle 1. Check engine oil level.
lubricant. 2. Check coolant level.
5. Replace the secondary filter and clean the 3. Check hydraulic oil level.
primary filter of the transmission.
4. Check fuel level.
6. Clean the return oil filter element of the
hydraulic oil tank. 5. Drain any water and impurity from the fuel
pre-filter and filter of the engine.
6. Daily inspection.
7. Check the engine fan and belt.
Replace transmission oil, axle lubricant and
secondary filter of the transmission 8. Check working condition of lights and
according to operation instructions. gauges.
9. Check tire inflation pressure and look for tire
damage.
90
Maintenance Manual June 1, 2020
Maintenance Interval Schedule CLG856H

10. Check the working condition of the backup 2. Tighten all connecting bolts on drive shafts at
alarm. the first 100 service hours, tighten them
every 2000 service hours later on.
11. Push the manual water drain valve at the
bottom of the air reservoir upward to drain 3. Replace transmission oil, the filter element
water of the air reservoir. and seal ring of transmission oil filter, and
clean the primary filter in the transmission oil
Every 50 Service Hours or Every Week sump at the first 100 service hours, and
doing once every 1000 service hours later
In addition to all previous service checks: on. If the operating hours are less than 1000
hours a year, replace the transmission oil at
1. Check the transmission oil level.
least once every year.
2. At the first 50 service hours, check the
4. For the machine with LiuGong wet axle,
clearance between the parking brake shoe
replace gear oil of the axles after the first 100
and brake drum, adjust it if necessary; check
service hours, replace once every 1000
the wear condition of the friction disc, replace
service hours later on. If the operating hours
it if it has been worn away, and exhaust air in
are less than 1000 hours a year, replace the
the clamp. Check once every 250 service
gear oil of the axles at least once every year.
hours later on.
5. Clean the engine cylinder head.
3. For the machine equipped with air
conditioner, clean the dust and sundries from 6. Clean the radiator groups.
the cab recirculating air strainer and fresh air
7. Clean the filter strainer of the fuel tank.
strainer. Wash them if it is necessary. Check
the compressor belt for tightness and check 8. Check nitrogen precharge pressure of the
the condenser for grease, dirt and sundries. accumulators at the first 100 service hours
(suitable for the machine with accumulators).
4. Check the lubrication condition of the
lubricating points and lubricate every
Every 250 Service Hours or Every Month
lubricating point according to lubrication
diagram on the machine. If the machine is
In addition to all previous service checks:
equipped with central lubrication system, for
those manual lubricating points, pump 1. Check battery voltage.
grease by hand according to the lubrication
2. Check the tightening torque of the rim set
diagram on the machine.
bolts.
5. Check the oil level of the booster cup, the oil
3. Check the tightening torque of the
level should align with the inner screen
transmission and engine mounting bolts.
(suitable for the machine with air reservoir).
4. Check the work implement, and each stress
6. Check nitrogen precharge pressure of the
weld and mounting bolt of the front & rear
accumulators at the first 50 service hours
frames for cracks and looseness.
(suitable for the machine with accumulators).
5. Check the engine air intake system, air filter
Every 100 Service Hours or Two Weeks service indicator or air filter alert indicator (if
equipped). If the yellow piston of the service
In addition to all previous service checks: indicator rises to red area or the alert
indicator blinks, clean or replace the air filter
1. Lubricate every drive shaft according to
element.
lubrication diagram on the machine.
6. Replace the fuel pre-filter (the fuel /water
separator) and fuel filter on the engine.
 91
June 1, 2020 Maintenance Manual
CLG856H Maintenance Interval Schedule

7. Replace the engine oil and engine oil filter. 7. Replace the pilot oil filter element of the
Use higher grade engine oil can prolong the hydraulic system at the first 500 service
service hour of engine oil, contact LiuGong or hours. Replace the pilot oil filter element of
engine manufacturer for details. the hydraulic system once every 1500
service hours later on (suitable for the
8. Replace the coolant filter (it does not suitable
machine with pilot oil filter element).
for the machine equipped with GCIC engine).
8. For the machine with LiuGong axle, ZF axle
9. Check tension and wear conditions of the
or ZFAP axle, replace gear oil of the axles
engine belt and air conditioner compressor
after the first 500 service hours, replace once
belts.
every 1000 service hours later on. If the
10. Check the service brake ability and parking operating hours are less than 1000 hours a
brake ability. year, replace the gear oil of the axles at least
once every year.
11. Check the clearance between the parking
brake shoe and brake drum, adjust it if 9. Exhaust air in the clamp if the machine is
necessary; check the wear condition of the equipped with clamp.
friction disc, replace it if it has been worn
away, and exhaust air in the clamp. Every 1000 Service Hours or Six Months
12. Check nitrogen precharge pressure of the
In addition to all previous service checks:
accumulators at the first 250 service hours
(suitable for the machine with accumulators). 1. Adjust the engine valve lash.
13. Check the oil level of the front and rear axles. 2. Check the engine tensioner bearing and fan
shaft housing.
Every 500 Service Hours or Three Months
3. Replace transmission oil, the filter element
and seal ring of transmission oil filter, and
In addition to all previous service checks:
clean the primary filter in the transmission oil
1. Check the density of anti-freeze and coolant sump.
additives.
4. Change gear oil of the drive axles.
2. Tighten connecting bolts of the front & rear
5. Clean the fuel tank.
axles and front & rear frames.
6. Tighten all mounting bolts of the battery and
3. Check bolts on the articulation joint of the
clean the battery surface.
frame for loose condition.
7. Check nitrogen precharge pressure of the
4. Check nitrogen precharge pressure of the
accumulators at the first 1000 service hours
accumulators at the first 500 service hours
(suitable for the machine with accumulators).
(suitable for the machine with accumulators).
8. For the machine equipped with air
5. Replce the breather filter element of
conditioner, replace the fresh air strainer of
hydraulic oil tank.
the cab.
6. Replace the return oil filter element of the
hydraulic system at the first 500 service Every 1500 Service Hours or Nine Months
hours. Replace the return oil filter element of
the hydraulic system once every 1500 In addition to all previous service checks:
service hours later on.
1. Replace the return oil filter element of the
hydraulic system.
92
Maintenance Manual June 1, 2020
Maintenance Interval Schedule CLG856H

2. Replace the pilot oil filter element of the

hydraulic system (suitable for the machine
with pilot oil filter element).

Every 2000 Service Hours or Every Year

In addition to all previous service checks:

1. Replace coolant, coolant filter (it does not
suitable for the machine equipped with GCIC
engine) and clean the cooling system. If the
operating hours are less than specified,
replace the coolant at least every two years.
2. Replace hydraulic oil, clean the hydraulic oil
tank and check the oil suction hose.
3. Check the service brake system and parking
brake system. Remove and check the friction
disc for wear condition and replace if
necessary.
4. Check airtight condition of the control valve
and work cylinder by measuring natural
sediment of the cylinder.
5. For the machine equipped with air
conditioner, check the refrigerant pipe and
water hose of the air conditioner for cracks,
wear or foaming by oil. Check the connectors
and clamps for loose condition.
6. For the machine equipped with air
conditioner, replace the recirculating air
strainer of the cab.
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.
10. Check the tightening torque of the
transmission mounting bolts.
11. Check nitrogen precharge pressure of the
accumulators at the first 2000 service hours,
check the pressure every 2000 hours later on
(suitable for the machine with accumulators).
 93
June 1, 2020 Maintenance Manual
CLG856H General Torque Specifications

General Torque Specifications

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

Standard Torque lb.ft (N·m)

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

British System

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

1/4 9±3 (12±4)
5/16 18±5 (25±7)
3/8 33±5 (45±7)
7/16 52±11 (70±15)
1/2 74±11 (100±15)
9/16 110±15 (150±20)
5/8 148±18 (200±25)
3/4 266±37 (360±50)
7/8 420±59 (570±80)
1 645±74 (875±100)
94
Maintenance Manual June 1, 2020
Tire Inflation Information CLG856H

Tire Inflation Information Ply rating Front wheel Rear wheel

Tire size or strength inflation inflation
index pressure (kPa) pressure (kPa)
Liugong recommends the use of dry nitrogen for 23.5R25 PR12 225~245 205~225
tire inflation and tire pressure adjustments. It 23.5-25 PR16 300~320 280~300
includes all machines with rubber tires. Nitrogen 23.5-25 PR20 375~395 355~375
is an inert gas that will not aid combustion inside
23.5-25 PR24 475~495 455~475
the tire.
23.5-25 PR28 550~575 530~550
The use of nitrogen for tire inflation can not only 23.5R25 ★ 475~495 455~475
reduce the risk of explosion, but also help to 23.5R25 ★★ 600~620 580~600
prevent oxidation, aging of the rubber, and 26.5-25 PR20 350~375 330~350
corrosion of the wheel rim parts. 26.5-25 PR24 400~420 380~400
26.5-25 PR28 475~495 455~475
26.5-25 PR32 550~570 530~550
26.5R25 ★ 475~495 455~475
Training for using the equipment is 26.5R25 ★★ 600~620 580~600
necessary to avoid over inflation. A tire 29.5-25 PR22 325~345 305~325
blowout or a rim failure can cause personal 29.5-25 PR28 425~445 405~425
injury. Do not set the tire inflation equipment 29.5-25 PR34 525~545 505~525
regulator higher than 140 kPa (20 psi) over 29.5R25 ★ 475~495 455~475
the recommended tire pressure. 29.5R25 ★★ 600~620 580~600
35/65-33 PR24 350~370 330~350
Check and adjust the tire inflation pressure after 35/65-33 PR30 425~445 405~425
the tire cools down completely. Ask all other 35/65-33 PR36 525~545 505~525
persons to leave the danger area (around the
35/65R33 ★ 550~570 530~550
rim).
35/65R33 ★★ 650~670 630~650
The inflation pressure for nitrogen and air are the 750/65R25 ★★ 625~645 605~625
same when charging the tires. Consult your tire 850/65R25 ★★ 625~645 605~625
dealer for operating pressures. “ ★ ”: the star represents the bearing capacity of tires, for
radial tires of the same size, the more the stars, the
See the following table for the tire inflation greater the bearing capacity.
pressure under normal temperatures.
The tire pressure will significantly change when
Ply rating Front wheel Rear wheel you drive the machine into freezing temperature
Tire size or strength inflation inflation from a normal environment with a temperature of
index pressure (kPa) pressure (kPa) 18°C to 21°C (65 °F to 70 °F). If you inflate the
17.5-25 PR8 225~275 205~225 tire to the correct pressure under normal
17.5-25 PR12 350~370 330~350 temperature, the tire will be under inflated in
17.5-25 PR16 475~495 455~475 freezing temperature. Low pressure will shorten
17.5-25 PR20 575~595 555~575 the service life of the tires. Consult your Liugong
17.5R25 ★ 475~495 455~475 dealer when you are not sure about the tire
17.5R25 ★★ 600~620 580~600 inflation pressure.
20.5-25 PR12 250~270 230~250
20.5-25 PR16 350~370 330~350
20.5-25 PR20 470~490 450~470
20.5-25 PR24 525~545 505~525 If the machine travels for a long distance at
20.5-25 PR28 625~645 605~625 high speed, stop the machine for 30 minutes
20.5R25 ★ 475~495 455~475 each time when it has travelled for 45km so
20.5R25 ★★ 600~620 580~600 as to let the tires cool down.
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June 1, 2020 Maintenance Manual
CLG856H Lubrication Specifications

Lubrication Specifications

Oil Change Interval and Refill Capacities

Care must be taken in order to ensure that fluids are contained during performance of
inspection, maintenance, testing, adjusting and repair of the equipment. Collect the fluid with
suitable containers before opening any compartment or disassembling any component. Obey
all local regulation for the disposal of liquids.

Interval (service
Item Approximative quantity(L)
hours)
Torque converter oil, transmission oil 1000 45
Hydraulic oil 2000 236
Front axle oil 1000 33
Rear axle oil 1000 33
Engine oil 250 25.6 (the highest oil level)
Cooling system 2000 44
Brake fluid 2X3.5
Fuel 300

Oil Specifications

For Plain & Plateau Area

Type of oil Name of oil Position of use

≥ -10°C ★ SAE 15W/40CH-4
Engine oil
≤-10°C SAE 5W/40CH-4
For diesel engine
≥4°C No.0 light diesel oil
Fuel
≤4°C -No. 35 light diesel oil
-15~40°C ★ HM-46 anti-wear hydraulic oil For implement hydraulic system &
Hydraulic oil
-25~40°C HV-32 low temperature anti-wear hydraulic oil steering hydraulic system.

Manual For roller bearings, bushings, pins,

lubrication
★ 2# MOS2 lithium based grease
frame pins, swing frame of rear axle,
Grease
Centralized drive shaft spline, universal joint and
lubrication ★ 2# compound lithium based grease water pump shaft etc.

Transmission oil ★ 8# hydraulic transmission oil For torque converter and transmission
Gear oil ★ SAE85W-90 (API GL-5) heavy load gear oil For bevel gear and final drive
Brake oil ★ DOT4 For brake system assistor

Note: " ★ " used by the manufacturer after the machine is newly produced.
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Maintenance Manual June 1, 2020
Important Maintenance Procedures CLG856H

Do not mix oils of different brands even if they have the same specifications. Clean the system
before refilling with different oil.
If the machine is used at low temperature in severe cold areas for a long time, HV-46 low
temperature anti-wear hydraulic oil should be used, and ATF220 or DEXRON-III or Donax TC
transmission oil should be used.
Replace the lubricant periodically even though the lubricant is very clean because the lubricant
might break down after long use.
Choose the fuel according to the lowest air temperature in the local area where the machine is
used.

Important Maintenance Check the hydraulic oil tank, all of the tubes and
hoses, plugs, seals, connectors and grease
Procedures fittings for leakage. Repair the leakage and
replace the hose if necessary.
Daily Inspection Check all of the implements and linkage for
cracks and damage.
Ensure that all doors, covers and shields are
securely attached. Check them for damage.
Check the ladder, walkway and handrail. Clear
Watch carefully for leakage. If you find
away all the trash and repair or replace any
leakage, service it. If you suspect leakage or
damaged part.
observe leakage, check the fluid level more
frequently. 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 engine compartment and clean the
accumulated sundries from it and the radiator. Check the ROPS for visible damage. Consult
your Liugong dealer for repair information if there
Check the engine for damaged parts. is damage.
Check the axles, differential, wheel rim brakes Check all the lighting equipment and replace
and transmission for leakage. Repair the leakage cracked bulbs and glass if necessary.
point.
Check the cab and keep the cab tidy.
Check the instrument panels and indicators for
damage. Replace damaged parts if necessary.
It is a normal phenomenon if there is a little Check the seat belt, buckle and tighten the bolts.
oil stain around the breather of the Replace the worn or damaged parts if necessary.
transmission during machine operation.
Adjust the rearview mirrors and check the
window to ensure good vision for the driver.
Clean the windows if necessary.
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June 1, 2020 Maintenance Manual
CLG856H Important Maintenance Procedures

Engine System

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

Anti-freeze has been added into the

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

If the temperature is forecasted to drop below

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

When adding anti-freeze, use the anti-freeze

2. Check the coolant sight glass on the of the same brand.
recovery tank. Add coolant if the coolant level
is lower than the centerline of the sight glass.
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Important Maintenance Procedures CLG856H

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

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

Permitted max. content

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

If the temperature is forecasted to drop below 0

°C (32° F), add anti-freeze suited to local climatic
conditions into coolant. If only anti-freeze
concentrate is available, it is needed to mix it
with soft water in a certain proportion. Refer to
the proportioning instruction for the mixing
proportion of anti-freeze concentrate.
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Since the heat absorption capacity of anti-freeze 5. Turn the manual valve on the water inlet hose
to the engine isn’t as good as water, add anti- of the engine to ON position. (The valve is at
freeze into the engine before thoroughly mixed ON as shown).
with water will cause overheat of the engine.
Before adding anti-freeze, use refractometer to
measure the freezing point of the well mixed anti-
freeze accurately to ensure that the anti-freeze
adapt to the local lowest temperature. The mixed
anti-freeze by experience is just a general range,
the anti-freeze measured by refractometer is
accurate, which can effectively avoid frost
cracking and damage to the radiator and engine.

Add coolant as follow:

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

O I

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

Close the radiator filler cap before stopping

the engine, or coolant will spray out from the
filler.
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Maintenance Manual June 1, 2020
Important Maintenance Procedures CLG856H

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

Pollutants Permitted limit value

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

Care must be taken in order to ensure that Note ★ : The replacement limit of the min. pH value may
fluids are contained during performance of change with the product changes. Consult the
product manufacturer for the pH value limit. The
inspection, maintenance, testing, adjusting pH value less than 6.5 is unacceptable generally.
and repair of the equipment. Prepare to
collect the fluid with suitable containers Steps for cleaning the cooling system
before disassembling any hydraulic oil lines.
Obey all local regulation for the disposal of 1. Turn on the disconnect switch.
liquids.
If the cooling system failed to be cleaned
thoroughly, the new coolant may be polluted
O I
during adding, and result in the cooling
system and engine failure.
Do not mixed use multiple brands of coolant,
otherwise the consequent cooling system
and engine failures are not covered by
2. Insert the start switch key and turn clockwise
warranty.
to the ON position to turn on the power of the
machine.
3. Turn on the warm air switch of the air
conditioner.
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CLG856H Important Maintenance Procedures

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

5. Start and run the engine at idle speed for

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

When adding cleanser into the cooling

system, exhaust air from cooling system
lines of the engine. During cleaning of the
cooling system, never cover the water
radiator filler cap of the recovery tank while
running the engine.
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Important Maintenance Procedures CLG856H

11. Keep the water radiator filler cap open, start Main Filter Element of the Air Filter
the engine, when the coolant temperature --Clean/ Replace
reaches over 80°C, run the engine for 5~10
minutes again.

If the engine air filter alert indicator on the

If the coolant temperature can not reach instrument panel is on, then maintain the
80°C, use a hardboard to cover the water engine air filter.
radiator filler cap of the recovery tank.
1. Stop the engine and open the engine hood.
12. Stop the engine, drain out cleanser.
2. Remove outer cover of the air filter.
13. Add clean water into cooling system of the
engine until it reaches normal level and
keeps stasble within 10 minutes. keep the
water radiator filler cap open, start the
engine, when the coolant temperature
reaches over 80°C, run the engine for 5~10
minutes again.
14. Stop the engine, drain out water in the
cooling system. If the drained water is still
dirty, clean the system again until the drained
water gets clean.
15. Replace with a new coolant filter (it does not 3. Take out the main filter element along with
suitable for the machine equipped with GCIC the housing direction.
engine), close all drain plugs, then add new
coolant according to the operation rules
previously described in section “Coolant--
Add”.

The coolant of the engine is poisonous and

impotable. Dispose of it according to the
local laws and regulations.

4. Check the main filter element.

a) Replace the main filter element if any
damage is found to pleats and gaskets.
b) Clean the main filter element if it is not
damaged.
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June 1, 2020 Maintenance Manual
CLG856H Important Maintenance Procedures

5. Clean the inner wall of the air filter housing. 8. Install a clean main filter element into the air
filter and ensure an even contact with the
housing.
9. Clean and install the cap of the air filter, make
sure that the inner cap gasket in the air filter
contacts evenly with the air filter housing.

6. Clean the main filter element with The main element should be replaced after
compressed air (below 300kPa) from inside being cleaned for 4-5 times. It is forbidden to
to outside. remove the safety element when servicing
the main element.

10. Close the engine hood.

It is not allowed to clean the main element
from outside to inside with compressed air. Air Filter Safety Element--Replace
Do not use oil or water to clean the main
element.
Do not hit the main element when cleaning it.
Otherwise the engine could be damaged. Replace the main element and safety element
at the same time. Always replace the safety
filter element with a new filter element. Never
use again after cleaning.

1. Stop the engine and open the engine hood.

2. Remove the outer cap of the air filter.

7. After cleaning the main filter element, check

with a bulb, if small holes and particles as
well as damage of the washer and seal are
found, replace with a new main filter element.
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Maintenance Manual June 1, 2020
Important Maintenance Procedures CLG856H

3. Remove the main filter element along with Fuel--Add

the housing direction.

No smoking and keep away from the flames

or spark area when adding fuel.

The fuel tank of the machine is located on the

rear lower side of the engine.

4. Remove the safety filter element.

5. Cover the air inlet. Clean the inside wall of
the air filter.

1. Stop the engine.

2. Open the engine hood to access the fuel filler
of the fuel tank.

6. Check the gasket between the air inlet tube

and the air filter housing. Replace with a new
one if it is damaged.
7. Open the air inlet. Install a new safety filter
element, make sure the seal ring on the top
of the safety filter element contacts evenly.
8. Install a new main filter element and install
the outer cap of the air filter. Tighten the clip
to secure the cap of the air filter housing.
9. Close the engine hood.

Fuel Level--Check

The fuel level gauge is on the cab instrument

panel. It has two zones. “1” indicates the high
fuel level. “0” indicates the low fuel level. Add fuel
in time when the fuel level is lower than “0.2”.
If the fuel level is lower than 0.2, ensure enough
time for the operator to add fuel.
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June 1, 2020 Maintenance Manual
CLG856H Important Maintenance Procedures

3. Pull up the lock plate of the fuel filler cap, turn Fuel Tank--Clean
the cap counterclockwise to the next position
and move it outwards, and then remove the
cap.

Care must be taken to ensure that fluids are

contained during performance of
inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
collect the fluid with suitable containers
before disassembling any component
containing fluids. Dispose of all fluids
according to local regulations.
No smoking and keep away from the flames
or spark area when cleaning the fuel tank.
4. Add fuel.
1. Stop the engine.
2. Remove the flange cover in front of the fuel
tank. Wash the inner surface of the tank with
clean fuel.

1
Don't take out the strainer of the fuel filler
when adding fuel.
2

1. Flange cover
2. Drain plug
3. Remove the drain plug to drain out the
residual fuel.
4. Repeat washing until the drained fuel is
clean.
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Maintenance Manual June 1, 2020
Important Maintenance Procedures CLG856H

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

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

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

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

1. First clean the fuel pre-filter surroundings and

the support.
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June 1, 2020 Maintenance Manual
CLG856H Important Maintenance Procedures

2. Remove the fuel pre-filter from the support Fuel Filter--Replace

with a wrench.
The fuel filter is located on the right side of the
engine.

3. Remove the gasket on the thread connector

of the support. Clean the seal surface of the
support with a non-fibrous cloth.
1. First clean the fuel filter surroundings and the
support.
2. Remove the fuel filter from the support with a
wrench.

1. Gasket
4. Check the gasket, replace if damaged.
5. Install a new fuel pre-filter to the support.
3. Clean the fuel filter surroundings and the
support. Make sure that all old gaskets are
removed.
Do not fill with fuel before the fuel pre-filter is
installed. Fuel contamination will quicken
damage of the fuel system parts.
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Maintenance Manual June 1, 2020
Important Maintenance Procedures CLG856H

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

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

Too much or too little engine oil can result in

damage to the engine.

1. Drive the machine to flat ground, stop the

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

1. Engine oil dipstick

2. Engine oil filler
4. Take out the dipstick. Wipe it with a clean
cloth and completely reinsert the dipstick into
the end of the oil level of the engine. Take the
dipstick out again and check the oil level. The
Do not fill with fuel before the fuel filter is oil level on the dipstick should be between
installed. Fuel contamination will quicken the low (L) and high (H) graduation marks.
damage of the fuel system parts.
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June 1, 2020 Maintenance Manual
CLG856H Important Maintenance Procedures

5. If the oil level is below L, add oil. If the oil 2. Stop the engine and engage the parking
level is above the H, screw out the oil drain brake.
plug at the bottom of the engine oil pan to
3. Loosen the engine oil drain plug at the
release some oil.
bottom of the oil pan to drain the oil into a
Oil level range suitable container.

6. Reinsert the the oil dipstick and close the 4. Tighten the oil drain plug.
engine hood.

Engine Oil--Replace

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any component containing 5. Add clean engine oil to the oil filler of the
fluids or dismounting any hydraulic lines. engine until the engine oil is at H on the oil
Dispose of all fluids according to local dipstick. Run the engine at idle speed to
regulations. check the engine oil filter and oil drain plug
Do not mixed use multiple brands of engine for leakage.
oil. Drain out all the old engine oil before
adding clean engine oil everytime.

High-temperature engine oil can cause

personal injury.

1. Park the machine on flat ground, start the

engine and run until the water temperature
reaches 60°C.
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Maintenance Manual June 1, 2020
Important Maintenance Procedures CLG856H

6. Stop the engine and wait for about 10 4. Clean the surface of the gasket of the
minutes, let the engine oil fully return to the support with a clean cloth. If old O-ring
oil pan, check the engine oil level again, if adheres to the support, remove it.
insufficient, add engine oil to the H on the
dipstick.

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. If no reading is found, shut
down the engine immediately to protect the
engine. Check to see if the engine oil level is
correct.

Engine Oil Filter--Replace

The engine oil filter is located on the left side of

the engine.
Fill the filter with clean engine oil before the
engine oil filter is installed. If an empty
engine oil filter is installed, the engine could
be damaged due to a lack of lubricant.

6. Secure the engine oil filter on the support and

tighten the gasket of the engine oil filter until
it contacts with the support. Tighten engine
oil filter according to the specified
requirements with the spanner.
7. Close the engine hood.

1. Open the engine hood.

2. Clean the area around the support of the
engine oil filter.
3. Remove the engine oil filter with a belt
spanner and check it.
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Radiator Group--Clean Engine Air Intake System--Check

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

Engine Tensioner Bearing and Fan Hub

--Check

Check the tensioner to ensure it can turn freely.

Check the fan hub, it should rotate without any
wobble or excessive clearance.
2. Remove the dust and debris on the radiator
group by compressed air. Engine Belt--Check

Check the belt of the engine by sight for cracked

surfaces.
If the belt cracks lengthways or if flaking material
falls off, replace it with a new belt. For more
information about the replacing procedure, refer
to the Operation and Maintenance Manual of the
Engine.

Fan Belt Tension--Check/Adjust

For more information on fan belt adjustment

procedures, refer to the Operator and
Maintenance Manual of the Engine.
Reduce the compressed air pressure when
cleaning. Keep any bystander away and use
protective devices to avoid being hurt.
Loose fan belt could cause improper battery
Engine Valve Lash--Adjust charging, engine heating and rapid
abnormal belt wear problems. But an over
tightened fan belt will cause damage to both
bearings and the belt .

Adjustment of the engine valve lash must be

performed by trained personnel with special
tools.

For more information about the adjusting

procedure of the engine valve lash, refer to the
Operation and Maintenance Manual of the
Engine.
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Power Train System 3. Start and run the engine at idle speed for 3~5
minutes. Check the transmission oil sight
glass. The oil level should be between HOT
Transmission Oil Level--Check and COLD.

HOT
Stop the machine on flat ground when
checking the oil level. Turn the shift control
lever to NEUTRAL position, engage the COLD
parking brake and install the steering frame
lock to avoid movement of the machine.
4. If the oil level is above the HOT zone, loosen
Check the transmission oil level every 50 service the drain plug at the bottom of the
hours or once a week to ensure enough oil. transmission to release excessive oil. If the
oil level is below COLD zone, add some
The transmission oil filler is located on right side transmission oil.
of the articulation joint. The transmission oil sight
glass is near the oil filling pipe.

Too much or too little transmission oil can

result in damage to the transmission. Keep
11 the transmission oil in proper level.
Pay close attention to cleanliness when
22 checking the transmission oil level and
replacing transmission oil and filter. Do not
let impurity enter the transmission system
to avoid damage to the transmission.
1. Transmission oil filler
2. Sight glass

Check transmission oil level:

Before starting the engine, check the cold oil

level to ensure the transmission oil is at proper
level after the machine is started. It is quite
important for machines stored for a long time.
1. Park the machine on flat ground.
2. Turn the shift control lever to NEUTRAL
position. Engage the parking brake and
install the steering frame lock to avoid
movement of the machine.
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Transmission Oil--Replace 4. Turn on the water drain valve under the

torque converter oil radiator to drain out the
oil in the torque converter oil radiator and
collect the oil with a container.

Care must be taken to ensure that fluids are

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

Replace the transmission oil at the first 100

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

22
Before replacing transmission oil, cover the
parking brake by cloth to prevent the friction
disc from touching with oil to ensure the
parking brake performance.

Transmission Oil Filter--Replace

1
1

3
Care must be taken to ensure that fluids are
4
contained during performance of
inspection, maintenance, testing, adjusting
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any hydraulic lines or
component containing fluids. And dispose
all fluids according to local regulations.
5
Clean and reinstall primary filter as follows:
1. Oil drain plug
2. Oil suction hose
1. Remove the oil drain plug on the rear right 3. Bolt
side of the transmission, drain out oil in 4. End cap
transmission oil tank. 5. Transmission primary filter

2. Remove the oil suction hose.

3. Loosen bolt and remove end cap. Remove
the transmission primary filter. Collect oil with a suitable container when
draining out oil in the oil tank. Obey all local
4. Clean the transmission primary filter with
regulations for the disposal of transmission
clean compressed air or fuel and dry it.
oil.

Replace secondary filter as follows:

1. Loosen and remove housing with a belt

wrench.
2. Loosen the filter element.
3. Replace new filter element and O-ring.
4. Reinstall housing and tighten it.
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5. Refill oil for the machine according to Oil Axle Oil Level--Check (LiuGong Axle)
Change Interval and Refill Capacities.
Check the axle oil level at every 250 hours or
once a month in order to ensure enough oil.

11
Be careful of the splashing hot oil when
adding, draining, or loosening the plug.

As the drain plug on the wheel end of the front

and rear axles could not be at the level position
at the same time, so check the oil level of the
front and rear axles separately.
1. Park the machine on level ground, slowly
drive the machine to keep the oil level
auxiliary line on one wheel end of one axle at
2
level position, and the oil drain plug should
be above the oil level auxiliary line at the
same time.

4
11
22

1. Secondary filter
2. O-ring
3. Filter element
4. Housing 1. Oil drain plug
2. Oil level auxiliary line
2. Turn the shift control lever to NEUTRAL
position, engage the parking brake to prevent
Collect the fluid with a suitable container movement of the machine and stop the
when disassembling any component. Obey engine.
all local regulations for the disposal of 3. Clean the surface around the oil drain plug
liquids. before checking the axle oil level.
4. Loosen the oil drain plug on this wheel end of
the axle to check the oil level, the axle oil
should flow over the axle. If it isn’t, remove
the oil drain plug, and add clean axle oil.
Observe for about 5 minutes after refilling
until the oil keeps stable.
5. Tighten the oil drain plug.
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6. Check the oil level of another axle according 2. Turn the shift control lever to NEUTRAL
to the previous operation steps. position, engage the parking brake to prevent
movement of the machine and stop the
Axle Oil--Replace (LiuGong Axle) engine.
3. Loosen the oil drain plug on the wheel end of
Replace the axle oil after the first 500 service the front axle and the oil drain plug in the
hours. Replace the axle oil every 1000 service middle of the axle to drain oil, and collect with
hours at least once a year later on. a container.

Care must be taken to ensure that fluids are

contained during the performance of 11
inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
collect the fluid with suitable containers 22
before disassembling any hydraulic line or
component containing fluids. Dispose of all
1. Oil filler
fluids according to local regulations. Drain oil 2. Oil drain outlet
after the machine runs for a period of time to
let the impurities deposited in the oil
suspend.

Because the oil drain plugs on both wheel ends

of the front and rear axles could not be at the Because the axle oil temperature is still hot
lowest position at the same time, therefore, when draining, wear protective clothing and
replace oil of the front and rear axles separately. be careful to prevent injury.

1. Drive the machine for a while to let the 4. Tighten the oil drain plug on the wheel end of
settling impurities in the axle suspend fully. front axle and the oil drain plug in the middle
Park the machine on level ground. Slowly of the axle.
operate the machine to locate the oil drain 5. Start the engine, disengage the parking
plug on one wheel end of the front axle at the brake. Turn the shift control lever to the first
lowest position. Because the oil drain plugs gear, and slowly operate the machine to
on both wheel ends could not be at the locate the oil drain plug on the other wheel
lowest position at the same time, so drain oil end of the front axle at the lowest position.
of the axle separately. Then turn the shift control lever to NEUTRAL
Oil drain plug position, engage the parking brake and stop
the engine.
6. Loosen the oil drain plug on the wheel end of
the front axle and the oil drain plug in the
middle of the axle to drain oil, and collect with
a container.
7. Tighten the oil drain plug on the wheel end of
front axle and the oil drain plug in the middle
of the axle.
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8. Add clean axle oil from the oil filler in the Hydraulic System
middle of the axle until the oil flows over the
oil filler. Observe for about 5 minutes after
adding, the oil level should keep stable, and
then tighten the oil drain plug of the oil filler.
9. Start the engine, disengage the parking Care must be taken to ensure that fluids are
brake. Turn the shift control lever to the first contained during performance of inspection,
gear, and slowly drive the machine to keep maintenance, testing, adjusting and repair of
the oil level auxiliary line on one wheel end of the product. Be prepared to collect the fluid
the front axle at level position, and the oil with suitable containers before
drain plug should be above the oil level disassembling any hydraulic line or
auxiliary line at the same time. Then turn the component containing fluids. Dispose of all
shift control lever to NEUTRAL position, fluids according to local regulations.
engage the parking brake and stop the
engine.
Hydraulic Oil Level--Check

1. Ensure that the hydraulic oil tank, hydraulic

lines, radiator and other hydraulic parts are
full of hydraulic oil before checking the
hydraulic oil level.
2. Park the machine on level ground. The front
and rear frames must be aligned in a straight
line.
3. Tilt the bucket backward to limit position,
raise the boom to the highest position by full
10. Add clean axle oil to the oil drain outlet on engine speed.
this wheel end of the axle until the oil flows 4. Let the engine run at idle speed, push the
over the oil filler. Observe for about 5 minutes pilot control lever to lower the boom to the
after refilling, the oil level should keep stable. lowest position at constant speed, and lower
11. Tighten the oil drain plug on this wheel end of the bucket onto ground. Stop the engine and
the axle. take off the start switch key, push the pilot
control lever forward and backward, left and
12. Add axle oil to the oil drain outlet on the other right to release pressure.
wheel end of the front axle according to the
above operation steps.
13. Refer to the section “Lubrication
Specifications” for axle oil refill capacity. But
in the actual operation, add axle oil until the
oil flows over the oil filler as mentioned in
above operation steps.
14. Replace the rear drive axle oil according to
the previous operation steps.
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5. Check the sight glass of the hydraulic oil tank 1. Unscrew mounting bolts of access plate on
when there aren’t bubbles. The hydraulic oil the top of hydraulic tank and mounting bolts
level should be within green range of MAX of the breather filter cap plate on the rear
line and MIN line of the sight glass. hood to remove the access plate and the cap
Sight glass plate.

22
11

6. Add hydraulic oil if the oil level is lower than 1. Access plate
MIN line. And check the hydraulic oil level 2. Cap plate
again according to the above method. 2. Unscrew the breather filter cap of the
hydraulic oil tank to release the pressure.
Hydraulic Oil--Add
Hydraulic oil tank
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3. Unscrew four mounting bolts of the oil filler Hydraulic Oil--Replace

flange to remove flange and add hydraulic
oil. Check the hydraulic oil level of the
hydraulic oil tank according to the steps on
the section of “ Hydraulic Oil Level--Check”.
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any component containing
fluids or dismounting any hydraulic line.
Dispose of all fluids according to local
regulations.
Pay close attention to the cleanliness when
replacing the hydraulic oil, do not allow dirt
enter the hydraulic system.
4. Install the oil filler flange of the hydraulic oil
tank and screw the breather filter cap. 1. Park the machine on flat ground, push the
5. Mount the access plate on the top of shift control lever to NEUTRAL position, pull
hydraulic tank and the breather filter cap up the parking brake button (parking brake
plate. handle) and install the steering frame lock.

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

minutes. Operate the boom and tilt the
bucket repeatedly to raise the hydraulic oil
temperature.
3. Raise the boom to the highest position, tilt
the bucket backward to the limit position, and
stop the engine.
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4. Push the work implement control lever

rightward to let the bucket tilt forward by its
deadweight, and discharge the hydraulic oil 3
in the tilting cylinder. After the bucket tilts to
the limit position, push the work implement
control lever forward to let the boom lower by
its deadweight, and discharge the hydraulic
oil in the boom cylinder.
5. Dismount the bolt of the hydraulic oil tank
drain line clamp in the left side of the web
plate on the rear frame, lead out the oil drain
line from the articulation joint and loosen the
oil drain plug to drain out hydraulic oil and
1. Web plate
collect with a container. Meanwhile, open the
2. Bolt clamp
breather filter cap (oil filler cap) of the 3. Breather filter
hydraulic oil tank to quicken the oil
discharging speed.

Because the hydraulic oil temperature is still

high when draining, wear protective clothing
and be careful to prevent injury.
1 6. Turn on the water drain valve of the hydraulic
oil cooler and drain residual hydraulic oil from
the cooler.

2
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7. Remove the end cap of the return oil filter 12. Remove the steering frame lock and start the
from the hydraulic oil tank, take out the return engine. Operate the work implement control
oil filter element and replace with a new one. lever to raise and lower the boom for 2~3
times. Tilt the bucket forward and backward
and turn from left to right to the maximum
angle to fill cylinders with hydraulic oil. Then
run the engine at idle speed for five minutes
4
to drain air in the system.
13. Stop the engine. Open the hydraulic oil filler
5 cap, refill the hydraulic oil tank.

Serious Polluted Hydraulic Oil--Replace

4. Return oil filter

5. Return oil filter end cap
Care must be taken to ensure that fluids are
8. Open the oil filler flange and take out the contained during performance of inspection,
strainer. maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any component containing
fluids or dismounting any hydraulic line.
Dispose of all fluids according to local
regulations.
Pay close attention to the cleanliness when
replacing the hydraulic oil, do not allow dirt
enter the hydraulic system.

1. Park the machine on flat ground, push the

9. Wash the oil filler flange and strainer with shift control lever to NEUTRAL position, pull
nonflammable detergent. Dry them in the air up the parking brake button (parking brake
or with compressed air. handle) and install the steering frame lock.
10. Install the oil drain plug, return oil filter,
strainer and oil inlet pipe of the hydraulic oil
cooler.
11. Refill the hydraulic oil tank from the hydraulic
oil filler until the oil level reaches the upper
graduation of the sight glass. Tighten the oil
filler flange after finishing.
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2. Start and run the engine at idle speed for 10

minutes. Operate the boom and tilt the
bucket repeatedly to raise the hydraulic oil 3
temperature.
3. Raise the boom to the highest position, tilt
the bucket backward to the limit position, and
stop the engine.
4. Push the work implement control lever
rightward to let the bucket tilt forward by its
deadweight, and discharge the hydraulic oil
in the tilting cylinder. After the bucket tilts to
the limit position, push the work implement
control lever forward to let the boom lower by 1. Web plate
its deadweight, and discharge the hydraulic 2. Bolt clamp
oil in the boom cylinder. 3. Breather filter

5. Dismount the bolt of the hydraulic oil tank

drain line clamp in the left side of the web
plate on the rear frame, lead out the oil drain Because the hydraulic oil temperature is still
line from the articulation joint and loosen the high when draining, wear protective clothing
oil drain plug to drain out hydraulic oil and and be careful to prevent injury.
collect with a container. Meanwhile, open the
breather filter cap (oil filler cap) of the 6. Disconnect one end of the oil inlet pipe to
hydraulic oil tank to quicken the oil drain the residual hydraulic oil from the
discharging speed. steering cylinder, oil cooler and other pipes.
7. After finish draining, install the oil drain plug
and all the disconnected pipes.
8. Refill the hydraulic oil tank from the hydraulic
oil filler until the oil level reaches the upper
graduation of the sight glass. Tighten the oil
1 filler flange after finishing.
9. Replace the polluted hydraulic oil according
to the procedures described in section
"Hydraulic Oil--Replace".

2
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Breather Filter of Hydraulic Oil Tank Return Oil Filter Element of Hydraulic
--Clean Oil Tank--Replace

The breather filter is located on the top of the Replace the return oil filter element at first 500
hydraulic oil tank. service hours, replace it every 1500 service
hours later on. Replace the return oil filter
element in advance if the working condition is
very bad.
1. Dismount the bolt of the hydraulic oil tank
drain line clamp in the left side of the web
plate on the rear frame, lead out the oil drain
line from the articulation joint and loosen the
oil drain plug to drain out hydraulic oil and
collect with a container. Meanwhile, open the
breather filter cap (oil filler cap) of the
hydraulic oil tank to quicken the oil
discharging speed.
1. Take out the breather filter.
2. Wash the breather filter with clean and
nonflammable detergent. Dry it in the air or
with compressed air.
3. Install the breather filter.

1. Oil drain plug

2. Remove the end cap of the return oil filter,
take out the return oil filter element and
replace a new element.

2. Return oil filter element

3. Return oil filter end cap
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3. Install a new return oil filter element and O 4. Remove the flange cover and oil filler cap,
ring. Mount the end cap of the return oil filter take the strainer.
and the oil drain plug.

Hydraulic Oil Tank--Clean 4

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any component containing 3. Flange cover
fluids or dismounting any hydraulic line. 4. Oil filler cap
Dispose of all fluids according to local
5. Wash the bottom and four walls of the
regulations.
hydraulic oil tank with fuel through the return
oil filter cover. Then wipe with clean cloth.
1. Stop the engine.
2. Unscrew the oil drain plug on the left side
articulation joint of the rear frame to drain
hydraulic oil. Collect with a container.
3. Remove the end cap of the return oil filter,
take out the return oil filter element and O
ring. Place the element and the O ring
properly.

1 6. Wash the bottom and four walls of the

hydraulic oil tank with hydraulic oil again.

2 7. Replace with a new return oil filter element

and O ring. Install the end cap of the return
oil filter, oil drain plug, flange cover and
strainer.

1. Return oil element

2. Return oil filter end cap
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Brake System Parking Brake Performance--Inspect

Service Brake Performance--Inspect

Check the parking brake performance

frequently to ensure the machine can safely
stop and ensure its emergency braking
Before checking the service brake ability, capability.
make sure the machine's parking brake
system works normally in case of any
1. Adjust the air pressure of the machine tires to
emergency.
the specified value, lay the bucket flatly with
a distance about 300mm above the ground.
Check the service brake performance of the Make sure the service brake is performing
machine on hard, dry and flat road surface. Make normally.
sure no personnel or obstacles are around when
checking. Fasten the seat belt before checking. 2. Start the engine and drive the machine to a
slope with a gradient of 15% (the angle is
1. Start and drive the machine at 32km/h about 8°32'). The load capacity is 5T. The
(20mph). Depress the service brake pedal to slope surface should be smooth and dry.
fully brake the machine. After the machine
stops, turn the shift control lever to
NEUTRAL, engage the parking brake then
release the service brake pedal. The brake
distance should not exceed 15m.
2. Start and drive the machine at 32km/h
(20mph). Perform spot braking, the machine
should stop immediately without deflection. 8°32’
If the brake distance exceeds 15m(49'3"),
consult your LiuGong dealer for brake system 3. Depress the service brake pedal to stop the
checking. Eliminate the problems before going machine. Turn the shift control lever to
on working. NEUTRAL position, and do not stop the
engine.
4. Engage the parking brake and slowly release
the service brake pedal. 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

moves while checking.
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Booster Oil Level--Check The brake pad is located in front of transmission

output shaft.
1. Park the machine on flat ground.
2. Shut down the engine, engage the parking
brake to avoid machine movement.
3. Unscrew the booster cap to check the oil
level of the oil cup. If the booster oil is below
the inner screen, add synthetic brake fluid
(DOT4) until the oil surface keeps the same
level with the sceen.

1. Park the machine on flat ground, stop the

engine and install the steering frame lock.

Keep the brake fluid filler clean before adding

brake fluid to prevent the booster oil cup
from being contaminated. 2. Release the parking brake handle to
disengage the parking brake.
Parking Brake Clearance--Check /
Adjust

Check and adjust the parking brake

clearance when the parking brake is cooled
down.

Check the parking brake clearance after the first

50 service hours. After that, check the parking
brake clearance every 250 service hours to
ensure the good brake performance of the
machine.
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3. Measure the clearance between the brake Air Reservoir Water Drain Valve--Check
shoe and the brake drum with a plug gauge.
The clearance should be between 1. Park the machine on flat ground and engage
0.15~0.22mm. the parking brake. Continuously depress and
release the service brake pedal to release
1
the air pressure in the air reservoir.
2
2. Push the water drain valve upwards to drain
water in the air reservoir. If loosen the water
drain valve, it will close automatically.
3

2
4

1. Adjusting rod
2. Brake shoe
3. Brake drum
4. Brake shoe friction disc
4. If the clearance is beyond 0.15~0.22mm, turn
the adjusting rod to adjust the clearance
between the brake shoe and brake drum.
5. Replace the brake shoe friction disc when it
is impossible to meet the clearance Check the water drain valve every two weeks
requirement through clearance adjustment. if the machine works in greasy and dusty
environment.
6. Operate the parking brake button repeatedly
to check the brake performance of the When the ambient temperature is lower than
machine on a slope. 0°C, the water at the bottom of the air
reservoir of brake system will freeze, which
will affect the safety of brake system or result
in accidental shudown. Drain water in the air
reservoir timely every day or every 10 hours.
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Clamp--Exhaust 5. Cooperation of two operators are needed to

finish this step. One operator presses the
If air enters the oil line of brake system, the service brake pedal and hold it on in the cab.
braking performance of clamp will be effected. The other one unscrews the exhaust nozzle
Therefore, it is necessary to exhaust air in the for about 0.25~0.50 circle, and then observes
clamp when replacing clamp parts, the exhaust condition and screws the
disassembling and assembling oil lines, and exhaust nozzle, finally releases the brake
cleaning brake system. Exhaust air as follows: pedal. Repeat the above steps many times
untill liquid column without bubbles flows
1. Park the machine on the flat ground. from the exhaust nozzle. At this time, air has
2. Push the shift control lever to Neutral been exhausted totally, screw the exhaust
position, start the engine and let it run at idle nozzle.
speed (about 800r/min), press the parking
brake handle.

6. Check the oil level of booster oil cup when

exhausting, add brake fluid if insufficient to
3. Stop the engine when the service brake
prevent air from entering the brake system
barometer reaches 0.71~0.784MPa, and turn again.
on the engine start switch.
4. Connect the exhaust nozzle of each clamp of
the front axle with a translucid hose, and put
the other end of the hose into an oil
container.

7. Check the clamps for leakage when

exhausting, if there is leakage, handle it
promptly.
8. Exhaust air for the left and right clamps of the
rear axle according to the above steps.
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Centralized Lubrication System

Lubrication Diagram and Intervals

Add lubricant according to the lubrication diagram and intervals.

1. #2 COMPOUND LITHIUM BASED GREASE IS USED FOR

CENTRALIZED LUBRICATION SYSTEM
TYPE OF LUBRICATION OIL
2. #2MOS2 LITHIUM BASED GREASE IS USED FOR MANUAL
LUBRICATION
LUBRICATE NO. 4, 5, 6, 8, 9, 10, 11, 12, 15, 16 POINTS EVERY 100
HOURS OR TWO WEEKS
RECOMMENDED LUBRICATION INTERVALS
OTHER LUBRICATION POINTS EVERY 50 HOURS OR EVERY
WEEK
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Electrical System 3. Check the battery hydrometer color. Green

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

1. The battery is located in the battery box at The battery clamp plate, battery terminals
the rear left side of the machine, it can be and cable leads will become loose due to the
seen only open the cover. machine vibration after operating the
machine for a period of time. Check the
tightness of the nut located in the middle of
the clamp plate. Tighten it if it is loose.

Battery--Install

Before installing the battery to the machine,

make sure that the battery hydrometer is green.

2. Check whether the clamp nut, battery The battery should not be inclined over 40°.
terminal and cable lead are loose. Tighten Do not place the battery reversely or by any
them if they are loose. side of it.
Make sure the hydrometer is green before
installing the battery. It is not allowed to
install the battery with a black hydrometer
5 onto the machine.
5
Do not install a leaked battery onto the
11 33
machine.

1. Turn the start switch (also called ignition

4
4 22 switch) to OFF position then remove the key.
Turn disconnect switch to OFF position.
2. Clean the battery terminals and surface with
1. Battery terminal a clean cloth. Do not use harsh chemicals or
2. Nut cleansers for cleaning.
3. Battery terminal(without jacket)
4. Clamp plate 3. When connecting:
5. Hydrometer
a) Connect the positive post of one battery
to the negative terminal of the other
battery with the cable.
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b) Connect one end of the battery positive A long-time use of the electric appliances without
lead terminal to the battery positive post, starting the engine or a long-time stop, electricity
the other end to start motor. leakage, or the alternator can not charge; all
these reasons could lead to an abnormal battery
c) Connect one end of the battery negative
charge and result in an electricity insufficiency or
lead terminal to the battery negative post,
even can not start the machine. Recharge the
the other end to the battery disconnect
battery if this happens.
switch.
d) Connect the battery disconnect switch to
ground cable.
Charge the battery to let it work normally if
To start motor
the above-mentioned phenomenon
5 3 happens.

Check the outlook of the battery before charging:

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

Wear safety goggles when charging.

A wrong installation of the negative and
positive terminal will result in a serious Keep ventilated when charging. Charge the
damage to the battery. Distinguish the battery under normal temperature.
positive (+) and negative terminal (-) Do not smoke when charging the battery,
correctly. keep any kindling away.
The battery could have an explosion danger
Battery--Charge if it is deposed improperly when charging.

A maintenance-free battery is used in this

1. Turn the start switch to OFF position and take
machine. Obey the following instructions when
out the key, and then turn the disconnect
dealing with the battery.
switch to OFF position.
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2. Clean the battery terminals and surface with Below 11.00VDC 14h
a clean cloth, remove the oxidation surface.
8. Check the hydrometer color after finishing
3. Remove the battery from the machine. When charging. Green hydrometer indicates that
removing, first disconnecting the negative the battery is fully charged.
terminal of the battery.
● If the hydrometer is black, check the cable
4. Connect the cables after finishing charging. connection and connecting points. Charge
Cennect the positive cable first. the battery again according to the above
table until the hydrometer is green.
● If the hydrometer lost color, bubbles might
exist in the hydrometer. Shake the battery
When connecting the battery, first connect slightly to remove the bubbles. If the
its positive terminal; when disconnecting hydrometer still lost color, then electrolyte is
the battery, first disconnect its negative lost seriously, discard the battery and replace
terminal. with a new one.
5. Connect the positive clamp of the charger to 9. As for the battery with a voltage under
the positive terminal of the battery, the 11.0VDC, it may not be able to be charged at
negative clamp to the negative terminal the beginning. Due to the serious
under room temperature. insufficiency of electricity, the proportion of
vitriol is close to water, therefore, the battery
6. It is recommended to use a charger with a
resistance is higher. The vitriol proportion
constant voltage of 16VDC (the maximum
increases during recharge and the circuit can
voltage cannot exceed 16 ± 0.1 V, maximum
get right gradually.
current can not exceed 25A) to charge the
battery. Green hydrometer indicates the
battery charging is finished.
7. Charge the battery according to the following Fix the two terminals tightly. Do not charge
specification if the above-mentioned the battery of 24VDC voltage in serial
requirement can not meet: connection.
● 1/10 of rated current to charge. Stop charging immediately to check the
● Table of charge time and battery voltage for reason if the battery discharge hole spurts
reference(lower current means a longer acid during the charging process.
charging time).
10. Stop charging if the battery temperature
Battery Voltage Charge Time exceeds 45°C during the charging process.
Halve the circuit before recharging after the
12.55-12.45VDC 2h
battery temperature drops to the ambient
12.45-12.35VDC 3h temperature.
12.35-12.20VDC 4h
12.20-12.05VDC 5h
12.05-11.95VDC 6h
11.95-11.80VDC 7h
11.80-11.65VDC 8h
11.65-11.50VDC 9h
11.50-11.30VDC 10h
11.30-11.00VDC 12h
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11. Check the battery voltage every hour during Battery--Store/ Service
the charging process. The battery is fully
charged if the hydrometer is green. 1. Turn off the battery disconnect switch when
storing the batteries being installed on a
machine, and check the battery voltage state
at least every other month.
If the hydrometer is black, check for loose 2. Disconnect the negative terminal of the
cable and clean connecting terminal. Check battery if the machine is stored over 15 days.
whether the voltage has come to 16VDC. If Check the electricity state of the battery
the hydrometer is clear, it is likely that air every 3 months (with cable disconnected).
bubble exist in it. If the hydrometer is still
● Green hydrometer means the battery is in
clear after slight shaking (indicates that the
normal condition. Black hydrometer means
electrolyte loss), replace with a new battery.
the battery needs charging.
12. It is recommended applying vaseline on the ● Replace the battery if its electrolyte was lost
battery terminals to avoid electric corrosion seriously and hydrometer lost color.
after charge is completed.
● Check the battery voltage every 3 months
Charge the battery according to the following during machine storage. Recharge if the
method when the battery voltage is low, but the battery lacks for electricity. Recharge
machine still can be started and alternator works according to special procedures.
normally.
3. Recharge if the battery lacks for electricity.
1. Start the engine, and ensure that the battery Recharge according to special procedures
charging system is in normal (observe the
battery voltage through gauge), keep the 4. As for the machine which has not
engine speed at second gear to charge the disconnected the battery terminals, check the
battery until the hydrometer turns green. battery voltage state every month. If the
voltage is under12.4V, recharge it according
2. Turn off the A/C, radio, lights (except night) to special procedures.
and other high-power electric equipment
during battery charging. 5. As for the machine which is stored over 1
year, replace with a new battery and dispose
3. Avoid starting the machine frequently as far the old one if the above- mentioned
as possible during battery charging. If restart requirements can not be followed.
is necessary, it is recommended to restart the
machine after finishing charging the battery. Battery--Recycle

When discarding a battery, its inner material

such as lead, acid and plastic shell can pollute
the environment due to its outer frayed structure
or other reasons. Therefore, do not throw away
the old battery randomly, deal with it by collecting
for a battery disposal station or put it into a
recycle can set by the manufacturer (if there is
any) in a local place.
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Battery, Cable, Battery Disconnect Alternator--Maintain

Switch--Replace

1. Turm the engine start switch key to OFF

position. Turn all of the switches to OFF
position. Take out the switch key. It is forbidden to check the alternator by
short-circuiting the negative and positive
2. Turn the battery disconnect switch to OFF
terminal of the alternator, otherwise the diode
position.
will be burnt and the voltage regulator coulde
3. Disconnect the negative battery cable from be affected.
the battery disconnect switch.
Keep any metallic conductor away from
4. Sequences for disconnecting the battery positive termianl of the alternator.
cables:
● Disconnect the negative battery cable from The alternator is a supporting component of the
the battery. diesel engine. Its working voltage is 24VDC and
electric current is 35A. It has a built-in electronic
● Disconnect the positive battery cable from voltage regulator. Check the connections of the
the battery. alternator terminals frequently. Connection
looseness at either positive terminal or negative
terminal will result in trouble of the electrical
system, even cause serious failure.
Do not let the disconnected negative battery Turn off the start switch before checking the
cable contact with the battery disconnect positive terminal or negative terminal.
switch.

5. Inspect the battery terminals for corrosion.

Inspect the battery cables for wear or
damage. The cable of the terminals can not be
incorrectly connected, otherwise the diode
6. Make any necessary repairs. If necessary,
could be burnt and result in serious failure.
replace the battery cables or the battery.
7. Sequences for connecting the battery cables: Method of judging whether the alternator
works normally and the handling measures:
● Connect the positive battery cable to the
battery. 1. Turn on the start switch (ignition switch) and
observe the reading of the voltmeter, and
● Connect the negative battery cable to the then start the diesel engine and observe
battery. reading of the voltmeter again. The latter
8. Connect the battery cable with the battery reading should be higher than the former
disconnect switch. one.

9. Install the switch key and turn the battery 2. You can also use the 200V DC voltage
disconnect switch to ON position. position of a multimeter to check. Turn on the
start switch, measure terminal voltage of the
alternator (red meter pen connects the
positive terminal of the alternator while black
meter pen connects the negative terminal ),
and then write down the reading of the
multimeter.
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3. Start the engine and increase the engine Fuse--Check/ Replace

speed to rated speed. Check the voltage of
the alternator again and write down the The fuse box is located in the cab. The fuses
reading of the multimeter. The latter reading protect the electrical system from being
should be higher than the former one. damaged due to circuit overload. If the fuse is
4. In case the alternator does not work: broken, replace with a new one. Check the circuit
if the new fuse is broken again. Repair the circuit,
a) Check the drive belt of the alternator for if necessary. See the following table for the sclice
looseness. type fuse color:
b) Turn off the start switch (ignition switch), Model Color
and then use a wrench to check the
connections of the alternator terminals. BK/ATC-5A Orange

c) Check to see whether the alternator BK/ATC-7.5A Brown

connects correctly to the ground. BK/ATCC-10A Red
BK/ATC-15A Blue
Starter Motor--Maintain
BK/ATC-20A Yellow
The starter motor is a supporting component of BK/ATC-30A Green
the diesel engine. It mainly consists of a
solenoid, DC motor, shifting fork and driving
gear. The starter motor converts electrical energy
of the battery into mechanical energy through the
DC motor. Then the driving gear will drive the Replacing fuses with the same type and size
flywheel of the engine to start the engine. from different brands is allowed. Do not use
copper wire, otherwise the circuit could be
After the engine starts, the starter motor should damaged.
immediately stop. Otherwise, the driving gear
may be damaged, the DC motor may be burnt, It is recommeded to use fuse supplied by
the chock electromagnet may be damaged, and Liugong if it needs to replace the fuse when
capacity and service life of the battery may also repairing. Do not buy the fuse randomly in
be greatly affected. the market as fuse of poor quality will bring
bad effect to the machine, even could cause a
It is prohibited to allow any metallic conductor to fire.
approach any naked terminal freely. Especially
ensure that the other metallic articles around the
starter motor will not contact or rub the naked
terminal after a long and severe shock or
If it is necessary to replace fuses frequently,
operation of the machine. Otherwise, fire may
an electrical problem may occur. Contact
occur to the machine.
your LiuGong dealer.
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Air Conditioning System Other Maintenance

Heating-only Air Conditioner--Check Bucket Cutting Edges--Check/Replace

The heater unit is under the operator seat.

Making use of heating cycle to get warm air. After
starting the machine, the water temperature will
Personal injury or death can result from
rise to normal value after 8-15 minutes, turn on
bucket falling. Chock the bucket before
the heater unit at this time.
replacing bucket cutting edges.
Turn on the heating-only air conditioner, mainly Cutting edge
check the warm air pipe lines and fan, check
whether the heater unit runs without abnormal
sound, whether the ventilation duct is
unobstructed. Check whether there is sundries
near air inlet or air-inlet grille electronic fan;
check engine cooling system, heating control
system, temperature control switch of the
electronic fan, and water temperature
thermostat, etc.

Heating-only Air Conditioner--Maintain

Check the cutting edges and the end bits for

wear and for damage. Use the following
It is very important to disinfect the warm air procedure to service the cutting edges and the
outlet before use. end bits:
1. Raise the bucket and chock the bucket.
Disinfect the warm air outlet before using
heating-only air conditioner in winter. Vinegar 2. Lower the bucket onto the wedge. Stop the
fumigation is commonly used. Turn on the inner engine.
circulation of the air conditioner to the max. air 3. Remove bolts, cutting edge and the end bits.
volume, and close the doors and windows of the
cab for 10-15 minutes. Clean the air outlet 4. Clean all contact surfaces.
periodically. 5. lf the opposite side of the cutting edge is not
When maintaining the heating-only air worn, use the opposite side of the cutting
conditioner, always use compressed air to blow edge. The end bits are not overturned. If both
away dust; if the engine has cooled down, water sides are worn, replace a new cutting edge.
gun can be used to wash the above positions 6. Screw the bolts to the specified torque.
inside-out.
7. Start the engine. Raise the bucket and
remove the wedge. Lower the bucket to the
ground.
8. After a few hours of operation, check the
bolts for proper torque.
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CLG856H Important Maintenance Procedures

Backup Alarm--Test Window Washer Reservoir--Fill

Turn the engine start switch to I or ON position to Add washer through the water filler of the washer
turn on the power of the machine. reservoir. The washer reservoir is located on the
rear of the articulation joint at the right side of the
Pull the parking brake button (parking brake
machine.
handle) up to engage the parking brake.
Turn the engine start switch to II or START
position to start the diesel engine.
Turn the shift control lever to REVERSE position,
the backup alarm should sound immediately.
The backup alarm will sound continuously until
the shift control lever is turned to NEUTRAL or
FORWARD position.

Seat Belt--Inspect

The driver should check the seat belt for its

condition and security before use. Replace it, if Check the washer reservoir frequently to
necessary. ensure enough water in it, otherwise dirty
Adjust the length of the seat belt to ensure its windshield may impact the visibility of the
restraint and comfort ability before use. Adjust it operator.
by moving its buckle position on the belt. Do not use wiper to wipe windshield when
Replace the seat belt every 3 years even though the washer reservoir is out of water,
it is in good condition. A valid date is provided on otherwise the wiper motor may be burnt out.
every seat belt, confirm the use deadline of the The washer reservoir should be emptied or
seat belt according to it. filled with antifreeze when the ambient
For further information of the seat belt temperature is below 0°C, otherwise the
replacement, refer to your Liugong dealer. washer will not work or even be damaged by
being frozen.
As the washer with additive may be harmful
to human body, dispose of it according to
local laws and regulations.
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Important Maintenance Procedures CLG856H

Welding Operation ● Electronic parts

● Other possible parts on the machine
To avoid possible damage to the machine, read
and understand the following cautions before 10. Keep any inflammable and explosive
welding and always observe the welding materials away from the welding site, protect
operation procedures as follows: any cable, do not allow sparks and solders
produced in welding to splash onto the
1. Park the machine on flat ground. cables, thus cause a fire and resulting in loss
2. Engage the parking brake. and injury.
3. Turn the pilot cut-off lever to OFF position (if 11. Use proper safety welding operation
equipped). procedures for welding.
4. Turn off the start switch to stop the engine.
Cautions for Welding Operation
5. Turn off the battery disconnect switch to
disconnect the battery and frame. ● Never use the earth position of the electrical
parts on the machine as that of the welder.
6. Disconnect the controller of the shift control
system and the instrument panel before ● When performing welding near the earth
welding to avoid damaging them, or position of an electrical part, always
disconnect the cab harness (under the right disconnect the earth position of this electrical
side of the cab, near the articulation joint) part, and perform welding operation after
from the machine. ensuring that the welding circuit of the welder
doesn't get across this electrical part.
7. If your machine is equipped with other
Otherwise it will result in damage to this
electronic components such as
electrical part or even result in a fire.
loudspeakers, remove all connectors of the
electronic components connected to the ● Do not keep using voltage above 200V. Keep
machine harness before welding to avoid the welding area and earth cables within 1m.
possible loss.
● Avoid seals and bearings located between
8. Clear away paint from those parts to be the welding area and earth cables.
welded to prevent harmful air from
● Never weld any pipe or container with fuel,
production.
engine oil or hydraulic oil.
9. Clamp the earth cables of the welder with the
● Never weld any sealed container or container
parts to be welded, keep the earth position
which is poorly ventilated.
close to the welded place. Check and confirm
the circuits from the earth cables to the ● Do not allow sparks and solders produced in
welded parts don't get across any of the welding to splash onto the cables, rubber
following parts: hoses and other inflammable materials, thus
cause a fire and resulting in loss and injury.
● Bearings
● Hydraulic cylinders
● Controllers
● Internal circuit of other electronic parts
Any damage to the following parts could be
avoided by doing so:
● Bearings
● Hydraulic parts
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June 1, 2020 INDEX
CLG856H

INDEX

A Combination Switch ........................................ 53

Control Devices .............................................. 52
Coolant Level--Check ..................................... 97
Accelerator Pedal ............................................56 Coolant--Add .................................................. 98
Air Conditioning System ................................136 Coolant--Replace .......................................... 100
Air Filter Safety Element--Replace ................103 Crushing and Cutting Prevention .................... 20
Air Reservoir Water Drain Valve--Check ......127
Alternator--maintain ......................................134
Application and Specification ..........................36 D
Applications .....................................................36
Attachment Cautions .......................................24 Daily Inspection .............................................. 96
Auxiliary Control Lever ....................................59 Door Lock ....................................................... 67
Axle Oil Level--Check ...................................115 Door Positioner ............................................... 67
Axle Oil--Replace ..........................................116 Downhill Operation ......................................... 74
Driving Operation of the Machine ................... 73
B Driving the Machine ........................................ 82
Dumping Operation ........................................ 77
During Storage ............................................... 81
Backup Alarm--Test ......................................137
Battery Disconnect Switch ..............................42
Battery, Cable, Battery Disconnect Switch-- E
Replace .........................................................134
Battery--Charge ............................................131 Electrical Storm Injury Prevention .................. 23
Battery--Check ..............................................130 Electrical System .......................................... 130
Battery--Install ...............................................130 Engine Air Intake System--Check ................. 111
Battery--Recycle ...........................................133 Engine Belt--Check ....................................... 111
Battery--Store/ Service ..................................133 Engine Hood ................................................... 70
Before Operation .............................................41 Engine Oil Filter--Replace ............................ 110
Before Reuse ..................................................81 Engine Oil Level--Check ............................... 108
Before Storage ................................................81 Engine Oil--Replace ..................................... 109
Booster Oil Level--Check ..............................126 Engine Start Switch ........................................ 43
Brake Operation of the Machine .....................74 Engine Starting ............................................... 71
Brake System ................................................125 Engine System ............................................... 97
Breather Filter of Hydraulic Oil Tank--Clean .123 Engine Tensioner Bearing and Fan Hub--Check
Bucket Cutting Edges--Check/Replace .........136 ....................................................................... 111
Burn Prevention ..............................................20 Engine Valve Lash--Adjust ........................... 111
Excavating With Bucket .................................. 76
C
F
Cautions about Machine Maintenance ............32
Cautions about Machine Operation ................25 Fan Belt Tension--Check/Adjust ................... 111
Central Instrument Panel ................................45 Fire &Explosion Prevention ............................ 21
Centralized Lubrication System ....................129 Fire Extinguishers and First-aid Kit ................. 22
Check Before Starting the Engine ...................71 Front Left Instrument Panel ............................ 48
Clamp--Outlet ................................................128
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CLG856H

Front Right Instrument Panel ..........................49 Stopped .......................................................... 80

Front Right Upright Column Instrument Panel 49 Lubrication Diagram and Intervals ................ 129
Fuel Filter--Replace ......................................107 Lubrication Specifications ............................... 95
Fuel Level--Check .........................................104
Fuel Pre-filter--Replace .................................106
Fuel Strainer--Clean ......................................106
M
Fuel Tank--Clean ..........................................105
Fuel--Add ......................................................104 Machine Operation ......................................... 75
Fuse--Check/ Replace ..................................135 Main Components ............................................ 3
Main Filter Element of the Air Filter--Clean/
Replace ........................................................ 102
G Main Specifications ......................................... 37
Maintenance Guidance ................................... 86
General Hazard Information ............................16 Maintenance Interval Schedule ...................... 89
General Torque Specifications ........................93 Maintenance Manual ...................................... 86

H O

Heating-only Air Conditioner Panel .................50 Oil Specifications ............................................ 95

Heating-only Air Conditioner--Check ............136 Operation during Cold Weather ...................... 75
Heating-only Air Conditioner--Maintain .........136 Operation Information ..................................... 72
Horn Switches .................................................53 Operation Manual ........................................... 41
Hydraulic Oil Level--Check ...........................117 Operation Method ........................................... 79
Hydraulic Oil Tank--Clean .............................124 Operation Techniques .................................... 72
Hydraulic Oil--Add .........................................118 Operator Controls and Instrument Panels ...... 42
Hydraulic Oil--Replace ..................................119 Operator Station ............................................. 24
Hydraulic System ..........................................117 Other Devices ................................................. 60
Other Maintenance ....................................... 136
I
P
Important Maintenance Procedures ................96
Important Safety Information .............................1 Parking ........................................................... 80
Instrument Panel .............................................44 Parking Brake Clearance--Check / Adjust .... 126
Parking Brake Handle ..................................... 56
Parking Brake Performance--Inspect ........... 125
K Power Train System ..................................... 112
Preface ............................................................. 1
Key Spare Parts to be Periodically Changed ..35 Preparation before Operation ......................... 75

L R

Latch ...............................................................68 Radiator Group--Clean ................................. 111

Leaving the Machine .......................................80 Rear View Mirrors ........................................... 69
Lifting the Machine ..........................................83 Return Oil Filter Element of Hydraulic Oil Tank--
Lights ..............................................................66 Replace ........................................................ 123
Lowering the Work Implement with Engine ROPS/FOPS ................................................... 24
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Run-in .............................................................88 W

S Water and Impurity--Remove ....................... 106

Welding Operation ........................................ 138
Safety Decals and Decal Locations ..................5 Window Washer Reservoir--Fill .................... 137
Safety Information .............................................5 Work Implement Control Lever ....................... 56
Safety Signs ......................................................5
Safety Symbol ...................................................5
Scraping Operation .........................................78
Seat .................................................................60
Seat Belt .........................................................62
Seat Belt--Inspect .........................................137
Serious Polluted Hydraulic Oil--Replace .......121
Service Brake Pedal .......................................55
Service Brake Performance--Inspect ............125
Shift Control Lever ..........................................55
Shoveling ........................................................75
Shoving Operation ..........................................78
Small Tool Kit ..................................................65
Sound and Vibration .......................................34
Sound System (Optional) ................................62
Starter Motor--Maintain .................................135
Steering Frame Lock ................................ 24, 70
Steering Operation of the Machine .................74
Steering Wheel ...............................................53
Stopping the Machine .....................................80
Storage ...........................................................81

Tire Explosion Prevention ...............................23

Tire Inflation Information .................................94
Towing Information .........................................84
Towing Operation ............................................78
Towing the Machine ........................................84
Towing with a Running Engine .......................85
Transmission Oil Filter--Replace ...................114
Transmission Oil Level--Check .....................112
Transmission Oil--Replace ............................113
Transportation Information ..............................81
Transportation of Materials .............................77
Transportation of the Machine ........................81
Turning off the Engine .....................................80
Type and Serial Number of the Machine and
Parts ..................................................................4
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