CLG925LC/925LL

HYDRAULIC EXCAVATOR
CUMMINS Ⅱ POWER

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
CONTENTS

CONTENTS

Preface Operator Controls and Instrument Panels ...... 42

Main Components ............................................ 3 Engine Starting ............................................... 73

Operation Techniques .................................... 76

Safety Information
Safety Decals and Decal Locations .................. 5 Maintenance Manual
Decal location ................................................ 6 Maintenance Guidance................................... 91

General Hazard Information............................ 17 Run-in ............................................................. 93

Crushing and Cutting Prevention .................... 20 Maintenance Interval Schedule ...................... 94

Burn Prevention .............................................. 21 General Torque Specifications ....................... 96

Fire & Explosion Prevention............................ 22 Lubrication Specifications ............................. 100

Fire Extinguishers and First-aid Kit ................. 23 Important Maintenance Procedures ............. 101

Electrical Storm Injury Prevention ................... 23 Troubleshooting ............................................ 149

Special Protective Devices ............................. 24

INDEX
Operator Station.............................................. 24

Attachment Cautions....................................... 24

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

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

Key Spare Parts to be Periodically Changed . 34

Application and Specification

Application ...................................................... 35

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

Operation Manual
Before Operation............................................. 41

Preface
This manual includes important instructions
concerning operation, lubrication, checking
testing, adjusting the machine and permanent
key components.
This manual should always be kept safe, clean
and with the machine where it is convenient to
find for operators to use. This manual should not
be separated from the machine even when
reselling or leasing.
Some photographs and illustrations in this
manual show details of attachments those may
be different from your machine. Guards and
covers may have been removed for the purpose
of illustration.
Read this manual carefully and follow all
instructions for proper operation and
maintenance of this machine. Instructions in this
manual should help the reader avoid possible
personal injury or damage to the machine. The
operator should proficiently and correctly operate
the machine to ensure safety.
Use this machine only for the purpose described
in this manual. Contact your Liugong dealer for
approval before making any modifications or
adding attachments to the machine. The addition
of any unauthorized attachment may cause
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi
Liugong accepts no liability for any damage
resulting from the use of unapproved
attachments or working practices.
Only trained or experienced personnel should be
allowed to operate or maintain this machine.
Correctly record the machine type, serial
number, engine serial number and all major
component serial numbers for your reference
when ordering parts or in the event of theft.
Record the correct numbers to both the
operator’s manual and a secure place outside
the machine.
1
Preface
Safety
The safety section lists basic safety precautions.
In addition this section identifies the text and
locations of warning signs and labels used on the
machine.
Read and understand the basic precautions
listed in the safety section before operating or
performing lubrication, maintenance or repairs
on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. Read, understand and reference it
whenever necessary. This section includes a
description of gauges, machine controls,
switches and other controls at the operators’
station. It also provides transportation and towing
information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication
are basic. Skill and techniques develop as the
operator gains knowledge of the machine and its
capabilities.
Maintenance
The maintenance section is a guide for
equipment care. The illustrated, step-by-step
instructions are grouped by servicing intervals.
Items without specific intervals are listed under
the "When Required" service interval. Items in
the "Maintenance Intervals" are referenced to
detailed instructions that follow.
2
Preface

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 8 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.

Certified Engine Maintenance

Correct maintenance and repair methods are

essential to keeping the engine and machine
systems operating correctly. As the owner, you
are responsible for performance of required
maintenance listed in the Maintenance Manual
for this machine. It is prohibited for person
engaged in the business of repairing, servicing,
selling, leasing or trading engines or machines to
remove, alter or render inoperative any
emissions related device or element of design
installed on or in an engine or machine that is in
compliance with the regulations. Certain
elements of the machine such as exhaust
system, fuel system, electrical system, air intake
system and cooling system may be emission
related and should not be altered unless
approved by Liugong.
 3
Preface
Main Components

Main Components

1
3

37

38
36
39

35
4
5
6
34
33 7
32 8
9
31

30

29 10

11
28
12

27
13
26

25 14
24
23
22 15
21 16
20 17
19
18

1. Linkage 14. Diesel engine 27. Track tensioner

2. Bucket cylinder 15. Radiator group 28. Idler
3. Arm cylinder 16. Track shoe 29. Revolving frame
4. Tool kit 17. Track link 30. Foot pilot valve
5. Swing motor and reduction gear 18. Sprocket 31. Cab
6. Control valve 19. Travel motor and reduction gear 32. Hand pilot valve
7. Fuel tank 20. Center joint 33. Electronic control box
8. Hydraulic oil tank 21. Track roller 34. Boom cylinder
9. Muffler 22. Battery 35. Work light
10. Pilot valve group 23. Carrier roller 36. Boom
11. Fuel pre-filter 24. Air filter 37. Arm
12. Hydraulic pump 25. Swing bearing 38. Lever
13. Counterweight 26. Track frame 39. Bucket
4
Preface
Main Components

Type and Serial Number of the Machine and Parts

Manufacturers Name Guangxi Liugong Machinery Co., Ltd.

Type of the Machine

Serial Number of the Machine

Type of Engine

Serial Number of Engine

Type of Hydraulic Pump

Serial Number of Hydraulic Pump

Type of Main Control Valve

Serial Number of Main Control Valve

Type of Swing Motor

Serial Number of Swing Motor

Type of Travel motor

Serial Number of Travel motor

Cab Manufacturer

Serial Number of Cab

Note: The user should fill out the above table according to the specific configuration of the machine after receiving the
machine.

Safety Information
Safety Symbol
The symbol for safety alerting appears
on machines, safety signs, manuals or
for important safety information at
other places. When you see this
symbol, you should follow the instructions in the
safety information, guarding against any
possibility of personal injuries or death.
Safety Signs
Definitions of the safety signs with the words
"Danger", "Warning" and "Caution" which appear
in this manual and on the machine are as
follows:
● Danger: this word denotes an impending
danger, failure to observe instructions could
result in death or serious injuries.
● Warning: this word denotes potential danger,
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.
5
Safety Information
Safety Decals and Decal Locations
"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 signs "Danger" or "Warning" are placed
near particular dangerous places. General notice
information is placed on the safety sign
"Caution."
Safety Decals and Decal
Locations
There are several specific safety decals on your
machine. The exact location of and description of
the hazards are reviewed in this section. Take
time to read, understand and familiarize yourself
with each and every one of these safety decals.
Make sure that you can read all safety decals.
Clean or replace if you cannot read the words or
see the pictures. When cleaning the decals use a
cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the
safety decals. Solvents, gasoline or harsh
chemicals could loosen the adhesive backing of
decals causing them to fall off the machine.
You must replace a decal if it is damaged,
missing or cannot be read. If a decal is on a part
that is replaced, make sure a new decal is
installed on the replacement part. Pay attention
to the instructional and safety decals located in
the cab before starting.
6
Safety Information
Decal location

Decal location

警 告
当试 图使 用24V负 极接 地系
统 的正 常机 器对 亏电 的机 器进
行 起动 时，必 须按 照以 下程 序
正 确操 作，否 则会 导致 严重 的
人 身伤 害。
连 接跨 接电 缆的 正确 方法：
首 先辨 认每 台机 器的 蓄电 池正
极 接线 柱，正 极接 线柱 有一 根
红 色的 电缆 与发 动机 的起 动机
相 连。 将跨 接电 缆一 端连 接到
故 障机 器的 正极 接线 柱， 另一
端 连接 到正 常机 器的 相应 正极
接 线柱 。将第 二根 跨接 电缆 的
一 端连 接到 正常 机器 的车 架上 ，
另 一端 连接 到故 障机 器的 车架
或 发动 机机 体上， 并尽 可能 远
离 蓄电 池。从 司机 座椅 上起 动
正 常机 器，然 后从 司机 座椅 上
起 动故 障机 。当 故障 机起 动后 ，
按 相反 顺序 拆除 跨接 电缆 。

警 告
在处理电缆时，电
缆会导致伤害。请阅
读操作说明书以获得
正确的处理电缆方法。

1. DANGER DECAL 12. DECORATION

2. DECORATION 13. DECORATION
3. SYMBOL 14. SYMBOL
4. NAMEPLATE 15. TRADEMARK
5. SYMBOL 16. WARNING DECAL
6. DECAL GROUP 17. SYMBOL
7. WARNING DECAL 18. LUBRICATION CHART
8. SYMBOL 19. DECAL GROUP
9. DANGER DECAL 20. LUBRICATION CHART
10. REFLECTOR 37. SYMBOL
11. DECAL
 7
Safety Information
Decal location

Decal location

14. SYMBOL 28. DECAL GROUP

15.TRADEMARK 29. SYMBOL
16. WARNING DECAL 30. RIVET
21. WARNING DECAL 31. NAMEPLATE
22. WARNING DECAL 32. WARNING DECAL
23. SYMBOL 33. DECORATION
24.CAUTION DECAL 34.NOTICE DECAL
25.CAUTION DECAL 35. WARNING DECAL
26. SYMBOL 36. CHART
27. LIFT CAPACITY CHART 38. SYMBOL
8
Safety Information
Decal location

Decal Information

1. DANGER DECAL
(Located on the arm)
CRUSH HAZARD. Keep clear of machine
during operation

74A3079

6A. SYMBOL
(Located beside the fuel filler)

74A4457

6B. WARNING DECAL

(Located near the fuel filler)
When servicing or repairing machine, keep
surfaces free of oil, water, grease, tools, etc.
to avoid possible slipping and/or falling from
machine, which can cause personal injury.
74A3084

6C. WARNING DECAL

(Located near the fuel filler)
When servicing or repairing machine, keep
surfaces free of oil, water, grease, tools, etc.
to avoid possible slipping and/or falling from
machine, which can cause personal injury.
74A3081

7. WARNING DECAL
(Located near the hydraulic oil filler)
Relieve tank pressure. With engine off,
remove cap slowly to prevent burns from hot
oil.
74A3093
 9
Safety Information
Decal location

Decal Information

8. SYMBOL
(Located beside the hydraulic oil filler)

74A4458

9. DANGER DECAL
CRUSH HAZARD. Keep clear of swing area.
(Located at rear end of machine)

74A3631

16.WARNING DECAL
(Located near the track takeup valve)
Extreme high pressure in track adjustment
cylinder can cause personal injury. When
adjusting track tension, loosen grease valve
with care to relieve pressure gradually.
74A3076
10
Safety Information
Decal location

Decal Information

19A.WARNING DECAL
Only attempt to use jumper cables from an
operating machine with a 24 volt negative
ground system. Failure to observe could
result in serious injury. Follow this procedure
when attaching jumper cables. Confirm
positive terminal(+) of each machine.
Positive(+) terminal has a red cable
connected to machine starter motor not to
other battery. Connect a jumper cable to
positive terminal (+) of disabled machine and
connect other end to positive terminal (+) of
operating machine. Connect a second jumper
cable to machine frame of operating machine
and connect other end of jumper cable to
disabled machine frame or engine block as
far away from batteries as possible. Start
operating machine from operator seat only.
Start disabled machine from operator seat
only. Once disabled machine is started
remove jumper cables in reverse order. 74A3187

19B.NOTICE DECAL
(Located in the cab)
Prevent damage to electronic parts, turn off
the battery disconnect switch when machine
is not being used. Always disconnect
batteries and upplug controllers before
welding on machine. 74A2866

19C.WARNING DECAL
Electric hazard may cause injury when
mishandling the cable. Read operation
manual for safe and proper handling.

74A3091
 11
Safety Information
Decal location

Decal Information

19D.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.
74A3188

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

74A3161
12
Safety Information
Decal location

Decal Information

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

74A3082

24.CAUTION DECAL
(Located near the engine hood lift switch)
Rotating engine fan, hot engine parts and
drive belt can cause severe injury. Do not
open engine cover with engine running.
74A3090

25.CAUTION DECAL
(Located in the cab)
Falling front window can cause injury. Always
lock securely in place with locks on both
sides.
74A3094

28A.DANGER DECAL
(Located in the cab)
Contact with electrical power lines will result
in severe injury or death. Keep machine and
attachment a safe distance from electrical
power lines as per following instruction.
74A3096
 13
Safety Information
Decal location

Decal Information

28B.CAUTION DECAL CAUTION

FOR
(Located in the cab) INTERFERENCE

Some attachments when installed on machine

may contact cab or boom. Check for
clearance and beware of contact when
operating.
74A3098

28C.NOTICE DECAL
(Located in the cab)
Stopping engine without allowing it to cool can
result in overheating and shortened engine
life. Before stopping engine, run at low idle for
at least 5 min. to allow engine and
turbocharger to gradually cool down. 74A2978

28D.WARNING DECAL
(Located in the cab)
Releasing power boost switch while lifting a
load can cause unexpected lowering of load,
resulting in severe injury or death. Never use
power boost switch for lifting a load.
74A3089

28E.WARNING DECAL
(Located in the cab)
Put travel speed switch in low position before
descending a slope, loading on or unloading
machine from a trailer. If travel speed switch
is in high position during these operations,
sudden changes in machine speed can occur
with an adverse effect on machine control,
resulting in personal injury.

74A3085
14
Safety Information
Decal location

Decal Information

28F.WARNING DECAL
(Located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine.
Failure to follow or pay attention to
instructions in operation manual can result in
injury or death. It is your responsibility to be
aware of and follow all local laws and
regulations. Before starting machine, make
sure hydraulic control lever is in lockout
position and all control levers are in neutral.
Before leaving operators compartment, park
on level ground, lower attachments to ground,
make sure hydraulic pilot cut off lever is in
locked position and stop engine. Inspect and
maintain machine daily. 74A3148

28H.NOTICE DECAL
(Located in the cab)
When in ”on” position engine speed is
reduced when no levers are operated. Any
lever movement will cause the engine speed
to rise to speed set at the engine speed
control dial. It is advised to switch ”off" Auto-
idle system preventing any sudden movement
of the machine during loading or unloading of
machine and when performing delicate tasks.

74A2824
 15
Safety Information
Decal location

Decal Information

28I.CAUTION DECAL
(Located in the cab)
Slow or unexpected movement of hydraulic
functions may result when hydraulic oil is
cold. Always perform hydraulic oil warm up
procedure before attempting normal machine
operations. Always keep personnel away
from the area around machine during warm
up procedure.

74A3087

32.WARNING DECAL
(Located near the boarding gate)
Do not attempt to board the machine while it
is operating.

74A3095

34.NOTICE DECAL
Lack of hydraulic oil will cause damage to
main hydraulic pump. Before starting
operation: -Fully retract arm and bucket
cylinders and lower boom to ground.-Check
hydraulic level gauge.

74A2981
16
Safety Information
Decal location

Decal Information

35. WARNING DECAL

(Located near the battery)
CONTAINS HGHT PRESSURE GAS. To
avoid explosion and personal injury, do not
expose to fire, do not weld, do not drill.
Relieve pressure before discharging.
74A3075
38. SYMBOL
(Located near ladder)
1. Refer to the pin nameplate on the machine
for the machine mass.
2. The machine mass on the pin nameplate
does not include optional attachment.
3. Use proper rated cables and slings for
lifting, and must calculate the maximum load 1. Refer to the pin nameplate
on the machine for the
machine mass.

capacity of the crane and slings to ensure 2. The machine mass on the
pin nameplate does not
include optional attachment.
security. 3. Use proper rated cables
and slings for lifting, and
must caculate the maximum
load capacity of the crane
4. Pass wire ropes through the gaps of the 1st and slings to ensure
security.

and 2nd rack rollers from the front and last

4. Pass wire ropes through
the gaps of the1st and 2nd
track rollers from the front

two track rollers from the rear.

and last two track rollers
from the rear.
5. Lifting through foot pedal
prohibited.

5. Lifting through foot pedal prohibited. 74A5635

 17
Safety Information
General Hazard Information

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
N
AR
W

batteries, by flying scraps when the engine is in

er ot
!

op o n

e
at

operation or you are using tools to strike objects,

d

remove springs or resilient parts, add acid/

r:
te
ra

electrolyte to batteries, you should wear a full

pe
O

:
ate
D

face protective mask. When carrying out welding

operations or gas cutting operations with a
Do not wear loose fitting clothing, dangling
welding torch, wear specific safety goggles
jewelry or long hair that can catch on controls or
suitable for the task being performed. Consult
in other moving parts of the machine.
your welding equipment dealer for more
information.
18
Safety Information
General Hazard Information
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
noise on your hearing.
Make sure all protective guards and covers are
secured in place on the machine. Always replace
protective guards and covers removed for
servicing or maintenance. Repair damaged
guards and covers before operation.
Keep the machine, especially the panels,
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.
Pay attention when opening fluid compartments
to prevent foreign materials from entering the
system. Always remove loose materials from
near caps and plugs.
Know the appropriate worksite hand signals and
who gives them. Accept signals from one person
only.
No smoking and keep open flames away when
maintaining air conditioner or if there is
refrigerant gas, the flames contact the refrigerant
and the cigarette smoke will cause personal
injury or death.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
other materials.
Use all cleaning solutions with care. Do not use
any flammable material to wash components, for
example, diesel oil or gasoline. They may easily
catch fire.
Report all required repairs in time.
 19
Safety Information
General Hazard Information

Do not allow unauthorized personnel on or Even a pin-hole size leak can cause serious
around the machine. injury, If you are hit by spraying high-pressure oil,
see a doctor for treatment at once.
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.
Compressed air could penetrate your skin and Disposal of Waste Fluids
cause serious injury or death. The maximum air
pressure used should not exceed 25psi Improper handling of the waste fluid will cause
(0.2Mpa). pollution of the environment. Obey all local
regulations for disposal of waste fluids.
High-pressure Fluid
Collect all waste fluids when performing
inspections, maintenance, testing, adjusting and
WARNING: Avoid injury from high-
repairs to the machine.
pressure oil. When repairing hydraulic lines,
ensure that system pressure is completely Prepare to collect fluids with suitable containers
released before beginning the repair. before opening any compartment or
Hydraulic oil under pressure contacting the disassembling any component that contains
skin could cause serious injury or damage. fluids.
Use suitable containers to collect waste fluids.
Use caution before disconnecting hydraulic lines
Do not use food containers or beverage bottles
or connectors. High pressure oil that is released
as they could mislead people to drink the
can cause a hose to whip.
contents.
Always support attachments and release
residual pressure before attempting to
disconnect hydraulic lines. Pressure applied by
loads on attachments could cause hydraulic oil to
spray when lines are removed.
Wear safety glasses and leather gloves. Never
check for high-pressure leaks with your
unprotected hand. Use a board or cardboard
when checking for leaks.

Cautions about Accumulators

High-pressure nitrogen is contained in the

accumulators making them dangerous articles.
Read the following requirements and pay
attention to the proper use of accumulators.
20
Safety Information
Crushing and Cutting Prevention

Check accumulators before charging with Obey environmental regulations for the disposal
nitrogen. Safe use cannot be guaranteed if there of asbestos.
is not a nameplate attached to the accumulator.
Shower after contact with asbestos.
Never charge accumulators that have an
incomplete nameplate or that is of an unidentified Wear an approved respirator if there is no other
type. way to control the dust. .
Accumulators are charged with nitrogen. The
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.
Crushing and Cutting
Do not drill any hole in the accumulator or close
a hole by welding. Keep the accumulator away Prevention
from fire or heat source.
Do not weld a boss on the accumulator. Don't put hands, arms, or any other parts of the
body in the way of removable parts.
Accumulators are high-pressure vessels and
should be repaired only by trained specialized Support equipment and attachments properly
personnel. when working beneath them. Do not depend on
hydraulic cylinders to hold up the implement/
Always release pressure in the accumulator attachment. The implement/attachment can fall if
before disposing of it. a control lever is accidentally moved, or if a
hydraulic line breaks.
Asbestos Danger
For those parts fitted with shields, if it is
Breathing asbestos dust can be hazardous to necessary to remove shields in order to perform
your health. Equipment and replacement parts maintenance, always install the shields after the
shipped from Liugong have no asbestos in them. maintenance is performed.
Liugong recommends the use of genuine factory Rotating or moving parts have cutting or crush
spare parts only. Observe the following rules if hazard. Keep clear or stop engine before
you are handling any spare parts that contain servicing.
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.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Do not grind materials that contain asbestos.

Keep hands and objects away from moving fan
blades. They can throw or cut any object that
contacts the moving blades.
Never attempt adjustments while the machine is
moving or the engine is running unless otherwise
specified.
If the machine must be repaired with engine
running, make sure that a qualified operator is
available in the cab to shut down the engine if
required.
Do not use a kinked or frayed wire cable. Wear
gloves when handling wire cables.
Retainer pins, when struck with force, can fly out
and injure nearby persons. Make sure the area is
clear of people when driving retainer pins. Wear
protective glasses when striking a retainer pin to
avoid injury to your eyes.
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
cool after it has been operating for a long period
of time.
Coolant
At operating temperature, the engine coolant is
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.
21
Safety Information
Burn Prevention
Check the coolant level only after the engine has
been stopped and the coolant filler cap is cool
enough to remove with your bare hand.
Remove the cooling system filler cap slowly to
relieve pressure.
Coolant contains alkali that can cause personal
injury. Avoid contact with the skin, eyes and
mouth.
Oil
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact the skin.
At operating temperature the hydraulic oil tank is
hot and can be under pressure.
Remove the hydraulic oil tank cap only after the
engine has been stopped and the cap is cool
enough to remove with your bare hand.
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
Batteries give off flammable fumes which can
explode.
Batteries and battery terminals may contain lead;
do not touch batteries with metal or your bare
hands, otherwise it will cause the batteries
exploding. Always wash your hands right after
maintaining a battery.
Do not smoke when observing the battery
electrolyte levels.
22
Safety Information
Fire & Explosion Prevention
Electrolyte is an acid and causes personal injury
if it contacts skin or eyes. If contact occurs flush
with water and seek medical attention right away.
Always wear protective glasses and gloves when
checking batteries.
Fire & Explosion Prevention
All fuels, most lubrication and some coolant
mixtures are flammable.
Fuel leaked or spill onto hot surfaces or electrical
components can cause a fire.
Do not smoke while refueling or in a refueling
area, or where flammable materials are stored.
Clean and tighten all electrical connections.
Check daily for loose or frayed electrical wires.
Have all loose or frayed electrical wires
tightened, repaired or replaced before operating
the machine.
Check the electric circuit periodically to avoid fire
caused by overload or short circuit.
Keep all fuels and lubrications stored in properly
marked containers and away from all
unauthorized persons.
Store all oily rags or other flammable materials in
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.
Remove all flammable materials such as fuel,
lubrication and other debris before they
accumulate on the machine.
Do not operate the machine near an open flame.
Keep all open flames or sparks away from the
battery. Do not smoke in battery charging areas.
Follow the correct procedures when starting the
machine with normal ground connection under
electrolyte loss of batteries, or it will cause an
explosion which will cause hurt. Do not charge a
frozen battery. This may cause an explosion.
Ether
WARNING: EXPLOSION HAZARD. Do not
attempt to ether-start this machine. The
machine is equipped with electrical cold
weather start aid device.
Starting the machine by use of ether could result
in serious damage to the engine or personal
injury or death.
Cautions Concerning Lines, Tubes and
Hoses
Do not bend or strike high-pressure lines. Do not
install bent or damaged tubes or hoses.
Tighten any loose fuel or oil pipes, hydraulic
system tubes or hoses. Repair any damaged fuel
or oil lines, tubes or hoses. Leaks can cause
fires. Contact Liugong or your Liugong Dealer for
factory authorized replacement parts.
 23
Safety Information
Fire Extinguishers and First-aid Kit

If you see evidence of any of the following Keep telephone numbers of doctors, first-aid
situations, replace the part before using: centers or fire stations etc with you so you can
contact them in case of an emergency. Post the
● Connectors damaged or leaking.
contact telephone numbers in regulated places.
● Outer covering frayed or cut and reinforcing Ensure that all persons know where the
wire exposed. telephone numbers are located and know the
correct contact method.
● Outer covering ballooning.
● Evidence of kinking or crushing.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
Make sure that all clamps, guards and heat
shields are properly installed. During operation
this will prevent vibration, abrasion, friction with
other parts and guard from excessive heat.
Inspect and service the fire extinguisher
Before removing or servicing any lines of the air regularly. Obey the recommendations on the
conditioning system, always ensure there is not instruction plate and all local laws and
an open fire nearby; any escaping gas coming regulations relating to fire extinguishers.
into contact with fire could result in poisonous
fumes. Never smoke when servicing or repairing
the air conditioning system, any escaping gas Electrical Storm Injury
that burns and inhaled can cause bodily harm or Prevention
death.

When lightning is striking in the vicinity of the

Fire Extinguishers and First- machine, the operator should never attempt to
aid Kit mount and dismount the machine.
If you are in the cab during an electrical storm,
A fire extinguisher that meets with all local fire stay in the cab. If you are on the ground during
extinguisher laws and regulations should be an electrical storm, stay away from the machine.
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-
aid kit.
A first-aid kit should be available at the work site.
Periodically check the contents of the kit and
replace used medical supplies as necessary.
24
Safety Information
Special Protective Devices
Special Protective Devices
TOP Guard & FRONT Guard (If equipped)
To prevent the driver from being hurt by falling or
flying objects an optional protective device can
be installed. Before carrying out any dangerous
task, you must close the front window. Except
the driver, all other people should be away from
dangerous area. If necessary, you should install
TOP Guard & FRONT Guard devices.
1 hazard during travel over rough terrain or in the
2 CAUTION: Contact your local dealer to
1. Top guard
2. Front guard
Emergency Measures
In the event of an emergency, an emergency
hammer is placed inside the cab, use it to break
window glass and escape from the cab.
1 service life of the machine and the attatchments.
2 Liugong bears no responsibility for injuries,
1. Emergency hammer
2. Fire extinguisher (Optional)
Operator Station
This machine is equipped with a cab that meets
with industry standard: SAE J154 and ISO 3411.
Any modifications or aditional equipment added
to the inside of the operator station should not
project into the operator space. The addition of a
radio, fire extinguisher and other equipment must
be installed so that the defined operator space is
maintained. Any item that is brought into the cab
should not project into the defined operator
space. A lunch box or other loose items must be
secured. Objects must not pose an impact
event of the machine tipping.
maintain or replace the cab if it is damaged.
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.
Incorrect installation of attachments or optional
parts not only will result in safety problems, but
also will negatively influence the operation and
It is forbidden to modify the machine or any
attachments without permission from your
Liugong dealer.
accidents or machine damage resulting from the
use of unauthorized attachments.

Cautions about Machine
Operation
Mounting and Dismounting
Before mounting or dismounting the machine,
check the condition of handrails, ladders and
steps. Clean them of grease, lubricants and dirt
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.
Understand Your Machine
Be able to operate all the equipment on your
machine.
Understand the purpose of all control systems,
instruments and indicators.
25
Safety Information
Cautions about Machine Operation
Understand the rated load, speed range, the
characteristics of braking and steering, turning
radius and the space clearance for operation.
Remember that rain, snow, ice, gravel and soft
earth may change the performance of the
machine.
Understand the safety signs on the machine
(Danger, Warning, Caution) and any other signs.
Understand Your Working Area
Before starting, inspect the area where you will
be working. You should check for the position of
any slopes, visible ditches, falling or hanging
objects, conditions of soils (soft or hard),
accumulated water and swamp areas, rocks or
stumps, hidden groundwork, posts or the outer
limits of walls, the outer limits of the areas where
garbage is buried or that are filled in with earth,
holes or openings, obstacles, mud or ice, traffic,
heavy dust, heavy smoke, heavy fog, the exact
locations of cables or pipes for power supply, gas
supply, phone service, water supply, sewage
disposal and other utilities that are hidden or
hung. If necessary before starting work you
should ask the utility companies to mark out,
close or move out these utilities.
Before Starting the Engine
Inspect the machine carefully before starting the
engine, ensure all systems are in good
operational condition. Make sure nobody is on or
around the machine before starting the engine.
Keep the steps and handrail clean. Clear any dirt
and sands from your shoes before mounting the
machine.
Check all structural members, covers and
fenders for deformation or damage.
Check the condition of safety guards such as
doors, guards and covers. Repair any damage
as necessary.
Check the hydraulic system for oil leakage.
Check the condition of hoses and pipes.
Check all fasteners for security.
26
Safety Information
Cautions about Machine Operation

Check the condtion of electrical wiring harness Do not start the engine until seated in operators
and fuses, replace or repair as neccessary. Also seat and the seat belt is firmly fastened.
check the connectors for good connection.
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.
Replace all damaged or lost parts and carry out
lubrication according to the maintenance interval
schedule.
Remove all loose objects from the cab. Loose
objects may affect the operation and cause Ensure the pilot shutoff lever (if equipped) is in
accidents. the LOCK position before starting the engine.

Make sure that all the windows if fitted are clean Sound the horn to alert personnel before starting
and the screenwiper works normally. the engine.

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.
Check all the illumination equipment before
operation in low light, and ensure that the
illumination system is in good condition. Only start the engine from the operators seat in
the cab. Never start the engine by short-circuiting
Engine Starting the starter motor terminals. Starting the engine
by short-circuiting could result in damage of the
Do not start the engine if there is a DO NOT electrical system, personal injury or death.
OPERATE or similar tag attached to the start After the engine is started, you should observe,
switch or control levers. instruments and warning lights, and make sure
that they work and every reading is within
working range.
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Observe machine movements and listen
carefully for unusual noises. If there is any fault
or abnormality, you should stop the engine
immediately. Locate the source of the problem
and fix before further operation.
Never run the engine in a closed or poorly
ventilated environment. If working inside a
building, open the doors and windows to ensure
enough ventilation and try to prevent exhaust
gas poisoning. Use a power exhaust system
when working in an enclosed area.
Take special measures, such as applying air
cleaning system or oxygen system, to protect the
driver from danger if operating the machine in a
polluted area where there is harm to health.
Before Operating the Machine
Make sure the machine is free of personnel and
fasten the seat belt before operation.
Keep all the windows, lightshades and rearview
mirrors clean. Secure doors and windows in
either the open or close position.
Adjust the rearview mirrors for best vision,
especially close to the machine.
27
Safety Information
Cautions about Machine Operation
Clear all obstacles from where the machine will
be working. Be aware of hazards such as high
voltage wires, ditches, etc.
Make sure the horn, backup alarm (if equipped)
and all other alert devices are working properly.
Machine Operation
Before operating the machine on roads, check
whether the machine meets the requirements of
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. You can
depress the front part of the pedal, or push the
operating lever to drive the machine into low
speed state.
Dust, heavy rain, and heavy fog will blur your
vision. You should keep windows, mirrors and
lights clean and in good condition. When the
visibility decreases, you should decrease the
speed and apply the proper lights.
The increase of the temperature will cause the
surface of the ground to become soft. Make sure
that the ground at the working area is firm
enough to support the machine. When operating
in a icy road surface, you should be careful not to
turn over.
28
Safety Information
Cautions about Machine Operation

If driving or operating the machine with a bad When driving uphill or downhill, you should keep
view or in a crowded area, you should work with the bucket about 20~30cm above ground. If the
a signaler, keep the signaler within the field of machine begins to slip or become unstable, you
your vision, and coordinate your hand signals. should put the bucket down immediately.

You should not put any part of your body out of

the window frame. If the body is stretched out of
the window frame, and comes into contact with a Operating the machine on a slope is very
control lever by mistake, you may be injured by dangerous. Operate the machine on flat ground
the boom. If the window is missing or damaged, only. If you have to work on a slope, you should
you should replace it immediately. level out an area of land which is large enough
When the operation is close to a sunken pit, put for parking and swinging the machine, and then
the travel motor at the rear end to position the you can operate the machine.
machine. Drive the machine on a flat and hard
ground as much as possible. Drive the machine
in a straight motion as much as possible.
When driving on roads, place boards to prevent
damage to the road surface. Take care to drive
the machine on tar road in summer.
When driving across railway, place boards to
prevent damage to the railway.
When driving across a river, measure the depth
of the river with bucket, and travel at low speed.
When the surface of water is higher than the top
end of the track roller, don't cross the river. If the machine has already tilted, you should not
jump out of the vehicle! You should fasten the
Reduce the travel speed when driving on rough safety belt firmly, and not put your hand or foot
ground, which will reduce the possibility of out of the cab so as to prevent them from being
damaging the machine. thrown out by the machine and causing serious
Avoid any operations that could damage the injury or death.
track and the chassis.
To avoid slipping, wipe off the snow and ice on
the track shoes before loading and unloading the
machine onto or from the trailer in winter.

The attachment equipped on the machine may
impact and damage the other parts of the
machine during operation. Check the operating
safety distance of the attachment before
operation, and operate it carefully when it gets
closer to the other parts.
You should prevent the boom and bucket from
contacting with any overhead obstacle.
29
Safety Information
Cautions about Machine Operation
When digging down deeply, you should prevent
the bottom of the boom and the hose of bucket
cylinder from bumping against ground. The
bucket is used for digging only, and should not
be used for crushing rock or chiseling holes in
rock. Before digging, you should be aware of the
locations of cables, gas pipes and water pipes,
and mark out the underground utilities.
The contact with electrical wire may cause
accidents, such as injury or death, do not make
any part of the machine close to electrical wire.
Check the area above the machine, and learn
about the exact distance between electrical wire,
machine and ground. If possible, you’d better cut
off the power supply. If it is impossible to cut off
the power supply, you should ask a signaler to
guide you.
If the machine has contacted the high voltage
wire:
● Alert all person to keep away from the
machine.
30
Safety Information
Cautions about Machine Operation

● If you can disconnect the contact point, You should not dig right under the machine.
separate the high voltage wire from the Failure to do so, a collapse may be caused, and
machine and leave. the machine may sink into the ditch dug, causing
accidents.
● If you can not disconnect the contact point,
stay inside the cab until the Electricity
Company cuts off the wire and you are
informed to go out.
● If a fire occurs, hold your feet as close as
possible and jump off the machine without
hands touching ground. Try to jump into a
safe place.
You should avoid operating on a cliff or on a soft
ground where there is a danger of turnover. If
you inevitably have to operate on a cliff or on soft
ground, you should keep the track perpendicular
to the edge of the working area.
When working in a dangerous area, in particular,
operating at the edge of excavation area, you Parking the Machine
should be on your guard specially. You should
make sure that the machine has enough When possible choose flat level ground to park
distance away from it so as to avoid collapse. the machine, apply the parking brake (if
You should not dig under a crag, because the equipped), always lower any attachment to the
collapse of the edge of the crag or landslide may ground and ensure the machine will not move,
cause injury. When operating, you should not let possibly causing damage or injury.
the machine close to hanging objects or the edge Consider any overhead hazards such as the
of material stacks. posibility of falling rocks, any powerlines or any
other overhead hazards that may exist.
Consider the ground conditions. Do not park the
machine near the edge of a cliff, close to an open
excavation or pit.
Consider environmental conditions such as the
posibility of flooding, heavy snow fall, electrical
storms and exposure to wind and cold. Any of
these conditions may cause damage to the
machine.
Do not cause an obstruction, consider the site
access and other emergency conditions the
When operating along river banks, under machine may obstruct.
hanging objects or inside buildings, you should
be cautious of falling rock or earth, and be
cautious of hanging branches and prevent the
danger of collapse.

If it is necessary to park the machine on a slope
or incline, lower the implement to the ground,
engage the parking brake (if equipped). Place
chocks under the tracks at the downhill side on
both sides to prevent the machine from moving.
Understand and obey all regulations relating to
public roads, if the machine is parked on a public
road. Additional signage or lighting may be
required.
Always lower attachments or other equipment
before leaving the machine, apply the parking
brake (If equipped).
Push the pilot shutoff lever to LOCK position (If
equipped).
Engage the parking brake (If equiped).
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 O position
to avoid battery discharge.
When leaving the machine lock all equipment
covers and doors with the key. Remove the key
and keep it with you.
31
Safety Information
Cautions about Machine Maintenance
Lowering the Attachment/ Implement with
Engine Stopped
CAUTION: For a machine controlled by
electro-hydraulically control lever, in order to
lower the implement, the engine start switch
must be on ON position .Turn the engine start
switch to OFF position after lowering the
implement.
In order to lower the implement to the ground or
trailer, move all control levers to DOWN position.
When release them, they will return to HOLD
position.
Store Accessories Safely
Store accessories and tools safely so as to
prevent them from falling and causing serious
injury or death. Keep playful children and
bystanders away from the storage area or any
area accessories are being stored while in use.
Cautions about Machine
Maintenance
Prepare the working area
Choose a clean and flat area with adequate
space, enough light, and good ventilation to carry
out any repair work. Clean the ground surface,
wipe up fuel, lubricating oil and water, and
spread sands or other absorptive materials on
the slippery ground. Keep the work area clean
and dry.
32
Safety Information
Cautions about Machine Maintenance

Support the machine correctly
Lower to the ground or support any attachments
with stands or other methods. Ensure that any
attachment can not move during maintenance or
repair work, use wheel chocks or other devices
to prevent machine movement.
Do not work under any part of the machine or
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use
stands or other measures that are secure and
can support the weight being applied to them.
Transportation information
Obey the appropriate laws that govern the
parameters of the load (weight, length, width,
and height).
Understand the correct procedures for loading
and unloading.
Carry out the loading and unloading operations
on flat ground.
Chock the wheel of the trailer to make it unable
to move.
Put the attachments and the bucket in the right
front of the machine.
Reverse the machine onto the trailer.
Use chains and blocks to secure the machine to
the trailer.
Keep bystanders away.
Place all the working equipment in the
transportation position, secure all the equipment
and attachments or additional equipment with
chains or other secure methods to prevent
accidental movement.
Lift the machine
Refer to the PIN nameplate on the machine for
the operating mass before lifting the machine.
The operating mass on the PIN nameplate does
not include optional attachment.
Use proper rated cables and slings for lifting.
Calculate the maximum load capacity of the
crane and slings to ensure security. Lifting
through foot pedal is prohibited.
Fasten the wire ropes separately into the gaps of
the first two and the last two track rollers.

1. Wedge
2. Block
3. Angle (Max. angle is 15°) Welding operation
4. Distance between the ramps
5. Ramp Any personnel engaging in welding operations
Use loading ramps appropriate for the machine must have occupational certificates and carry out
being moved. Consider: size, strength, departure the operation at a place with appropriate devices
angle and proper height. Make sure that the equipped, When carrying out the welding
loading ramp is anti-slip and free of mud and operation, the personnel must follow the
snow. instructions below:
 33
Safety Information
Cautions about Machine Maintenance

Before carrying out the welding operation, turn When carrying out the cleaning operation, wear
off the battery disconnect switch, disconnect the suitable PPE. Consider exposure to: chemicals,
battery, controllers, GPS and other electrical slippery surfaces, high pressure water spray and
units. material splash.
Remove all paint from the place to be welded, so
as to prevent harmful gas from being produced.
Do not inhale smoke produced buy burning paint.
Never weld pipes, close to rubber hose and
electrical wires.
Always remove residual pressure from the
machine. Never weld pipes that are fitted to the
machine.
Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
of the operation being performed. Do not spray the water directly onto sensors,
connectors or instruments of the electrical
Ensure good ventilation. system. If water enters the electrical system
Remove all the flammable materials, supply the malfunction may occur.
work area with a fire extinguisher.

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.
34
Safety Information
Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically Changed

Key spare parts to be periodically

No. Q'ty Changing intervals
changed
1 Hydraulic oil tank element 1 Every year or 2000 hours (which comes first)
2 Fuse hose (Fuel tank --fuel pre-filter) 1
3 Fuse hose (Fuel pre-filter--fuel lift pump) 1
4 Fuse hose (Fuel lift pump--fuel filter) 1
5 Fuse hose (Fuel filter--high pressure pump) 1
6 Fuse hose (Fuel return hose) 1
7 Return hose of turbocharger 1
8 Hose assembly (Pump--main control valve) 2
9 Hose assembly (Main suction hose) 1
Work equipment pipe (Boom cylinder inlet and Every two years or 4000 hours (which comes
10 4
outlet pipe) first)
Work equipment pipe (Bucket cylinder inlet and
11 2
outlet pipe
Work equipment pipe (Arm cylinder inlet and outlet
12 2
pipe)
13 Attachment hose 4
Swing circuit hose (Swing motor inlet and outlet
14 2
hose)
15 Travel circuit hose (Control valve--swivel joint) 4
16 Travel circuit hose (Swivel joint--travel motor) 4
Every three years or 6000 hours (which
17 Seat belt 3
comes first)

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

Application and
Specification

Application

This machine is applicable for digging and

loading of soil from class I to IV (Soil and rock
can be divided into sixteen classes according to
degree of hardness for digging). This machine
also can be equipped with hoe bucket, shovel
bucket, hydraulic hammer, grab bucket, etc.
This machine 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:

Altitude:≤3048 m
Environmental temperature: -32°C~40°C
Water Depth: Can not exceed the track carrier
roller center wherever the machine works (at
level ground or on slope)

CAUTION: Preventive measures for

operation, maintenance and safety rules
outlined on this manual are only suitable for
the stipulated applications of the machine.
Do not use the machine beyond the
stipulated application scope, Guangxi
Liugong Machinery Co., Ltd will not bear any
safety liability, and these safety liabilities will
be born by users. Under any cases, do not
use the forbidden operation outlined in this
manual.
36
Application and Specification
Main Specifications

Main Specifications

All rated lift capacities specification are collected from the machine operation on a hard and flat ground.
When the machine is operated in conditions that different from the above-mentioned condition (e.g. on
soft or uneven ground, on a slope), these conditions shall be taken into account by the operator.

Exterior Drawing
 37
Application and Specification
Main Specifications

Machine specifications

CLG925LC CLG925LL
Operating mass kg 25500 26000
Standard bucket capacity m3 1.2 0.5
Travel speed (High/Low) km/h 0~5.3, 0~3.1 0~5.3, 0~3.1
Swing speed r/min 11.5 11.5
Gradeability 35° (70%) 35° (70%)
Ground pressure kPa 50.5 52
J: Overall length mm 10200 12650
Overall width mm 3190 3390 (track shoe width 800)
Overall height mm 3200 3390
D: Overall height of cab mm 3050 3050
*H: Counterweight clearance mm 1055 1055
E: Overall width of upper structure mm 2800 2800
*C: Minimum ground clearance mm 440 440
I: Rear end length mm 2960 2960
Rear end swing radius mm 2985 2985
G: Track on ground mm 3840 3840
F: Undercarriage Width mm 4635 4635
A: Track gauge mm 2590 2590
B: Undercarriage Width mm 3190 3390 (track shoe width 800)
38
Application and Specification
Main Specifications

Main components specification

CLG925LC CLG925LL
Model Cummins 6BTAA5.9-C engine
Type 6-cylinders in line, four strokes, turbocharged
Emission Tier II
Type of cooling Water-cooled
Ignition sequence 1-5-3-6-2-4
Cylinder × stroke mm 102 × 120
Cylinder displacement L 5.88
Compression ratio 17.3: 1
Engine Rated power 133kW/2000r/min
Flywheel power 125kW/2000r/min
Maximum torque (1400r/min) N.m 708
Oil volume L 25
Net weight of diesel engine kg 432
Maximum rotating speed (without load) r/min 2290 ± 50
Minimum rotating speed (without load) r/min 950 ± 50
Rated oil consumption g/kW.h 224
Starting motor 24V-7.5kW
Alternator 24V-70A (Bosch)
Main pump Dual axial displacement piston pump
Maximum flow L/min 2 × 230
Relief valve Mpa 31.8
setting Power boost Mpa 34.3
Pressure Boom (head/rod) Mpa 36.3/36.3
setting of
Arm (head/rod) Mpa 35.3/37.2
outlet safety
valve Bucket (head/rod) Mpa 35.3/37.2
Pressure setting of swing motor relief valve Mpa 25.5
Pressure setting of travel motor safety valve Mpa 35.0
Hydraulic
Pilot pump Gear pump
System
Pilot circuit MPa 39
No.-bore × rod diameter ×
Boom mm 2-φ125 × φ90 × 1350
stroke
cylinder
Buffer Extend
No.-bore ×rod diameter ×
mm 1-φ140 × φ105 × 1610
Arm cylinder stroke
Buffer Extend and retract
No.-bore ×rod diameter ×
Bucket mm 1-φ130 × φ90 × 1075 1-φ95 × φ65 × 885
stroke
cylinder
Buffer Extend
 39
Application and Specification
Main Specifications

Work Boom (Standard configuration) mm 6000 8500

Equipment Arm (Standard configuration) mm 2960 6400
Track shoe width mm 600 800
Track pcs 2
Track shoe quantity (each side) 51
Travel Track tensioner pcs 2
System Sprockets pcs 2
Idler pcs 2
Track rollers pcs 9 each
Carrier rollers pcs 2 each
Electrical Voltage V 24
System Battery V 2 × 12
Cooling capacity W 5000
Cool air flow m3/h 550
Heating capacity W 5800
Warm air flow m3/h 400
Air Voltage V.DC 24
Conditioner Total power consumption W ≤310
System Compressor power KW 3.02
Refrigerant R134a
Refill capacity for refrigerant g 950 ± 50
Compressor 10S15C (DENSO compressor)
Cooling oil ND-OIL8 (Oil for DENSO compressor)
40
Application and Specification
Main Specifications

Work Range

Item CLG925LC CLG925LL

Arm length mm 2960 6400
Boom length mm 6000 8500
*A: Maximum cutting height mm 9567 13500
*B: Maximum dumping height mm 6691 11160
*C: Maximum digging depth mm 7015 11850
*E: Maximum vertical digging depth mm 5960 10010
H: Maximum digging radius mm 10265 15710
G: Maximum ground digging radius mm 10070 15560
*D: Maximum leveling depth (2.5m on ground level) mm 6690 11750
F: Minimum swing radius mm 4175 5410
Maximum bucket digging force (ISO) kN 149.8/161.3 (power boost) 89
Maximum arm digging force (ISO) kN 105.6 /113.9 (power boost) 62

Note: The dimensions with* exclude grouser height.

 41
Operation Manual
Before Operation

Operation Manual
Before Operation
Mounting and Dismounting
Before mounting or dismounting the machine,
check the condition of handrails, ladders and
steps. Clean them of grease, lubricants and dirt
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.
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.
Inspect the condition of the work equipment and
the hydraulic components.
Check all of the oil level, all of the coolant level,
and all of the fuel level. For more information,
please refer to "Maintenance Interval Schedule"
on page 90.
Direction
1
5
3 4

6 2

1. Front 2. Rear 3. Left 4. Right 5. Cab

6. Travel motor
The directions of left, right, front and rear in this
manual are determined based on the fact that
Never jump off the machine. the cab is located at front while the travel motor
is located at rear.
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.
42
Operation Manual
Operator Controls and Instrument Panels

Operator Controls and Instru- Turning the disconnect switch to "O" (OFF)
position can turn off the power of the machine.
ment Panels
O I
Battery Disconnect Switch

The battery disconnect switch is located on the

electrical control box on the left side of machine.
Open the left door to get access to it.

Turning the battery disconnect switch off

while the engine is running may damage the
electrical system!

Turn off the disconnect switch after the

machine stops working to avoid electricity
leakage or other accidents. Before welding
the machine, disconnect the connectors of
disconnect switch and instrument, otherwise
the units of the instrument will be burnt out.
Disconnect switch--ON

In this position, the battery disconnect switch key Start Switch

will point to the "I" (ON) position.
The start switch (also called ignition switch),
which is used to start or turn off the engine, is
O I located on the control panel on right side of
driver's seat. It has four positions. See the
following picture.

Turn the battery disconnect switch key clockwise

to "I" (ON) position before you start the engine.

Disconnect switch--OFF

In this position, the battery disconnect switch key

will point to the "O" (OFF) position.

1. PREHEAT——Turn start switch to this
position to preheat the engine. Preheat the
engine in winter.Hold the key until the
monitor light turns on. Then release the key
to let it reset to OFF position. Then turn the
start switch to START position to turn on the
engine.
WARNING: Do not exceed 15 seconds
when preheating the engine, otherwise the
battery will be consumed easily, which will
result in electricity insufficiency.
2. OFF——At this position, all of the electrical
appliances are turned off except for the dome
light.
WARNING: Only insert or take out the
start switch key from this position!
3. ON——At this position, the electrical circuit is
energized.
4. START——The engine will start at this
position. Release the start switch key at this
position, then the key will reset to ON
position automatically.
43
Operation Manual
Operator Controls and Instrument Panels
CAUTION: The battery disconnect
switch must be at “I” position, the pilot
shutoff lever must be at LOCK position, other
control levers and pedals must be in neutral
before starting the engine.
If the engine fails to start, turn the start
switch to the OFF position before restarting
or the start switch could be damaged!
Do not engage the start switch for more than
10 seconds at one time. Wait at least 30s
before restarting. Do not exceed three time
consecutive attempts before allowing the
start motor and choke solenoid to cool down.
Failure to comply could result in a reduction
of the service life of the battery as well as
damage to the start motor and solenoid.
Difference between start switch and
disconnect switch:
Turning off the disconnect switch can turn off the
electrical system at the same time. However,
turning off the start switch can only disconnect
some parts of appliances, the battery is still
connected with the machine, so some parts of
appliances can still work.
44
Operation Manual
Operator Controls and Instrument Panels

Operator Controls Push the pilot shutoff lever to lock the pilot
function. Then the hand control lever and travel
control lever will be locked and the work
implement, travel motor and swing motor will not
2 3 4 5 6 7 work.

A. LOCK

CAUTION: Push the pilot shutoff lever to

1. Pilot shutoff lever LOCK position after stopping the machine or
2. Left control lever/horn button
3. Left travel pedal leaving the cab, otherwise serious injury
4. Left travel control lever could result.
5. Right travel control lever
6. Right travel pedal
7. Right hand control lever/power boost button

Pilot Shutoff Lever To prevent the machine moving accidentally,

Pilot shutoff lever controls the oil flows to pilot
valve. The machine can not move even the
control lever is operated or the accelerator pedal
is depressed down when the pilot shutoff lever is
at LOCK position.
make sure the pilot shutoff lever is at LOCK
position when leaving the cab. Before
starting the engine, push the pilot shutoff
lever to LOCK position, otherwise the engine
could not be started.
 45
Operation Manual
Operator Controls and Instrument Panels

Push the pilot shutoff lever to unlock the pilot
function. Then the hand control lever and travel
control lever can be operated and the work
implement, travel motor and swing motor can
work normally.
Arm Control
Push the left control lever forward and backward
to operate the arm out or arm in.

B. UNLOCK

Hand Control Lever Swing Control

CAUTION: Be familiar with every Push the left control lever left and right to operate
controls's position and function before the upper structure to swing left and swing right.
operating. Keep your body inside the cab. If
not, the control lever could be operated by
your body accidentally and you will get
hurted by the boom. If the window gets lost
or damaged, replace it immediately.

The left control lever is used to control the arm

operation and swing operation. After being
released, the control lever will reset to the
NEUTRAL position and the arm/swing
mechanism will stop moving.

3 4
2

1. Arm out
2. Arm in
3. Swing left
4. Swing right
46
Operation Manual
Operator Controls and Instrument Panels

The right control lever is used to control the Bucket Control

boom operation and bucket operation. After
being released, the control lever will reset to Push the right control lever left or right to operate
NEUTRAL position automatically, and the boom the bucket in or out.
and bucket will stop moving.

7 8
6

Operating the control lever within 15 seconds

5. Boom down after the engine is shut down can lower the work
6. Boom up implement onto ground.
7. Bucket in
8. Bucket out Operate the hand control lever to release the
residual pressure in the hydraulic lines and lower
Boom Control the boom onto the truck bed before
transportation.
Push the right control lever forward or backwards
to operate the boom to lower or raise.

Pay attention to the control lever when

operating it under idling state because the
engine speed will raise suddenly.

Operate the control lever quickly, the work

implement will move quickly; vice versa.

Horn Button
The horn button is located at the top of the left
hand control lever. Press the button to sound the
horn.
Travel Control Lever and Travel Pedal
4 5
3 6
The left and right travel control lever(4),(5) and
left and right travel pedal (3),(6) are used to
control the travel direction of the machine.
See the following instructions of travel control
lever operation:
Push the travel control lever forward (direction
a), the machine will travel forward;
Push the travel control lever backwards
(direction b), the machine will travel backwards;
47
Operation Manual
Operator Controls and Instrument Panels
When the travel control lever is at NEUTRAL (N)
position, the machine will stop travelling.
a
a
b
b
a
a
b
b
Do not step on the pedals unless you intend
to drive the machine, othewise a serious
accident could result due to sudden
movement of the machine which is caused by
an unintended start.
When the track frame is at rear, the machine
will run to the opposite direction of the travel
control lever.
Before operating the travel control lever,
check the track frame direction.(Track frame
points forward when the sprocket is at rear)
Be extremely carefuel when operating the
travel pedal.
See the following instructions of travel pedal
operation:
Depress the pedal forward(direction a), the
machine will travel forward;
48
Operation Manual
Operator Controls and Instrument Panels

Depress the pedal backwards (direction b), the Switch Box

machine will travel backwards;
When the travel pedal is at NEUTRAL (N)
position, the machine will stop travelling.

Power Boost Button

The power boost button is located at the end of

the right hand control lever. It is used for dealing
with big load. Pressing this button, a power boost 1 2 3 4 5
symbol will be shown in the display and the
power will be increased by 7.9% which lasts for 8
1. Travel speed switch
seconds. Wait for 10 seconds before reuse this 2. Work light switch
function. Use the power boost function based on 3. Auto idling switch
the work mode. Do not use this function for lifting 4. Manual idling switch
purpose. 5. Travel alarm mute switch

1.Travel speed switch

Normally, low speed is defaulted with

“tortoise” indicator turns on. Pressing
this key can change to high speed, then “rabbit”
indicator turns on and “tortoise” indicator goes
out. Pressing the button again to return to low
speed, then “tortoise” indicator turns on and
“rabbit” indicator goes out.

CAUTION: Select low travel speed and

Instrument Panel and Radio cancel the auto idling function when the
machine is getting on/off a trailer or running
on a narrow road surface.
1 2 3
2.Work light switch

This switch controls the boom light and

the frame light. See the following for
the details.
a. Press the switch, the left indicator turns on
and the frame light turns on too.
4 5 6 b. Press the switch again, the right indicator
turns on, the left indicator goes out. Then
boom light turns on and frame light turns off.
1. Switch box
2. A/C panel c. Press the switch for the third time, the left
3. Radio and right indicator turn on and both the frame
4. Throttle switch and start switch light and boom light turn on too.
5. Switch assembly
6. Spare switch d. Press the switch for the fourth time, the left
and right indicators go out and both frame
light and boom light turn off.

3.Auto idling switch
This switch is used to turn on or turn off
the automatic idling function of the
system. If the engine speed is set between 3~5
position, push all of the control levers to Neutral
position for about 5 seconds, then the engine
speed will be decreased to 1000r/min to save
fuel and reduce the noise.
When the automatic idling switch is turned on,
the automatic idling symbol will be shown in the
display.
At automatic idling state, the engine can return to
the previous speed by carrying the following
operations.
(a) Operate the travel control lever or hand
control lever.
(b) Turn off the auto idling switch.
WARNING: When the machine is getting
on/off the trailer or works in a narrow space,
turn off the auto idling switch in order to
avoid personal injury or death caused by
sudden movement of the machine.
4.Manual idling switch
Press this switch, the indicator will turn
on and the engine speed will lower to
800r/min immediately. Press this switch again,
the indicator goes out and the engine returns to
the pre-set speed.
In default state, the indicator is off. But it has no
effect on the engine speed.
5.Travel alarm mute switch
Travel alarm is actuating when the
machine is traveling. When the
machine is running, the travel alarm sends out a
signal then the buzzer sounds. If the travel alarm
mute switch is turned on, the machine will stop
alarming. However, after the machine stops
running, the system returns to defaulted state
and the travel alarm will work again when the
machine is running.
49
Operation Manual
Operator Controls and Instrument Panels
A/C Panel
Refer to "A/C Panel" on page 58 for more
information.
Radio
Refer to Radio Manual for the operations
instructions.
Throttle Switch
There are 10 positions in this switch. Rotate it
clockwise; the engine speed will increase; rotate
it counterclockwise, the engine speed will
reduce. The 1st and 2nd position is for a spare.
These two positions are set for idling speed at
the factory. When the machine is working, the
current position is shown in the LED display.
Position Explanation
1st~2nd Idling
3rd ~4th Light-loaded operation
Engine speed increases gradually,
suitable for different working
5th~9th
conditions. 6th position is specially
suitable for hydraulic hammer.
Full power at this position. Idling
speed is 2150r/min.
At this position, the engine output
10 th power is matched to the hydraulic
system power and is controlled by
CAPC system according to the work
load.
WARNING: Before starting the engine,
make sure that the throttle switch is at low
speed, otherwise the engine components will
be damaged.
50
Operation Manual
Operator Controls and Instrument Panels
Switch Assembly
1 2
1. Wiper switch
2. Washer switch
Wiper switch
This switch controls the wiper. Three
positions are available: OFF, high
speed and low speed. OFF is default.
Washer switch
This switch controls the washer. Press
this switch, the water will be ejected
front the nozzle, release it, the washer will stop
working.
Spare Switches
1 2
1. Standard/emergency system switch
2. Spare throttle switch
1. Standard/emergency system switch
The electrical system can be shifted to “standard
system” or “emergency system” by using this
switch.
Under standard system, the engine speed is
controlled by the controller. In this system,
automatic idling function, manual idling function,
10 positions for engine speed, hydraulic absorb
power matches engine output power function are
available.
Under emergency system, the engine is not
controlled by the controller. In this system,
automatic idling function, manual idling function,
10 positions for engine speed are not available.
Engine rotating speed is controlled by the
standby accelerator switch.
2. Spare throttle switch
When emergency system mode is selected,
adjust this spare throttle switch to increase or
decrease engine speed. When the system is
shifted to standard system mode, this switch will
fail to work.
Lighter
2
1
1. Lighter
2. Display
Pressing the lighter button can start the lighter.
When the lighter is ready for use, the button will
be slightly sprung up.
To place the lighter properly after used, push it
into the holder until it aligns with the outer edge
of the holder.
Holder of the lighter is a terminal of DC 24V. The
maximum current is 10A. The holder is also
applicable to other adapters.
 51
Operation Manual
Operator Controls and Instrument Panels

Display Fuel level gauge

This gauge is used to indicate the fuel

This display is mainly made up of warning
indicators, LCD screen and keyboard. See the
following picture.
1
level.
Green indicates a good working state and red
indicates the fuel level is too low. Refill the fuel
immediately if the fuel level is too low.
Engine coolant temperature gauge

2 This gauge is used to indicate the

coolant temperature. Green indicates a
good working state and red indicates the coolant
temperature is too high.
3
CAUTION: When the coolant
temperature alert symbol and the red warning
indicator is flashing, park the machine at a
1. Warning indicators
2. Instrument symbols and display safe place for checking. Check the cooling
3. Keyboard fan, coolant level and engine belt. Do not go
on working until the trouble is eliminated.
Warning Indicators
WARNING: When checking the cooling
These three warning indicators are provided for fan, coolant level and engine belt, pay
spare use. attention to the high temperature and moving
parts to prevent scalded and getting hurt.
Display Interface
Service hour meter
3 4
To show the service hours of the
5 machine. For example, 10001.0H
2 6 shows that the machine worked for 10001.0
hours.
7
8 A flashing symbol of the service hour indicates
9 that the system is timing.
1
10
System voltage
11
The normal voltage for the machine is
1. Fuel level gauge 18V~32V.
2. Coolant temperature gauge
3. Service hour meter Engine speed setting
4. System voltage
5. Engine speed setting
6. Anti-overload mode (Optional) Indicates the current position of engine. There
7. Travel speed setting are 10 positions from position 1 ~10 available for
8. Power boost (Only for CLG916D) use.
9. Auto idling/manual idling
10.Lifting mode (Optional)
11.Date and warning massage
52
Operation Manual
Operator Controls and Instrument Panels

Anti-overload mode (Optional) Date/warning massage

White symbol will show when the anti- Date will be shown if no warning message
overload mode is selected without occurs.
overloading the machine. Red symbol will show
and flash when this mode is selected and the
machine is overloaded. No symbol appears
when this mode is cancelled.

Travel speed setting

To show the current travel speed.

Tortoise symbol indicates the machine
travels at low speed.

Rabbit symbol indicates the machine

travels at high speed. But when there is a warning, warning message
will then be displayed and the warning symbol is
flashing. The warning message is rolling per five
Power boost (Only for CLG916D) seconds if there are multiple warning messages.

Indicates the power boost function is being used.

Not shown when the moment power function is
cancelled.

Auto idling/manual idling

This symbol indicates the auto idling

function is selected.

This symbol indicates the manual

idling function is selected.

Lifting mode (Optional)

This symbol indicates that the machine

is in lifting mode status. This symbol
will disappear if lifting mode is not selected.
 53
Operation Manual
Operator Controls and Instrument Panels

Keyboard (8)RIGHT key. Press this key to

There are 8 keys on the keyboard, which are
used to input information into the electronic
monitor system.
4 5
3 6
move the cursor to the right.
NOTICE: Press return key to return back
to last menu. Press the direction key for a
long time to increase or decrease value
quickly or to scroll the screen.
Menu of the Display

2 7 Under normal conditions, press the Menu key

to enter into main menu display interface.
1 8

(1)DOWN key. Press this key to

move the cursor downwards or to
decrease the numerical value.

(2) LEFT key. Press this key to

move the cursor to the left.

(3)MUTE key. Press this key to

cancel the alarm sound. Press it Press up key or down key to select a
again, the alarm sound will be work menu item, and then press OK key for detail of
again. the selected item or go for second menu.
(4)UP key. Press this key to move
the cursor upwards or to increase
the numerical value.

(5)MENU key. Press this key to

enter the main menu.

(6)RETURN key. Press this key to

cancel the current selection or
parameter setting.

(7)OK key. Press this key to enter

into the selected menu or to store
parameter value.
54
Operation Manual
Operator Controls and Instrument Panels

System set 1. Adjust Time

Select ''Adjust Time'' to set the time as required
Select ''system set'' and press OK key to enter
and press OK key to store the setting and return
into system set interface. Press UP and DOWN
to the last menu.
key to select the four items in this interface.
Press OK key to go into the second menu.
Parameter Set, Manufacturer Set and Monitor
Set are used for adjustment before leaving the
factory.

2. Select Language
Select ''Select Language'' and press the up or
down key to select the menu item and press OK
key to store the setting and return to the last
menu..
General Set

Select ''General Set'' and press OK key to go into

the second menu. See following picture.

3. Adjust Display
Select '' Adjust Display'' and press the left or right
key to change the value. Press OK key after
setting is finished and return to the last menu

4. Stage Timer Set
Select '' Stage Timer Set'' and press OK key to
enter into the password interface. Input the
password and enter ''State Timer Set'' menu, if
wrong password is used, system will return to
last menu.
Enter menu of "Stage Timer Set", press up or
down key to select "Start Stage Timer" or "Stop
Stage Timer". Then, press OK key to store the
setting.
Stage timer starts from 0 in the main interface,
the service hours will be hidden and the stage
timer will be displayed as XXXX:X. It indicates
the total working time of the machine during the
course of the stage timer. In main interface,
Service hours and stage timer can be switched
by pressing up or down key. Press " Stop Stage
Timer" and press OK key, the machine will stop
stage timer.
55
Operation Manual
Operator Controls and Instrument Panels
5. Select RPM
Select RPM at general set status and then press
OK key to enter password interface. The
password is 29992569. The system will go to
“RPM Select” after being tested. If wrong
password is entered, the system will return to
the former menu. “Coolant temperature”, “PRV
current” and “Engine speed” will be shown in
“RPM Select” interface. Choose them if
necessary and their detailed information will be
shown in “System set” status. If the monitor is
powered off, the three items will not show in
“System set” status after the monitor is started
again.
6. Engine Speed Set
This function is only used when testing a new
machine or when it needs to adjust the engine
speed. Before starting the machine, press up or
down key to select "Engine Speed Set" and then
press OK key. Input the password to enter into
Password interface.
If the password is incorrent, the system will
return to initial interface directly. If the password
is correct, the system will go for next interface.
56
Operation Manual
Operator Controls and Instrument Panels
The controller will respond after it receives the
engine speed set requirement and the system
will automatically change to the next interface.
If there is no response from the controller within
10 seconds, the following interface will appear.
This interface can not exit for entering into next
interface unless the controller sends out engine
speed set data. In this process, the controller
keeps sending data to the display and 55%
indicates its' status in the process.
If engine speed set process is finished, restart
the machine. No keys will work at this time.
If engine speed set fails, the system will enter
into the next interface within 10 minutes.
Engine speed set is finished when the above two
interface appears. No keys will work at this time
and wait to restart the engine.
Parameter set
Input password when setting the parameter. This
parameter password is just for the service
personnel and personnel to adjust the
parameters before leaving the factory.
Manufacturer set
This setting is carried out by the manufacturer to
input system parameters or data.

Using info
Select ''Using Info'' in the main menu and press
OK key to enter into the following interface.
Machine details can be viewed from the following
interface.
1. Error Logged
Select error logged item in this ''using info'' menu
and enter into the following interface.
View more error information by selecting up and
down key. Press OK key to view the information
of error. For example: Hydraulic oil overheat.
57
Operation Manual
Operator Controls and Instrument Panels
CAUTION: Warning indication will show
when the fuel level is below 10% and when
machine comes to maintenance intervals.
This is not an error and will not be logged by
the system.
2. Machine Information
See the following interface for the machine
information.
3. Monitor Information
See the following interface for the monitor
information.
System status
Select ''System Status'' in main menu. Input the
password 29992569 to enter into the following
interface. If wrong password is input, the system
will go back to the former menu. Different
monitors show different system status.
58
Operation Manual
Operator Controls and Instrument Panels

In defaulted state, the system will not show 1. Loosen the bolt at the back of the display.
“Coolant temperature”, “PRV current” and
“Engine speed”. If necessary, enter into “RPM
Select” to choose the three items and store them
before exit. The chosen items will be shown after
entering the “System set” again with the monitor
always powered on.

2. Then adjust the display to desired angle.

3. Tighten the bolt.

A/C Panel

1 2 3 4 5

Maintenance information

Select ''Maintenance Info'' in the main menu,

press OK key to enter into the following interface.
All of the maintenance interval items can be
viewed through the submenu of this interface.
9 8 7 6

1. OFF switch
2. Fan speed setting switch
3. Temperature setting switch
4. Air outlet mode setting switch
5. AUTO mode setting switch
6. COOL mode switch
7. LCD screen
8. Fresh air switch
9. Recirculating air switch

OFF switch
Display-Adjust
It's used to start or stop the fan and air
conditioner. Press OFF switch, setting
Adjust the display angle so that it can meet the
temperature and air speed symbol will disappear
need of different operators.
from LCD screen. Indicators of AUTO mode
setting switch and COOL mode switch are off.
The air conditioning system will stop running.
 59
Operation Manual
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Fan speed setting switch Air outlet mode setting switch

To set air volume to the cab from the air To set air outlet mode. Under normal
conditioner. working condition, press the setting switch
(MODE) of air outlet mode to change over the air
Pressing “∧” switch increases setting air
outlet mode. LCD screen will display the change-
volume, pressing “ ∨ ” switch reduces setting air
over. The air outlet mode is automatically
volume. The air volume automatically is changed
changed over at auto mode.
over at auto mode.
Air outlet position
Symbol Fan speed

Low

Medium

High

Temperature setting switch

To set temperature in the cab.

The temperature is set between 18°to Air outlet Air outlet
32°. Pressing “ ∧ ” switch increases Symbol
mode position
temperature by 0.5°C, pressing “∨” switch drops
temperature by 0.5°C. Commonly the service Front air outlet D
Front and rear air and E
temperature is 25°.
outlet and air
Rear air outlet A
Press the switch for long time, the temperature outlet under the
seat Air outlet under
set will change to the maximum or the minimum.
the seat B
Front air outlet D
Front and rear air and E
outlet
Rear air outlet A

Front air outlet D

**Front air outlet
and E

Air outlet under Air outlet under

the seat the seat B
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Operation Manual
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Air outlet under Under normal working condition, press this

** Air outlet under
the seat and the seat B switch, the air conditioner starts to work in the
defroster air manual COOL mode. Press this switch again,
Defroster air
outlet outlet C
the air conditioner will work in the fan mode.

LCD screen
**Defroster air Defroster air
outlet outlet C LCD screen shows the cab
temperature outside and inside, the
setting temperature, air volume and modes etc.
Note: ** indicates this item does work at AUTO mode.
when the air conditioner runs. And it also shows
AUTO mode setting switch the fault alarming and codes.
After pressing OFF switch, the setting
To change manual mode to AUTO temperature, air volume and air outlet disappear
mode. on the screen, the air conditioner stops running.
Under normal working condition, press the
switch, the indicator of the switch is turned on Fresh air switch
and AUTO mode will be selected.
Press the switch, the indicator of the
From AUTO mode to manual mode, only use switch is turned on and the fresh air
switches to set air volume, air outlet mode and mode works. Open the fresh air outlet to let fresh
fresh and recalculating mode again, the light on air come in the cab. This function is suitable for
the top of the AUTO mode setting switch is off. air exchange and defrosting.

COOL mode switch Recirculating air switch

To select the manual COOL mode or Press the switch, the indicator of the
fan mode. switch is turned on and the
recirculating mode works.Then the fresh air
outlet is closed, and air recirculates inside the
cab. This function is suitable for quick cooling,
heating or when the outside air is dirty.

Display explaining

DISPLAY Screen

Display screen could display all the information such as

temp. fan speed, fan mode, error, etc
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Operation Manual
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Display explaining

AUTO Mode Display

Press , the indicator turns on and the system shows

the auto mode. The display shows the work condition of the
system simultaneously.

COOL Mode Display

Press A/C switch, the indicator turns on and the cool mode
works.

Warm Mode Display

Press A/C switch, the indicator turns on and the warm mode
works when the inlet temperature is lower or equal to the set
temperature -2°C.

Fan Mode Display

Press A/C switch again, the indicator turns off and the fan
mode works.
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Operation Manual
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Display explaining

Fresh Air Mode Display

In fresh air mode, press the switch, the indicator turns on

and the fresh air mode works.

Recirculating Mode Display

In recirculating mode, press the switch, the indicator turns

on and the recirculating mode works.

DEF Mode Display

Press circularly, ''A'' will light and DEF mode works.

Air Flow Mode Display

Press circularly, ''A'' will display the mode of air flow.

A
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Operation Manual
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Display explaining

Fan Speed Display

Under any modes, ''A'' will display the fan speed.

A

Temp Display

In normal working state, ''A'' displays the setting

temperature 18°C~32°C. If error occurs, it will change to
display the error code.
A

Error Display

A ''A'' will display if there is an error in the system.

Air conditioner starting NOTICE: In cold weather, in order to

Press the auto mode switch or the fan speed
switch to start the air conditioner when the power
and engine turn on. Press the OFF key to turn off
air conditioner power. The air conditioner will turn
off.
avoid the refrigerant leak, keep air
conditioner and air compressor working for
20 minutes per week. This helps to keep the
air compressor working best.
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Operation Manual
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Auto function explaining Under WARM mode, the user can set the inside
temperature and fan speed. The system will
Under AUTO mode, the user can set the inside compare the actual temperature and the set
temperature and fan speed. Meanwhile, the temperature and the LCD screen will show the
system will judge whether the temperature status of the modes.
reaches the defrosting temperature so as to
When the air inlet temperature is 2°C≤ set
open or close the cooling function automatically
temperature, WARM mode is selected, when the
by comparing the actual temperature and the set
air inlet temperature is above the set
temperature. The LCD screen will show the
temperature, only natural air comes out.
status of the modes.
When the air inlet temperature is 2°C higher or Warm air operation
above than the set temperature, cool air comes
out; when the air inlet temperature is lower than The heating function of the air conditioning
the set temperature, natural air comes out. system can be realized by the coolant flows
through the warm air radiator of the air
Under COOL mode, when defrosting
conditioning system to release heat.
temperature is lower than 2°C, defrosting mode
works automatically and cooling stops; when
NOTICE: If it is necessary to repair the
defrosting temperature is higher than 4°C,
air conditioning system due to fault, use
defrosting mode stops automatically.
special tool to cover the air conditioner water
When the air inlet temperature is 2°C lower or outlet on the engine or collect the coolant
than the set temperature, warm air comes out; with a container to avoid coolant loss.
when the air inlet temperature is higher than the
set temperature, natural air comes out. NOTICE: When replacing the engine
coolant, drain out the coolant in the warm air
Manual cool function explaining radiator before replacing. Make sure the
engine coolant level is correct.
Press the COOL mode switch, the indicator turns
on and the system starts cooling.
Under COOL mode, the user can set the inside
temperature and fan speed. Meanwhile, the
The water radiator should be emptied or filled
system will judge whether the temperature
with antifreeze when the ambient temperature
reaches the defrosting temperature so as to
is below 0°C and the engine stops running,
open or close the cooling function automatically
otherwise the radiator lines will be damaged
by comparing the actual temperature and the set
by being frozen.
temperature. The LCD screen will show the
status of the modes.
Memo function
When the air inlet temperature is 2°C≤ set
temperature, only natural air comes out, when
When restart the machine, it would come back
the air inlet temperature is above the set
the last set automatically.
temperature, the system will start cooling.
Self-diagnosis function
Manual warm function explaining
The air conditioner controller can diagnose
Press the COOL mode switch, when the air inlet
trouble for every sensor and unit that is used in
temperature is 3°C ≤setting temperature, the
air conditioning system.
system starts warming.
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Operation Manual
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1. Press OFF switch, the setting temperature, Rearview Mirrors

air volume and air outlet mode disappears,
the air conditioner stops running.
Before operating the machine, adjust the
2. Simultaneously press the control button “ ∧ ” rearview mirrors and make sure the driver has a
& “ ∨ ”on the temperature setting switch for 3 good rear view when sitting on the seat.
seconds, trouble codes will show on the LCD
screen.
1
Trouble code information

Trouble code Description 2

E-- No trouble
Broken wire of the internal air
E11
sensor
Short circuit of internal air
E12
sensor
Broken wire of water
E15
temperature sensor Adjustment of rearview mirrors
Short circuit of water
E16
temperature sensor Loosen the bolt 1 that connected to rearview
E18 Short circuit of sunlight sensor mirror bracket 2, turn the rearview mirror bracket
E43 Abnormal air outlet to adjust the mirror to a desired angle.
E44 Air mixture, air door is abnormal After completing the above-mentioned
adjustment, tighten the bolt 1.
3. As for the newly-installed air conditioner or
one that has been eliminated trouble, set the
data again and press the fresh air and
recirculate air switch simultaneously for 3
seconds to cancel trouble code.

Abnormal use will result in damage and

invalidation of air conditioner system.

Air conditioner can not be repaired by users

themselves. If you need to repair it, connect
your Liugong dealer directly.

Although the internal circuit of air

conditioner system is damp-proof, do not
clean it by water or liquid detergent, or the
system will not work.
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Operation Manual
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Mechanical Suspension Seat Fore-and-aft adjustment

Fore-and-aft adjustment max. 110mm.

Armrest angle adjustment (Optional)

CAUTION: The seat provided on this Height and angle of the armrest is adjustable.
machine meets the standard of ISO7096. The armrest angle is 40°.

This is a seat which is featuring in mechanical

suspension and hydraulic shock absorption. It
can be adjusted in the aspects of fore-and-aft
direction, height, backrest angle, seat tilting
angle, armrest angle (optional), suspension
stroke, headrest angle and weight to meet the
need of different drivers in various working
conditions.
Make sure that the operator can depress down
the pedal to a full stroke after adjusting the seat.
Always adjust the seat by sitting in it.
CAUTION: The maximum supporting
CAUTION: In order to avoid accidents,
capacity of the armrest is 50kg.
never adjust the seat during operation.

NOTICE: Adjust the seat before

operating or after replacing a driver, so that
the driver can operate the control levers and
switches conveniently.
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Operation Manual
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Document box Nonretractable seatbelt

Headrest Weight adjustment and shock absorbing

function

Adjust according to the operator's weight. Weight

adjustment is infinite from 50 kg to130 kg.

NOTICE: Before removing the headrest,

first raise the headrest and take off the spring
under the bush cover.
3-Step height adjustment by lifting the seat
Backrest angle adjustment
top
Adjust the backrest angle according to the need
Adjust the seat height according to operator's
of the driver.
height or operating habit. Three increments are
available.
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Operation Manual
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Pneumatic Suspension Seat
(Optional)
NOTICE: The seat provided on this
machine meets the standard of ISO7096.
This seat features a pneumatic suspension and
automatic weight adjustment.
The pneumatic suspension seat realizes the
suspension and shock absorption function
through charged by a suspended air compressor.
The air compressor can charge automatically
when the power is turned on. The socket is
located behind of the seat.The rated voltage of
the air compressor is 24V.
Observe the following instructions when
charging:
1. Turn on the power and operate the
suspension handle, the seat can suspend
smoothly.
2. Start the machine if the suspension function
is under normal condition.
3. Shut down the machine; disconnect the
power socket or turn the battery disconnect
switch to O position to stop charging air.
NOTICE: The pneumatic suspension
function can only last for a short period after
charged. In order to ensure the normal use of
the suspension function, the operator should
check whether the seat has been powered on
before starting the engine.
The adjustment methods of pneumatic
suspension seat and mechanical suspension
seat are basically the same. The operator can
adjust the seat suspension infinitely with a
suspension stroke of 100mm and height of
80mm.
Seat Belt
This seat belt is provided based on customer's
need. Fasten the seat belt before operating the
machine. Before using the seat belt, check the
seat belt for worn condition and tightness,
replace if necessary.
Adjust length of the seat belt before using in
order to ensure safety and comfortability. Length
of the seat belt can be adjusted by moving
position of catch on the safety belt.
Replace the seatbelt every three years. Every
seat belt is provided with a date, replace the seat
belt according to the date label attached.
The seatbelt consists of catch and buckle. Insert
catch of the safety belt into the buckle to lock it.
A cover plate is provided on the buckle. Press
the cover plate, the catch will be released from
the buckle.
Before using the seat belt, check whether the
buckle of the seat belt can lock and release
normally.

Door Lock
See the following picture for the door lock
position.
Insert the key and rotate it clockwise for 180
degrees then take it out. Push the lock with your
thumb, then open the door by pulling the door
outward.
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,
the lock can't be pressed.
Latch and Latch Handle
Latch
When opening door to 180 degrees, the latch on
the door is stopped by the buckle behind and the
door will be fixed in that position.
1
2 ●
1. Latch
2. Buckle
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Operation Manual
Operator Controls and Instrument Panels
Latch Handle
The latch handle is located at the lower side of
the doorpost. At lock state, push the handle
downwards to unlock the latch, then close the
door.
1. Latch handle
CAUTION: Before the driver operates the
machine, close the door first to ensure safety.
Quick Coupler(Optional)
Wrong installation to the accessories and
options will result in unsafe operation and
reduction of the machine service life.
The customer can choose a machine that is
equipped with quick coupler lines or with quick
coupler equipment. Also, the customer can do
the coupler for the machine by himself if he gets
the proper sizes and proper procedures from the
dealer.
● The quick coupler lines are controlled
through the start switch.
A safety pin should be installed if the quick
coupler is equipped with work equipment
such as bucket, hammer and so on when the
machine is working.
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Operation Manual
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Hydraulic Hammer(Optional) Proper Position

Proper position must be applied for an effective

The size of the hydraulic hammer must match usage of breaking force. When position is
with the machine. Consult the excavator incorrect, hammering energy of the piston is too
manufacturer beforehand so as to prevent the weak to break rocks. Instead, hammering force
hydraulic hammer and excavator from being applies shocks to the hammer body, hammer,
damaged. arm and boom of the base machine, thereby
● To install the hydraulic hammer properly and resulting in damage to those parts.
safely, it is recommended to install the
hammer by the excavator manufacturer or
excavator dealer.
● Refer to the Operator's Manual of Hydraulic
Hammer.

The installation and testing must be carried

out by qualified and trained personnel.
Strictly follow the hydraulic hammer
operation manual to operate and maintain it.
Use protective devices for the operator to
prevent objects or debris flying out to hurt
the operator when working.
It is prohibited to operate the hammer with a
passerby nearby, to prevent objects or debris
flying out to hurt the passerby.
On the contrary, when position is excessive
enough to break rocks with the front of the base
machine raised, the machine may suddenly tilt
forward at the moment when rocks are broken.
Then, the breaker body or the end of bracket
may violently hit against rocks and result in
damage.

Wear protective googles, respirator, earcap

and helmet and so on when operating the
hammer.

The hammer can only be used within the

specific areas. Do not exceed the specific
areas, otherwise personal injury and death
could result.

The hammer is under hot temperature after

use. Do not touch it until it cools down.

Avoid the above-mentioned operation as much
as possible because improper hammering will
cause vibration transmitted to the base machine.
Therefore, make sure the position is correct
before hammering. Check and maintain the
hammer periodically when the hammer is not
used.
Position Direction
● The position direction of the hydraulic
hammer rod should be vertical to the surface
of hammering and try to maintain that as
much as possible.
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Operation Manual
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● If the hammering surface is oblique, the rod
may slip during hammering. This causes the
rod to be broken and piston to be damaged.
Before hammering, choose the proper position
point and make sure that the rod is secured and
stable.
Cautions for Safe Operation
1. After the hydraulic hammer is installed and
lines are connected, turn the two stop valves
of the hydraulic lines to position A(calibration
on the stop valve knob parallell with the axis
line of the stop valve)to connect the oil path.
2
B
1. Stop valve position
2. Stop valve
A. Stop valve OPEN
B. Stop valve CLOSE
72
Operation Manual
Operator Controls and Instrument Panels

2. If the high pressure and low pressure hose of 6. Do not shake the rod when hammering to
the hammer is too loose, stop immediately to avoid damaging the bolt and rod.
check and repair. To ensure safety, also
check for leakage at the same time.
3. Pay special attention when hammering. Keep
the hammer within sight.

7. Do not hammer for more than 1 minute.

Change the hammer position if the
hammering surface can not break within 1
4. Stop hammering immediately if the rocks minute.
have been crushed to avoid blank
hammering. Blank hammering will cause
damage to the machine.
5. Do not move rock with the hammer because
that will result in break to the moutning bolt or
bracket, rod ,arm and boom , even make the
boom cracks.

CAUTION: The rod could wear and tear

easily if the rod continues to hammer in one
point.

8. As for a big rock or large hammering surface,

hammer it from the edge.

9. Operate the hammer at 6th engine speed.
Raising engine speed more than necessary
does not strengthen hammering force but
increases oil temperature that affects the
lubrication ability and performance and
brings damage to the hammer and machine.
10. Do not operate the hammer in water and
mud. Any part of the hammer is prohibited to
work in water and mud except for the rod,
otherwise the hammer will be worn and torn
quickly.
11. Do not allow the hammer to fall to a rock.
Dropping the hammer will produce excessive
force to the hammer or the excavator,
causing damage to the parts of the hammer
or excavator.
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Operation Manual
Engine Starting
12. Do not operate at the stroke end of the work
cylinder because that will lead to damage to
the cylinders and other parts of the
excavator.
13. Do not lift things with the hammer. It will
cause damage to the hammer and is very
dangerous.
14. Warm up the machine for ten minutes before
a breaking operation, especially in winter.
Engine Starting
Check Before Starting the Engine
● Check engine coolant level.
● Check the engine oil level.
● Check the hydraulic oil level.
● Check the seal condition of each oil pipe,
water pipe and fuel hose.
● Check the battery for worn wires and loose
connectors.
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Operation Manual
Engine Starting

WARNING: Before starting the engine, 4. Make sure the pilot shutoff lever is at LOCK
Clear personnel around the machine. Clear position. If not, turn the lever to the LOCK
away any obstacles. Make sure the machine position.
is under controlled by the operator.

Engine Starting

1. Turn on the battery disconnect switch. After

the battery disconnect switch is turned on,
the key will point to I position.

CAUTION: Before starting, make sure

that the pilot shutoff lever is at LOCK
position, otherwise the engine can not be
started.

2. Mount and dismount the machine according 5. Check whether the hand control lever 2 and
to the safety regulations. travel control lever 3 is at NEUTRAL position.
If not, push them to NEUTRAL position.

2 3 3 2

3. Close the door of the cab. Check the seat

belt for normal condition and fasten it.

WARNING: Start the engine only when

the travel control lever 3 is at NEUTRAL
position to avoid accident caused by sudden
movement of the machine.

6. Turn the start switch to ON position to turn on
the power. Sound the horn to warn that the
machine is going to run.
7. During severely cold weather, preheat the
fuel by turning the start switch to PREHEAT
position. And the PREHEAT indicator will turn
on. Keep preheating until the monitor
indicator goes out. Then release the key to
let it reset to OFF position. Turn the key to
START position to start the machine.
WARNING: Do not use starting aid fluid,
otherwise an explosion could be resulted.
8. The display will keep monitoring all of the
monitors and instruments, if the scheduled
service item is overdue, then alert symbols
and the first warning category massage will
be shown on the display. Check this items
immediately.
9. After all of the warning indicators go out, turn
the throttle switch to idling speed.
WARNING: If the throttle switch is at high
speed before the engine is started, the engine
components will be damaged.
10. Turn the start switch to START position to
start the machine. After starting, release the
key to let it reset to ON position.
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Operation Manual
Engine Starting
CAUTION: Start motor operation should
not exceed 15 seconds. If the engine doesn't
start after 15 seconds, release the start
switch at once. Wait 30 seconds before trying
to start again. If the engine can not be started
for three times, wait for at least three minutes
before trying again to prevent damage to the
start motor.
11. Warm up the engine at idle speed of
750~850 rpm after the engine is started.
Check the coolant temperature gauge. Run
the engine with full speed only after the
coolant temperature reaches 55°C and the
engine oil temperature reaches 45°C.
12. Check the readings of all the gauges to make
sure they are in the normal range. Check that
all the lights, indicators, horn, windshield and
wiper work normally.
13. If there are no obstacles around the machine,
slowly operate the travel control lever and
travel pedal to observe for left and right
turning.
Warm-up Operation
NOTICE: In severely cold weather,
preheat the machine when the hydraulic oil is
at low temperature. This will help to extend
the service life of the machine.
1. Turn the throttle switch to middle position to
let the engine run at idling speed for about 5
minutes.
76
Operation Manual
Operation Techniques

2. Push the pilot shutoff lever to UNLOCK ● Be familiar with the travel pedals and travel
position. control levers before driving the machine.
● Reduce the engine speed when turning and
going over a hill.

WARNING: Personal injury or death can

result from falling material. Remove any
B suspensions and watch out for falling and
sliding objects.

Choose Proper Track Shoe

● Do not use wide track shoes when working

B. UNLOCK
3. Operate the hand control lever slowly to let
the boom cylinder, bucket cylinder and arm
cylinder extend and retract repeatedly for 5
minutes to quickly raise the hydraulic oil
temperature.
In severely cold weather, the work equipment
will move slowly without preheating.
Therefore, preheat the machine before
starting.
If any trouble is found, turn the start switch to
OFF position to stop the machine.
Operation Techniques
Operation Information
on rock, sand or other rough surface. Wide
track shoes is designed for soft surfaces.
● Using wide track shoes on rough surfaces
will cause the track shoes to bend or come
loose or cause damage to other parts of the
chassis.
● Check the screw tension of the track shoes
periodically.
Traveling Operation of the
Machine
1. Push the pilot shutoff lever to UNLOCK
position.
2. Operate the hand control lever to lift the
bucket off ground for 20~30cm.
3. When traveling for a long distance, swing the
upper structure to locate the travel motor to
rear part of the machine.

Follow these basic instructions when you are

operating the machine.
● To prevent injury, make sure that no one
works on the machine or near the machine. 1 2
Always keep control of the machine.
● Raise the bucket or the equipment high
enough to go over any obstacle.
● Make sure the operator has best visibility and 3
the best stability when driving.
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Operation Manual
Operation Techniques

1. Cab 7. Change the travel speed by the travel speed

2. Idler
3. Travel motor
NOTICE: Check the direction of the track
frame before traveling. If the track frame is at
rear (travel motor at front), the travel
direction is opposite.
switch. Rabbit will be shown when the
machine moves at high speed and Tortoise
will be shown when machine moves at low
speed.
8. Stop the machine before changing the travel
speed.

4. Depress the travel pedal or push the travel 9. Drive the machine at low speed when driving
control lever forward, the machine will move on an uneven surface or stony surface.
forward. 10. Drive with idler at forward direction when
driving at high speed.

5. Depress the travel pedal or push the travel

control lever backward, the machine will
move backward.

CAUTION: If the machine is equipped

with travel alarm, it will sound when the
machine travel forwards or backwards.

6. When the travel pedal or travel control lever

is at NEUTRAL position, the machine will
stop moving automatically.
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Operation Manual
Operation Techniques

Downhill Operation 2. When driving downhill, keep at low speed by

using the travel control lever and engine
speed switch. If the slope gradient exceeds
15°, lower the work equipment as shown in
the figure and lower the engine speed.
Do not drive in reverse when going down a
hill.

Do not turn or operate the work equipment

when working on a slope to prevent the
machine from tipping.

Do not swing the bucket downhill with a load

in the bucket. If you must, set up a platform
with soil on the slope to keep the machine
1
balanced.

Do not drive the machine up or down a cliff to 1. Sprocket

avoid a tipping over hazard.
1. When driving the machine uphill, if the track
slips or it needs extra force to drive the
machine forward, do not use the arm force to
avoid a tipping over hazard.
WARNING: When driving downhill, keep
the sprocket at the downhill side. If the
sprocket is at the uphill side, the track is
quite easily loosened and cause a tipping
over hazard.
3. When driving the machine uphill with a
gradient below 15°, lower the work
equipment as shown in the figure.
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Operation Manual
Operation Techniques

4. When driving the machine on a steep slope Steering Operation of the Machine
with a gradient above 15°, to keep the
balance, stretch the work equipment forward,
raise the work equipment off ground for
20~30cm and drive at low speed.
Before operating, check the sprocket
position. If the sprocket is at the forward
direction, the travel direction is the opposite
direction.

Turning on a slope will cause the machine to

lose balance and tip over.

Right turn

Depress the left travel pedal or push the left

travel control lever, the machine will turn
Drive downhill rightwards.

When driving downhill, pushing the travel control

lever to NEUTRAL position can stop the machine
from moving.

Engine shuts down on the slope

When driving uphill, if the engine shuts down,

you need to push all of the control levers to
NEUTRAL before starting the engine again.

Cautions when operating on slope

1. If the engine stops on the slope, do not use Left turn

the left hand control lever to swing the
machine, the upper structure will swing under Depress the right travel pedal or push the right
the service weight. travel control lever, the machine will turn
2. Opening or closing the cab door on a slope leftwards.
could cause the door to open or close
suddenly due to the door weight. Pay close
attention to it and lock it securely.
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Operation Manual
Operation Techniques
Self swing
Check the surrounding area for safety if the
rear part of machine extends beyond the
track width.
Swing fast, the upper structure will revolve
fast; swing slowly, the upper structure will
revolve slowly.
Depress the front part of any one travel pedal
and depress the rear part the other, or push any
one of the travel control lever forwards and push
the other backwards, the machine will rotate at
that spot.
Machine Operation
Preparation for Operation
Only operate the machine on flat ground. Before
operating, level the job site to remove an uneven
surface, fill a pit or remove sharp stones.
You should learn about the area where you will
be working in advance. You should check: the
position of a slope, visible ditches, falling or
hanging objects, conditions of soils (soft or hard),
accumulated water and swamp areas, rock and
stubs, hidden groundwork, posts or the outer
limits of walls, the outer limits of the areas where
garbage is buried or that are filled in with earth,
holes and openings, obstacles, mud or ice,
traffic, heavy dust, heavy smoke, heavy fog, the
exact locations of the 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.
Lifting Single Track with Boom and Arm
NOTICE: Keep 90°~110° angle between
the boom and the arm, then lower the bucket.
Rotate the upper structure to 90°, then lower
the bucket onto ground and lift the track off
ground.
90°~110°
Place wedges under the track frame to support
the machine.
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Operation Manual
Operation Techniques

Leveling Operation Operating in Water or Mud

CAUTION: Do not drive the machine with
a load in bucket or while dozing.
Operate the hand control lever to operate the
bucket in and operate the arm vertically. Lift the
boom slowly and operate the arm in. After the
arm exceeds the vertical position, lower the
boom slowly to keep the bucket at leveling state.
Leveling can be obtained through operating the
boom, arm and bucket.
If the machine needs to work under water, make
sure that the ground is strong enough to support
the machine and the water is below the carrier
roller. Check the machine position frequently if it
works under water. If necessary, adjust the
machine position in the water.

Prevent the swing bearing, swing gear, and

swivel joint from being submerged by water.
If the swing bearing, swing gear, or swivel joint is
submerged, take out the cover (2), drain the
water and mud, and clean the swing area. Fix
Operating on Soft Ground cover (2) and lubricate the swing bearing and
swing gear.
Do not drive the machine on soft ground that is
not strong enough to support the machine.
If the machine works on very soft ground or the
machine is blocked from moving, clean the
2
surrounding area of track frame. Rotate the
upper structure to 90°and lower the bucket to lift
the track off ground.
Keep the boom and arm at an angle of 90° or
110°, then lower the bucket to the ground.
Rotate the track forward and backward to
remove the mud and dirt on the track.
Lower the engine speed and travel speed, drive
the machine slowly to hard ground.
If the machine is blocked and engine can be
started, towing is allowed.
Install the towing cable correctly.
82
Operation Manual
Operation Techniques
Digging Operation
1. Place the bucket teeth into the ground. Keep
the bucket bottom and ground to 45°.
2. Use the arm as the main digging force to pull
the bucket in.
3. When the bucket is blocked by dirt, remove
the dirt by rapidly moving the arm or bucket
frontward and backward.
4. Avoid stopping suddenly when lowering the
boom, because that will bring a shock load
and damage the machine.
5. To prevent damaging the cylinder, do not
operate the boom cylinder to the end stroke
when operating the boom.
6. Make sure that the bucket teeth do not hit the
track when digging by an angle.
7. When digging a deep trench, make sure that
the hoses of the boom and bucket cylinder do
not hit the ground.
8. When digging for a straight trench, align the
machine track with the trench. After finishing
the desired digging depth, move the machine
to continue.
Lifting Operation
WARNING: The machine power, rated
capacity and width should be taken into
account before lifting. Do not exceed the lift
capacity of the machine, otherwise, damage
and personnel injury will result.
CAUTION: Lift overload text will be
shown and the indicator will sound if the
boom head is loaded beyond the rated load
capacity during lifting in the Lift Mode.
Cautions when lifting:
1. This excavator only can be used for lifting
when the bucket is provided with a special
hook. Standard buckets can not be used for
lifting.
2. Make sure that the shackle, lifting ropes,
hooks and so on are free from wear or
damage. Make sure all of the lifting devices
have proper capacity.
3. Rotate the upper structure to locate the
sprocket at the rear side.
4. Lower the engine speed when lifting.
5. Do not exceed the range specified in the Lift
Capacity Chart. This chart is located on the
right side of the cab.
6. Practice a lift in advance. Secure the lifted
load to the lifting device. Lift the load off
ground for 50 mm and rotate the upper
structure by 90° to the other side. Operate
the work equipment slowly to lift the load
away from the excavator to avoid shake or
movement. If necessary, use an extra towing
rope to control the lifting.

7. If the load or the excavator is unstable, put
the load onto ground and stop lifting.
8. Do not move the load suddenly.
9. Do not lift the load over head.
10. Keep anyone away from the load until it is
laid on the ground securely.
11. Use a signalman and obey his signals when
several operators work at the same time.
Avoid Improper Operation
Operating with swing force
Do not use the swing force for compacting or
cracking. It is quite dangerous and will shorten
the service life.
83
Operation Manual
Operation Techniques
Operating with driving force
1. Do not cut in the ground with the bucket.
Using the driving force to dig will damage the
machine or work equipment.
2. Do not lift the rear part the machine to use
that weight as an extra digging force. This will
damage the machine seriously.
Operating with cylinder stroke end
Operating the machine when the cylinder piston
rod reaches its end stroke will damage the work
equipment and hydraulic cylinder. Do not operate
the machine when the cylinder is fully retracted
or extended.
Try not to operate the hydraulic cylinder using
short stroke repeatedly. Oil in the cylinder will fail
to flow back to the cooler for cooling, which could
cause high temperature in the cylinder and
cause the piston rod coating being burnt and
decolored. If this is unavoidable, operate the
cylinder for a longer stroke to let the oil flow back
to the oil tank for cooling.
84
Operation Manual
Operation Techniques
Operating with the bucket falling force
Do not use the falling force of the bucket for
digging, hammering or pile driving. This will
shorten the service life of the machine.
Operating with machine falling force
Do not operate the machine using falling
force.This will damage the machine or work
equipment.
Digging hard ground
It is recommended to dig hard ground after the
ground has been broken. This will reduce the
damage possibility to the machine and is more
economical.
Shifting control lever suddenly at high speed
1. Avoid shifting the control lever suddenly,
otherwise the activated function will start
suddenly.
2. Avoid pushing the travel control lever
suddenly from FORWARD to REVERSE (or
from REVERSE to FORWARD)
3. Avoid shifting the travel speed switch from
high speed to NEUTRAL suddenly.
Operation during Cold Weather
CAUTION: If the ambient temperature is
too low the engine can't easily be started, and
the radiator will be frozen.
1. Use fuel, hydraulic oil and lubrication with low
viscosity and add anti-freeze to the coolant.
Refer to "Oil Specifications" on page 100.
2. Add anti-freeze in coolant.
WARNING: Keep anti-freeze away from
an open fire. Do not smoke when adding anti-
freeze.
3. In severe cold areas, use anti-cold batteries.
As the ambient temperature drops, the
electrolyte may be frozen. In order to prevent
battery capacity loss, cover the battery or
move it to a warm place and fix it the next
day, then the engine can be started easily at
the next day.
4. Thoroughly clean sludge, water or frozen
snow on the machine to avoid them entering
into the seam and damaging sealing
performance.
5. Park the machine on a dry and hard ground.
If impossible, park the machine on the
wooden board. The wooden board can
prevent the machine from being frozen.
6. After the weather turns warm, change fuel,
hydraulic oil and lubricant with half viscosity.
Refer to in the Maintenance Manual.

Stopping the Engine
1. Park the machine on flat ground. Push the
travel control lever(4), (5) and left and right
travel pedal (3), (6) to NEUTRAL position.
4 5
6
3
2. Lower all the work equipment onto the
ground and apply a slight downward
pressure to the bucket.
3. Run the engine at idling speed for 5 minutes
so that the parts can cool down.
NOTICE: Do not shut down the engine
after the engine runs with a load, otherwise
the engine will overheat and the service life
will be shortened.
4. Turn the start switch to OFF position and take
out the key.
5. Push the pilot shutoff lever to OFF position
and turn every switch to NEUTRAL or OFF
position.
Leaving the Machine
1. Check the engine compartment for debris.
Clean all of the debris and paper to avoid
fires.
2. Remove all flammable debris in order to
reduce a fire hazard. Dispose of all debris
properly.
3. Turn the battery disconnect switch to the “O”
position.
85
Operation Manual
Operation Techniques
4. If the machine is not filled with anti-freeze,
after the machine parks in winter, open all
water drain valves of the engine to discharge
coolant in the cooling system and air
conditioner system so as to prevent the
machine from being cracked by frost. If the
machine has been filled with anti-freeze
before leaving the factory, refer to the
instructions of the anti-freeze labels.
5. Close all covers, lock all equipment and
remove the key.
6. Close the cab door.
7. 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
clear of debris before you dismounting.
NOTICE: Avoid damaging the electronic
unit inside the cab by bad weather. When
parking, close the windows and cab door.
Storage of the Machine
Before storage
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
machine on concrete ground and cover with
canvas.
2. Before storage, refill the oil tank, lubricate
every moving pin & shaft and change
hydraulic oil.
3. Paint a thin layer of grease on the exposed
parts of hydraulic oil cylinder piston rods.
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 coolant of the engine till it reaches
the engine body and evaporator of the air
conditioner. Drain out water in the cooling
system, also drain out water in the
evaporator of the air conditioner.
86
Operation Manual
Operation Techniques

During storage 6. Operate the control levers for several times

1. Start the machine once every month and run
every system, and lubricate every part of the
moving pins and shafts. Charge the battery.
2. Before starting the machine, wipe off grease
from the hydraulic oil cylinder piston rods.
After operation, paint a layer of grease on
them.
3. Paint antirust additive on rusted parts.
WARNING: To avoid personal injury or
death, when working with anti-freeze inside a
closed room, open the windows for
ventilation.
to operate swinging, digging operation and
so on for repeatedly.
7. Check all of the systems carefully before the
machine is fully loaded.
8. Install a new fuel filter. Replace the engine
filter and inject engine oil into the engine.
NOTICE: If the machine is stored for a
long time, the grease layer on the surface
could be damaged. It needs to operate the
control lever to make a cycle running,
swinging and digging operation for 2~3 times
to lubricate the surface.

Before reuse
Transportation Information

1. Change lubricant of the engine, transmission, Transportation of the Machine

axles and hydraulic oil, brake oil and anti-
freeze of the engine.
2. Lubricate all moving pins and shafts.
3. Before starting the machine, wipe off grease
from the hydraulic oil cylinder piston rods.
NOTICE: If the machine is not coated
with antirust additive each month during
storage, consult Liugong dealer.
Moving Machine from Storage
Carry out the following maintenance procedures
when the machine is stored for a long time.
1. Check all of the hoses and connections.
2. If the extended piston rod is coated with
grease, wipe the grease off.
CAUTION: Obey the correlative laws
govern characteristics of the load (weight,
width, and length).
Investigate the travel route for overpass
clearances, Make sure that there will be
adequate clearance for the machine.
Clean ice, snow, or other slippery material from
the loading dock and from the truck bed before
you load the machine onto transport machine.
This will prevent the machine from slipping in
transit. This will also prevent a the machine from
moving while the during transportation.
Loading procedures onto trailer:
CAUTION: Load or unload the machine
on a flat ground.

3. Adjust the tension of the alternator belt and

fan belt.
4. Replenish the fuel tank and discharge air in
the fuel system. Check the fuel level.
5. Start the engine. Before the engine is fully
loaded, run the engine at middle speed for
several minutes.
 87
Operation Manual
Operation Techniques

1. Chock the trailer wheels or the truck wheels
before you load the machine.
5. Drive the machine slowly through the ramp.
Stop the machine when the machine goes to
the center of the trailer.
6. Push the left and right travel control lever to
NEUTRAL position after stopping.

1. Wedge
2. Block
3. Angle (not exceed 15°)
4. Ramp distance
5. Ramp 7. Lower the bucket to the floor of the trailer.
2. Use ramps between trailer and machine and
8. Stop the engine, turn every switch to
make sure that the ramps are at same level.
NEUTRAL or OFF position and remove the
The ramp gradient should not exceed 15°.
key.
3. Push the pilot shutoff lever to LOCK position.
9. Lock the door and remove the key.
10. Turn the battery disconnect switch to “O”
position.
11. Cover the exhaust outlet to prevent the
turbocharger from rotating during
transportation. Damage to the turbocharger
can result.
12. Use a strong chain or rope to fasten the
machine securely to the trailer.

WARNING: Fastening the machine will

4. Turn the travel speed switch to low speed. chain or steel ropes. Do not fasten the chain
or steel ropes to the hydraulic pipes or
hoses.

13. Place the wedge under front and rear side of

the track.

CAUTION: Select low speed when the

machine is going onto the trailer or running
on narrow road, also cancel the auto idling.
88
Operation Manual
Operation Techniques

WARNING: When moving or towing the 3. Push the pilot shutoff lever to LOCK position
machine, avoid the arm contacting the so that the machine can not operated.
overhead objects in order to prevent
personnel injuries to the passerby.

4. Shut down the engine and check the

surrounding area of the machine. Then close
and lock the cab door, window and engine
hood.
Lift the Machine
5. Lifting symbols are provided on the track
(See following figure).The lifting devices
WARNING: Improper lift or securing should attach to the lifting eye securely.
could cause the machine to move and cause
injury or damage.

1. The lift weight of the 925LCII is

25500±1300kg; and the 925LLII is
26000±1300kg, calculate the maximum lift
weight of the crane and loading capacity of
the lifting device to ensure the lift safety.
2. Start the machine and lay the work
equipment as shown in the figure.
6. The length of the four ropes on the lifting
device must be the same to ensure the four
lifting eyes share the same pressure.
 89
Operation Manual
Operation Techniques

7. After the lifting devices are securely attached
to the lifting eye, lift the machine for a little bit
to check the balance. If unbalanced, put
down the machine and adjust. Try again for
the balance until the machine is totally
balanced and safe for lifting.
3. As the figure shows, attach a U hook to the
hook hole of the track frame and tow the
machine slowly. Keep the steel rope and the
machine at level position.

Towing Information

Hook

Use strong enough steel ropes to tow the

machine. Steel rope

Do not apply force to the steel ropes

suddenly. NOTICE: A hook hole is provided to the
track frame with 7500kg(16500lbf) towing
capacity. Do not use the hook hole if the
If the machine sticks in the mud and it can not towed object exceeds the stipulated range.
drive out by itself, steel ropes should be used.
1. When towing, keep any personnel away from
the steel ropes to avoid personnel injuries
caused by broken ropes.
2. When your machine suffers from a collision
but still can be operated, attach a steel rope
to the track frame(See following figure), and
tow it to hard ground with another machine.
Place some protection materials between the
steel ropes and track frame.

Steel rope
90
Operation Manual
Operation Techniques

Maintenance Manual
CAUTION: Perform the maintenance
procedures at the intervals according to this
manual. Proper maintenance will extend the
service life of the machine and provide safer
operation.
Maintenance Guidance
Correct Maintenance Procedures
Learn how to maintain your machine correctly.
Follow the instructions of this manual, if your
machine has troubles, you must maintain or
contact your dealer before operating.
Daily Checks
1. Check the gauges.
2. Check the coolant, fuel and oil level.
3. Check hoses and tubes for leakage, wear
conditions and damage.
4. Perform a walk-around inspection of the
machine.
5. Check for loose or missing parts.
Check Service Hour Meter
1. The service hour meter determines when
your machine needs to be maintained. The
time in the maintenance table is basically
given for normal operation. If the machine is
operated in severe conditions, you must
maintain the machine more frequently.
Maintain Machine on Schedule
Follow the maintenance methods listed in this
maintenance manual.
Maintenance Suggestions
1. Use only recommended fuels and lubricants.
91
Maintenance Manual
Maintenance Guidance
2. Don't adjust the engine speed setting and/or
the hydraulic safety valve.
3. Protect electronic units from water and vapor.
4. Do not disassemble electronic units such as
sensors etc.
5. Use only recommended Lugging parts.
Cleanser of Windshield
Clean the windshield with special windshield
cleanser and ensure no foreign matter mixes
with cleanser.
Clean Engine Oil
Use clean engine oil and keep the engine oil
clean. Ensure no foreign matter mixes with the
engine oil.
Check Discharged Oil or Used Filter Element
After replacing the oil or filter element, check the
discharged oil or filter element for iron particles
and foreign matter. If any iron particles or foreign
matter is found, report this immediately and take
preventive measures.
Welding Cautions
1. Turn off the engine.
2. Do not keep using voltage above 200V.
3. Keep the welding area and earth cables
within 1m. If the earth cable is close to
gauges or connectors, failure could result.
4. Protect the seals and bearings located
between the welding area and earth cables.
5. Never use the surrounding area of the work
implement pin or cylinder as an earthing
point.
92
Maintenance Manual
Maintenance Guidance
Prevent Dropping Things into Machine
Interior
1. When checking through an open window or
tank filler, be careful not to drop nuts, bolts or
tools into the machine interior. If anything is
dropped carelessly, take them out at once.
2. It is suggested not to take unnecessary items
with you in your pockets, take necessary
tools only.
Dusty Environment
Pay attention to the following instructions when
working in dusty environments:
1. Check the air filter indicator regularly to see
whether it is blocked. Service the air filter
prior to the normal schedule.
2. Wash the radiator core frequently. Clean and
replace the fuel filter periodically.
3. Clean the electrical units, especially the
starter motor and alternator, to remove
accumulated dust.
Avoid Mixing Oil
Do not use oils of different brands. If it is really
needed, change the old oil prior to using the new
oil of another brand.
Lock the covers
If it is needed to service the machine with the
covers opened, lock the covers with the lock
lever.
Purge Hydraulic System
Purge the air from the hydraulic lines if the
hydraulic lines or components have been
repaired, replaced or removed.
Install Hydraulic Hoses
1. If components equipped with O-rings or
gaskets need to be removed, clean the
mounting surfaces. Do not forget to install
new O-rings and gaskets.
2. When installing hoses, do not twist or bend
them. This will damage and shorten the
service life of the hoses.
Proper Fuel and Lubricant
Use proper fuel and lubricant that adopts to the
environment.
Check Electrical Wiring
If a fuse is burnt out frequently or in short
circuit, find out the reason and repair or
contact your Lugging dealer for assistance.
Keep the battery surface clean.
1. Check the fuse for damage. Check the circuit
for broken or shorted wires. Check the
terminals for loose connections and tighten
any loose parts.
2. Check the circuits of the battery, starter motor
and alternator.
3. Contact your Lugging dealer for more
information about the solutions.
Check Air Conditioner
Check the fan speed switch of the air
conditioning system to see if it is at NEUTRAL
position and the work mode switch at the OFF
position. If not, turn them to the correct position.
Check Gauges
Check the gauges, lighting, indicators, horn and
wipers for good condition. Contact your Liugong
dealer if any problems are found.
CAUTION: Before starting the engine,
make sure nobody is on or near the machine.
Keep the machine controlled by the operator.
 93
Maintenance Manual
Run-in

Preparation before Maintenance 4. Avoid heavy load or high speed operation

Park the machine as follows before
maintenance:
1. Park the machine on flat ground.
2. Lower the bucket to the ground.
3. Set the engine speed to idling speed and run
it for 3 minutes.
4. Turn the start switch to OFF position and take
out the key.(If the machine needs to be
maintained with the engine running, make
sure the machine is under control of the
operator)
5. Push the pilot control lever to LOCK position.
6. Attach a ''DO NOT OPERATE'' tag to right
hand control lever if the machine is not
operated.
during run-in period.
5. It is better to load with loose material during
the first 50 hours of run-in period. Do not
operate at a fast speed. Fill the bucket to 1/2
of its rated capacity. Increase the load
capacity gradually after the first 50 hours.
Keep the load within 3/4 of the bucket rated
capacity.
6. Check the lubricant periodically. Replace or
refill the lubricant according to the
recommended period.
7. Check the moving components of the
machine. If any abormaty is found, look for
reasons and remove them.
8. Check the tighteness of all 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.

2. Check the belt tightness of the fan, engine
G
IN
N
AR

and air conditioner compressor.

W

er not
!

e
at
do

3. Check the level of the transmission oil,

op

hydraulic oil tank, engine oil and coolant.

r:
te
ra
pe
O

:
ate
D

4. Check the water in fuel separator and the

refrigerant of the air conditioner.

Run-in 5. Check the hydraulic system for leakage.

The run-in of new machine is an important
procedure for prolonging of the service life of the
machine, eliminating fault and avoiding
accidents. The user must read these guidelines
for a new loader and how to operate and
maintain the machine after purchase.
Run-in-Requirements for New Machine
1. Run-in of a new machine is 100 hours.
2. Start the engine and run at idling speed for 15
seconds. Do not attempt to operate the hand
control lever or the engine speed switch.
3. Run the machine at idling speed for 5
minutes at every start-up.
6. Check temperatures and connections of the
electrical system, power supply of the
alternator and the lights.
7. Lurbicate the work implement pins every 8
hours(at the the first 100 service hours)
CAUTION:Check oil level according to
the relevant operation regulations.
The following must be done after the first 50
hours of operation during the run-in period.
1. Lubricate the boom pin.
2. Lubricate the boom cylinder bottom pin.
3. Lubricate the arm, bucket and linkage pin.
94
Maintenance Manual
Maintenance Interval Schedule

4. Check and adjust the tension of the track.
5. Clean the air filter parts.
6. Replace the engine oil.
7. Replace the engine oil filter
8. Replace the fuel pre-filter, fuelfilter and fuel
suction filter.
9. Check the torque of those bolts which are
easily rusted.
Work should be done after the finish of run-in
1. Check the tighteness of all bolts and nuts,
especially diesel cylinder cover nuts, exhaust
pipe bolts and fixed bolts of diesel engine.
2. Check the tension of the fan belts.
3. Check, adjust and lubricate the components
of the excavator after run-in. Clean the return
filter element of hydraulic oil tank and check
the hydraulic oil cleaness simultaneously.
Replace the return filter element if necessary.
CAUTION: Replace the hydraulic oil
according to the stipulated procedures.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours or 3 months, also service those
items listed under every 250 service hours or
monthly, every 50 service hours or weekly and
every 8 service hours or daily.
Every 8 Service Hours or Every Day
● Check the battery and the battery disconnect
switch.
● Check the oil level of the engine.
● Check coolant level.
● Check hydraulic oil level.
● Check fuel level.
● Drain any water and trash from the fuel tank.
● Clean the fuel pre-filter, fuel filter and trash.
● Check the refrigerant for leakage.
● Check the lighting and gauges.
● Daily inspection.
Every 50 Service Hours or Every Week

In addition to the all previous service checks:

Maintenance Interval
● Lubricate the boom pin.
Schedule
● Lubricate the bottom pin of boom cylinder .
● Lubricate the arm, bucket and linkage pin.
CAUTION：Read and understand all the
safety instructions, warnings and indications ● Lubricate the boom and arm linkage pin.
before any operations or maintenances.
● Check and adjust the track.
The maintenance intervals stated in this manual ● Clean the air filter.
are determined according to the service hour
meter or calendar intervals shown (daily, weekly, Every 100 Service Hours or Two Weeks
monthly, etc). Liugong recommends that
maintenance should be performed according to In addition to the all previous service checks:
whichever of the above-mentioned intervals
● Lubricate the boom and arm pivot pin.
occurs first.
● Lubricate the piston pin and bottom pin of
Under extremely severe, dusty or wet operating
arm cylinder.
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart ● Lubricate the bottom pin of bucket cylinder.
may be necessary.
● Lubricate the piston pin of boom cylinder and
bottom pin of arm cylinder.
 95
Maintenance Manual
Maintenance Interval Schedule

● Check and adjust belt tension of fan.
● Check and adjust belt tension of compressor.
Every 250 Service Hours or Every Month
In addition to the all previous service checks:
● Check the swing reduction gear oil level.
● Check the travel reduction gear oil level.
● Check the tightening torque of bolts and nuts.
● Check the engine air intake system.
● Check the tension and condition of engine
belt and compressor belt.
● Check the refrigerant level.
● Change the engine oil.
● Change the engine oil filter.
● Change the primary fuel filter.
● Change the fuel filter.
● Clean the fresh air filter and recirculating air
filter of the cab.
Every 500 Service Hours or Three Months
● Clean the fuel lift pump filter.
● Replace the swing reduction gear oil.
● Replace the travel reduction gear oil.
● Replace the pilot oil filter.
● Replace the return filter of hydraulic oil tank.
● Lubricate the swing reduction gear bearing.
Every 2000 Service Hours or Every Year
In addition to the all previous service checks:
● Replace the hydraulic oil.
● Replace the suction oil filter of hydraulic oil
tank.
● Replace the fuel suction filter.
● Replace the coolant and clean the internal
surface of radiator.
● Check the air conditioner cooling hose and
water hose for cracks, wear and foaming by
oil contaminants. Check the joint and clamp
for loose condition.
● Replace the recirculating air filter of the cab.

In addition to the all previous service checks:

● Lubricate the swing bearing.
● Lubricate the swing gear.
● Clean the surface of radiator group.
● Change the internal and external
components of air filter.
● Replace the travel reduction gear oil for the
first time(Replace every 1000 hours later on)
● Replace the swing reduction gear oil for the
first time(Replace it every 1000 hours later
on).
● Clean the surface of the condenser/

Every 1000 Service Hours or Six Months

In addition to the all previous service checks:

● Adjust the engine valve lash.
96
Maintenance Manual
General Torque Specifications

General Torque Specifications

Tighten the bolts used in the machine according to the torque requirements shown in the following table
unless other specified.
The torque unit is kgf.m. E.g: 1 m spanner is used to tighten the bolts or nuts with 12 kgf applied, the
torque would be: 1m × 12kgf =12kgf.m.
0.25 m spanner is used to obtain a same torque, that is: 0.25m × kgf =12kgf.m, then the force would be
12 ÷ 0.25=48 kgf.
Spanner Torque
No Description Bolt
size(mm) N.m kgf.m
1 Fixed bolt of engine shock absorber M22-10.9 34 800 81
2 Fixed bolt of engine bracket M12-8.8 18 90 9
M12-8.8
3 Fixed bolt of flywheel housing 18 60 6

4 Fixed bolt of water radiator bracket M12-8.8 18 90 9

5 Fixed bolt of fuel tank M16-10.9 24 305 31
6 Fixed bolt of hydraulic oil tank M16-10.9 24 305 31
7 Fixed bolt of pump M20-10.9 17 Inner hexagon 600 61
8 Fixed bolt of main control valve M12-10.9 18 120 12
9 Fixed bolt of swing reduction gear M20-10.9 30 600 61
10 Fixed bolt of swing motor M16-10.9 14 Inner hexagon 305 31
11 Fixed bolt of battery M10 30 3
12 Fixed bolt of cab M16-8.8 24 225 23
13 Fixed bolt of revolving frame and swing bearing M22-10.9 34 800 81
14 Fixed bolt of undercarriage swing bearing M22-10.9 34 800 81
15 Fixed bolt of travel reduction gear M16-10.9 24 305 31
16 Fixed bolt of sprocket M16-10.9 24 305 31
17 Fixed bolt of track carrier roller M24-10.9 36 1020 104
18 Fixed bolt of track roller M18-8.8 27 310 32
19 Fixed bolt of track shoe M20-12.9 30 750 76
20 Fixed bolt of track guard M18-8.8 27 310 32

1. Tighten the fixed bolt of engine shock 3. Fixed bolt of flywheel housing
absorber.
Tool: 18mm
Tool: 34 mm
Torque:60N·m(6kgf·m)
Torque: 800N.m (81kgf.m)
4. Fixed bolt of water radiator bracket
2. Fixed bolt of engine bracket
Tool: 18mm
Tool: 18mm
Torque: 90N.m(9kgf.m)
Torque: 90N.m(9kgf.m)
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General Torque Specifications

5. Tighten the fixed bolt of fuel tank Torque:600N.m(61kgf.m)

Tool: 24mm.
Torque: 305N.m(31kgf.m)
6. Fixed bolt of hydraulic oil tank
Tool: 24mm
Torque:305N.m(31kgf.m)

10. Tighten the fixed bolt of swing motor

Tool: 14mm, inner hexagon spanner
Torque: 305N.m(31kgf.m)

7. Tighten the fixed bolt of pump

Tool: 17mm, inner hexagon spanner
Torque: 600N.m(61kgf.m)
8. Tighten the fixed bolt of control valve
Tool:18mm
Torque: 120N.m(12kgf.m)

11. Tighten the fixed bolt of battery

Torque: 30N.m(3kgf.m)
12. Tighten the fixed bolt of cab
Tool : 24mm
Torque: 225N.m(23kgf.m)

9. Tighten the fixed bolt of swing reduction gear

Tool: 30 mm
98
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General Torque Specifications

13. Tighten the fixed bolt of revolving frame and Torque: 305N.m(31kgf.m)
swing bearing
17. Tighten the fixed bolt of track carrier roller
Tool: 34 mm
Tool: 36mm
Torque: 800N.m(81kgfm)
Torque: 1020N.m(104kgf.m)

14. Tighten the fixed bolt of undercarriage and

18. Tighten the fixed bolt of track roller
swing bearing.
Tool: 27 mm
Tool: 34mm
Torque: 310N.m(32kgf.m)
Torque: 600N.m(81kgf.m)

19. Tigthen the fixed bolt of track shoe

15. Tighten the fixed bolt of travel reduction gear
Tool: 30mm
Tool: 24mm
Torque: 750N.m(76kgf.m)
Torque: 305N.m(31kgf.m)

20. Tighten the fixed bolt of track guard

16. Tighten the fixed bolt of sprocket
Tool: 27 mm
Tool: 24 mm
 99
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General Torque Specifications

Torque: 310N.m(32kgf.m)
100
Maintenance Manual
Lubrication Specifications

Lubrication Specifications

Oil Change Interval and Refill Capacities

Item Interval (service hours) Approximative Quantity (L)

Engine oil 250 25L
Swing reduction gear oil 1000 3.4L
Travel reduction gear oil 1000 (5.4L×2)L
Hydraulic oil 2000 Tank 230L (Hydraulic system 330L)
Fuel 450L
Cooling system 2000 30L

Oil Specifications

Type of oil Position of use Oil brand Ambient temperature

2# MSO2 lithium based grease ★ -20~40°C (-4~104°F)
Bucket, arm and boom,
Grease swing gear, swing bear- EP2 -20~40°C (-4~104°F)
ing, etc
EP2 or RO2 -20~40°C (-4~104°F)
1#(5W-40)(API CG-4) -20~20°C (-4~68°F)
Engine crankcase, fuel 1300 （15W-40）（API CG-4） -10~40°C (14~104°F)
Engine oil injection pump and regu-
lator 10W-30 （API CG-4） -20~35°C (-4~95°F)
15W-40 （API CG-4）★ -10~40°C (14~104°F)
0# ★ 4°C up (39.2°F up)
-10# -5°C up (23°F up)
Fuel -20# -14°C up (6.8°F up)
-30# -29°C up (-20.2°F up)
-50# -44°C up (-47.2°F up)
Anti-freeze(100% primary liquid) and water
Anti-freeze -30~40°C (-22~104°F)
42:58
Swing reduction gear SAE85W-140(API GL4~5) -20~40°C (-4~104°F)
Gear oil
Travel reduction gear SAE85W-90 (API GL4~5) -20~40°C (-4~104°F)
ISO VG 32 -20~20°C (-4~68°F)
Work implement hydrau-
Hydraulic oil ISO VG 46 ★ -20~40°C (-4~104°F)
lic system
ISO VG 68 -10~40°C (14~104°F)

1. Note: " ★ " used by the manufacturer after the machine is newly produced

CAUTION: 1. Do not mix oils of different brands even if they have the same specifications.
Clean the system before refilling the different oil.
 101
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Important Maintenance Procedures

2. Recommended engine oil: API CF class or
above. Common area: SAE30 or same class
(summer or winter); High temperature area:
SAE40 or same class; Low temperature area:
SAE10W or same class.
3. Replace the lubricant periodically even
though the lubricant is very clean because
the lubricant might go bad after a long time
use.
4. Choose the oil according to the lowest
temperature in the local area where the
machine is used.
Important Maintenance
7. Check the handrail for damage and check
the bolt for loose condition.
8. Check the bucket (which is equipped) with a
lifting hood for damage.
9. Check the air outlet and inlet of air
conditioner evaporator. Keep them away
from cotton, paper and plastics which easily
block the air inlet.
10. Check all the lighting equipment and replace
cracked bulbs and glass if necessary.
11. Check the cab and keep the cab clean.
12. Check the instrument panels and indicators
for damage. Replace the damaged parts if
necessary.

Procedures
Daily Inspection
CAUTION: Watch carefully for leakage. If
you find leakage, service it. If you suspect
leakage or observe leakage, check the fluid
level more frequently.
13. Check the seat belt, buckle and tighten the
bolts. Replace the frayed or damaged parts if
necessary.
14. Adjust the rearview mirrors and check the
windows to ensure good vision for the driver.
Clean the windows if necessary.

Check the following items before starting the

engine everyday:

1. Check the engine compartment and clean

the accumulated dirt from on it and from the
radiator.
2. Check the engine for damaged parts.
3. Check the swing reduction gear and travel
reduction gear for leakage. Repair the leaks if
any are found.
4. Check the hydraulic oil tank, all of the tubes,
hoses, plugs, seals, connectors and oil
nozzles for leakages. Repair the leakage and
replace the parts if necessary.
5. Check all of the implements, cylinders and
linkage for cracks and damages.
6. Check the track, sprocket, idler and guards
for damage and wear, loose bolts or leakage.
102
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Important Maintenance Procedures

Lubricant--Apply

Lubrication table

Lubrication Intervals (Hours)

Component Q'ty
8 50 100 250 500 1000 2000
Boom pin, boom hydraulic cylinder
1. Work bottom pin, arm, bucket and linkage 12 ★
implement pin ★★
Others 7 ★★
2. Swing bearing 2
3. Swing bearing gear 1
4. Swing reduction gear bearing 1

Note: ★ Lubricate every 8 hours at the first 100 hours. ★★ Need to be maintained when operating in water or mud.

Lubrication positions

1. Work implement
2. Swing bearing
3. Swing gear
4. Swing reduction gear bearing
 103
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Important Maintenance Procedures

Work Implement--Lubricate 3. Arm, bucket and linkage pin--- lubricate every

50 hours (lubricate every 8 hours within first
Park the machine on flat ground, with arm 100 hours).
cylinder and bucket cylinder fully extended.
Lower bucket to ground, For purpose of applying
grease, a centralized lubrication system is
adopted.

4. Boom and arm pivot pin, linkage pin of arm

cylinder piston and bottom pin of bucket
1. Boom pin---lubricate every 50 hours cylinder -lubricate every 100 hours (lubricate
(lubricate every 8 hours within first 100 every 8 hours within first 100 hours).
hours).

5. Piston rod pin of boom cylinder and bottom

2. Bottom pin of boom cylinder ---lubricate pin of arm cylinder-lubricate every 100 hours
every 50 hours (lubricate every 8 hours within (lubricate every 8 hours within first 100
first 100 hours). hours).
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Important Maintenance Procedures

Swing Bearing--Lubricate Swing Gear--Lubricate

NOTICE: Lubricate the swing gear and CAUTION: Lubricate the swing gear and
revolve the upper structure by one person upper structure by only one person. Before
only. Keep unauthorized persons away from starting the machine, keep all persons clear
the machine. of the machine.

1. Lower the bucket onto ground, stop the 1. Park the machine on the flat ground.
engine and push the pilot shutoff lever to
2. Lower the bucket onto the ground.
LOCK position.
3. Reduce the engine speed to idle speed.
2. Apply grease into the two grease fittings.
4. Turn the start switch key to the OFF position
3. Start the engine. Lift the bucket, then revolve
to stop engine, take out the key.
the upper structure to 45° (1/8 revolution).
5. Turn the pilot shutoff lever to the LOCK
4. Lower the bucket on the ground.
position.
5. Repeat these procedures for 3 times from
6. Remove cover (1).
step 1 to step 4.
6. Apply grease into the two grease fittings until
grease overflows out of the swing bearing
seals.

7. Check the lubricant on the gear, lubricant

must properly flow on the surface of gears. If
needed, refill about 0.5 kg lubricant.
8. Install the cover.
9. If any water and mud contamination in the
7. The fillilng capacity of the grease is lubricant are found, replace all the lubricant
approximate 0.5 kg. on the gears.

NOTICE: Do not over fill grease.

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Important Maintenance Procedures

10. Remove cover (2) near the swivel joint at the

bottom of the swing gear compartment to
drain lubricant and then install the cover.
Refill lubricant from cover (1). The refilling
capacity for the grease is about 4 kg.

2
2

1. Swing reduction gear grease fitting

2. Swing reduction gear vent hole

Swing Reduction Gear Bearing --

Lubricate

CAUTION: Lubricate the bearing of the

swing reduction gear with grease. Failure to
maintain the bearing timely may result in
damage to bearing and swing reduction gear.

Lubricate the bearing of swing reduction gear

grease fitting until the grease overflows from the
vent hole. The vent hole is located at the other
side of the swing reduction gear grease fitting.

1
106
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Important Maintenance Procedures

Diesel Engine System

Maintenance table

Interval (Hour)
Componenets Q’ty
8 50 100 250 500 1000 2000
Oil level check 1
1. Engine oil
Replace 25L ★★★
2. Engine oil filter Replace 1 ★★★
3. Drain water and contaminant from fuel tank １
Drain 1
4. Fuel pre-filter
Replace 1 ★★★
5. Replace fuel filter 3 ★★★
6. Air pre-filter Clean
Clean 1
7. External components of air filter
Replace 1
8. Internal components of air filter Replace 1
9. Check coolant level 1
10. Check and adjust the belt tension 1

11. Replace coolant and clean internal surface of 30L

One year or 2000 service hours
radiator

12. Clean external surface of radiator 1 ※

When the machine is stored for a long time or difficult
13. Discharge air in low-pressure fuel lines
to start

★★★ The first service time

※ Shorten the time of maintenance if the machine works in dusty environment.

Coolant Level--Check
Hot coolant can cause serious burn. To open
cap, stop engine until the radiator cools
down. Then loosen cap slowly to release the
pressure.
The coolant of the engine consists of coolant,
anti-freeze and additives. The water radiator is
located at the rear of the machine.
Checking Method for Coolant Level
1. After the engine coolant temperature drops
down to 50°C, slowly screw out the water
radiator cap (1) to release pressure in order
to avoid scalded by high temperature vapor
or splashing coolant.
1
2. Check if coolant level is at 1 cm below the
water filler, replenish coolant if necessary.
3. Check the seals of the water filler cap (1),
replace if damaged.
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Maintenance Manual
Important Maintenance Procedures
4. Screw in the water radiator filler cap (1).
CAUTION: Check the cooling system of
the engine for leakage if it needs to replenish
coolant everyday. If leakage is found,
eliminate the leakage and replenish coolant
until it reaches the proper level.
Check the Anti-freeze and Additives Density
NOTICE: Anti-freeze has been added
before leaving factory which can resist to -
30°C .
If the temperature is forecasted to drop below 0
°C (32Fahrenheit), refill the cooling system with
mixture of anti-freeze and soft water. If the
mixture is offered with instructions, prepare the
mixture according to the lowest temperature.
When replace the anti-freeze, use high quality
brand and replace on the instructions.
CAUTION: Anti-freeze is flammable.
Never expose anti-freeze to an open fire.
Never use water as the coolant only
otherwise it will cause corrosion damage to
the system.
The coolant must contain additive (SCA) to
prevent the engine parts which contact with the
coolant from rusted, corroded and smudged. 3%
additive has been added to the anti-freeze but it
could be consumed up during running the
engine. Therefore, check the anti-freeze density
every 500 work hours or per six months. Refill
the anti-freeze if necessary.
Refer to the Operation and Maintenance Manual
of Diesel Engine provided with the machine for
the additive density inspection method and
detailed instructions.
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Maintenance Manual
Important Maintenance Procedures
Coolant--Replenish
Replenish coolant as follow:
1. Mix the water and coolant completely
according to desired density level of the
coolant.
2. Turn on the battery disconnect switch. Insert
the key into the start switch and turn
clockwise to the first position to turn on the
power of the machine.
3. Turn the selector switch of the air conditioner
to WARM position.
4. Turn the manual valve on the water inlet hose
of the engine ON position (The valve is ON
as shown） .
5. Open the water radiator filler cap (1) and
slowly replenish coolant till the level reaches
1 cm below the water filler of the radiator and
is kept stable within 10 minutes.
1
CAUTION: When replenishing coolant,
exhaust air from the cooling system lines of
the engine.
6. Keep the water radiator filler cap (1) open,
start the engine and run at idle speed for 5
minutes, and at high speed for 5 minutes, the
coolant temperature reaches over 85°C.
7. Check the coolant level again, continue to
replenish coolant till the level reaches 1 cm
below the water filler cap of the radiator if
necessary.
8. Check the seals of the water radiator filler
cap, replace it if damaged.
Do not replenish coolant when the engine
temperature is high otherwise this could
cause the engine to damage. Replenish
coolant only after the coolant temperature is
below 50°C.
9. After filling the radiator, fill anti-freeze to the
auxiliary tank untill the anti-freeze surface
reaches to middle of the auxiliary tank.
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Maintenance Manual
Important Maintenance Procedures

Coolant--Replace 3. Turn the manual valve on the water inlet hose

of the engine to ON position (The valve is ON
as shown）

Care must be taken in order to ensure that

fluids are contained during performance of
inspection, maintenance, testing, adjusting
and repair of the equipment. Prepare to
collect the fluid with suitable containers
before disassembling any hydraulic oil lines.
Obey all local regulation for the disposal of
liquids.

Hot coolant can cause serious burn. To open

cap, stop engine until radiator cools down.
Then loosen cap slowly to release the
pressure.
Completely replace the coolant every 2000
service hours or two years (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
or bubbles appear in the radiator.
Steps for cleaning the cooling system:
1. Turn on the disconnect switch. Insert the start
switch key and turn clockwise to the first
position to turn on the power of the machine.
4. Start and run the engine at idle speed for five
minutes, then stop the engine.
5. Turn the start switch to the first position to
turn on power of the machine. Turn the
selector switch of the air conditioner to
WARM and keep the solenoid water valve of
air conditioner at OPEN.
6. Slowly screw out the water radiator filler cap
to release pressure after the coolant
temperature is below 50°C.
1

2. Set the air conditioner to WARM state.

110
Maintenance Manual
Important Maintenance Procedures
7. Open the water release valve at the bottom
of the radiator, drain out the coolant of the
engine and collect with a container.
8. After draining out coolant of the engine, close
the water release valve at the bottom of the
water radiator.
9. Check all water lines and clamps of cooling
system for damage, replace if necessary.
Check water radiator for leakage, damage
and piled-up trashes, clean and repair if
necessary.
10. Replenish cleanser which is mixed with water
and sodium carbonate into the cooling
system of the engine, its proportion is 0.5
kilograms of sodium carbonate with 23 liters
of water. The level should reach normal level
of the engine and keep stable within 10
minutes.
CAUTION: When replenishing 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 while running the
engine.
11. Keep the water radiator filler cap open, start
the engine, when the coolant temperature is
over 80°C, run the engine for 5 minutes
again.
12. Stop the engine, drain out cleanser.
13. Replenish clean water into cooling system of
the engine till it reaches normal level and is
kept stasble within 10 minutes. keep the
water radiator filler cap open, start the
engine, when the coolant temperature is over
80°C, run the engine for 5 minutes again.
14. Stop the engine, drain out water in the
cooling system. If the drained water is still
dirty, clean the system again till the drained
water gets clean.
15. Replace with a new coolant filter, close all
drain valve, then replenish new coolant
according to the operation rules previously
described in "Coolant--Replace" on page109.
16. Replace the coolant in the auxiliary tank at
the same time when replacing the coolant in
the water radiator.
WARNING: The coolant of the engine is
poisonous and impotable. Dispose according
to the local laws and regulations.
Radiator--Clean
CAUTION: When cleaning the radiator
with compressed air, reduce the pressure to
avoid flying object and wear protective
devices including goggles.
1. Open the side door and engine hood.
2. Clean or wash the water radiator and oil
cooler with compressed air or water.
Air Pre-filter--Clean
1. Park the machine on flat ground and lower
the bucket to the ground.
2. Stop the engine. Take the key out of the start
switch.
3. Loose air pre-filter cover.
 111
Maintenance Manual
Important Maintenance Procedures

4. Take out the dust collector to clean it.

3. Clean the inner wall of the air filter.

1

5. Install the air pre-filter and tighten the bolt.

Air Filter--Clean

The air filter is located inside the left side door of

the machine, which is used to filer the dust and
impurity in the air to keep the air clean for
combusting in the cylinder.
1. Shut down the engine and open the left side
door to get access to the air filter.
4. Clean the main filter element with
compressed air (below 300kPa). First wash it
out along the pleats inside the main filter
element, then repeat washing the pleats
along the inside and outside surface of the
main filter element.

2. Loosen clamp (2) and remove the cover, take

out the main element(1).

CAUTION: Do not hit when cleaning the

main filter element, or the engine damage
could result.
2
112
Maintenance Manual
Important Maintenance Procedures

5. 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.
Air Filter--Main Element and Safety
Element--Replace
CAUTION: Always replace the safety
filter element with a new filter element. Never
use again after cleaning.

1. Park the machine on a flat ground and lower

the bucket to the ground.
2. Stop the engine. Take the key out of the start
switch.
3. Push the pilot shutoff lever to LOCK position.

6. Install a clean main filter element into the air

filter and ensure an even contact at the end
of the main filter element. Tighten the nut on
the top of the main filter element, do not use
tool to avoid damage to the main filter
element.
7. 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.
8. Replace the main filter element after it has 4. Open the engine hood. Remove the inner
been cleaned up to six times. Replace once and outer cover of the air filter. Loosen
every year even if it hasn't been cleaned six clamp(2), open the cover and remove main
times. Change the safety filter element while element(1). .
changing the main filter element.
9. Open the dust outlet (1) to discharge the
dust.

5. Take out the safety element slowly.

 113
Maintenance Manual
Important Maintenance Procedures

6. Clean the inner walls of the air filter. Fuel--Replenish

7. Install a new safety element. Make sure the
seal ring on the safety element contacts The fuel tank of the machine is located below the
evenly. Tighten the safety element with hand rear of the engine. If the fuel level is insufficient,
only, do not use tools. replenish fuel in time.

8. Install new main element and the inner and

outer cover of the air filter. Tighten the safety
element with hand only, do not use tools.

CAUTION: Replace the safety filter

element together while replacing the main
filter element. After a clean main filter
element has been installed, if the air filter
alert indicator is still on or black smog is still
exhausted, replace the safety filter element.

Fuel Level--Check 1. Open the left side door of engine hood to get
access to the fuel filler.
The fuel level gauge is located in the display.
Replenish fuel immediately if the fuel indication
points to red zone.

2. Open the fuel filler cap to replenish fuel.

CAUTION: Don't take out the strainer of

the fuel filler when replenishing fuel.

Fuel Tank--Clean

CAUTION: 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. And dispose all
fluids according to local regulations.
114
Maintenance Manual
Important Maintenance Procedures

Periodically clean the strainer of the fuel filler and 3. Open the water drain valve (1) at the rear
fuel tank, clean the fuel tank according to the right door to drain the residual water and
following method: trash and close it after several seconds.
1. Open the water drain valve (1)at the rear
right door to drain the residual water and
trash. Collect the water with suitable
container.

4. If the condition is permitted, fuel should be

2. Wash the fuel tank surface with clean fuel
until the discharged fuel is clean.
3. Close the water drain valve (1)at the bottom
of the fuel tank.
Fuel Tank Water and Impurity--Remove
If the fuel is mixed with water or impurity, the fuel
pump and fuel injection nozzle can't work
properly and quickly wear. Measures should be
taken to remove water and impurity in fuel.
deposited for 24 hours before it is filled to the
tank.
5. After finish working everyday, replenish fuel
and remove the humid air in the fuel tank.
6. After replenishing the tank every time, wait
for 5 ~ 10 minutes before starting the engine
so that water and impurity can sink into the
bottom of the tank.
CAUTION: Never wait to fill fuel with the
fuel runs out completely. This will cause the
engine to stop and the engine performance
could be affected by the water and impurity at
the bottom of the fuel tank.

1. Swing the revolving frame for 90°, then park

the machine on a flat grond and lower the
bucket onto ground.

2. Shut down the engine and take out the key.

 115
Maintenance Manual
Important Maintenance Procedures

Fuel Pre-filter and Fuel Filter--Water and 2. Remove the filter with spanner from the
Impurity--Remove support.

Remove the fuel filter

1. After finish working everyday, loosen the
water drain plug at the bottom of the fuel pre-
filter and fuel filter to drain the water and
impurity.
2. Loosen the water drain plug (1) at the bottom
of the fuel pre-filter to drain water and
impurity until clean fuel flows out. Then
tighten the water drain plug.

2
3. Remove the gasket (1)on the thread
connector of the support. Clean the seal
surface of the support with a non-fibrous
cloth.

1 Clean the surface of the support

3. Loosen the water drain plug (2) at the bottom

of the fuel filter to drain the water and
impurity until clean fuel flows out. Then
tighten the water drain plug.

CAUTION: Do not overtighten the valve,

otherwise the thread and gasket will be
damaged.

Fuel Filter and Fuel Pre-filter--Replace

CAUTION: Do not install a fuel filter that

is filled with fuel. Fuel contamination will
quicken the wear of the parts of the fuel
system.

Replace the fuel filter and fuel pre-filter at the first

50 hours, replace the fuel filter and fuel pre-filter
every 250 hours later on.
1. Clean the filter surrounding and support.
116
Maintenance Manual
Important Maintenance Procedures
4. Install a new gasket on the thread connector
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.
Prepare a new fuel filter
5. Install the filter to the support with hand. After
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.
Install a new fuel filter
Fuel--Heat
If it is necessary to heat the fuel due to low
temperature, ensure that the temperature of fuel
doesn't exceed 35°C. Otherwise power loss
could be resulted.
Engine Oil Level-Check
CAUTION: Too much or too little engine
oil can result in damage to the engine.
1. Drive the machine to a flat area, stop the
engine.
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 dipstick (1) is
located above the engine.
1
4. Take out the dipstick. Wipe it with a clean
cloth and completely reinsert the dipstick into
the end of the oilfiller of the engine. Take the
dipstick again and check the oil level. The oil
level on the dipstick should be between the
low (L) and high (H) graduation marks.
 117
Maintenance Manual
Important Maintenance Procedures

5. If the oil level is below L, replenish oil. If the 1. Park the machine on flat ground, start the
oil level is above the H, screw out the oil engine and until the water temperature
drain plug at the bottom of the engine oil pan reaches 60°C.
to release some oil.

Oil level range

A. Engine coolant temperature gauge

2. Stop the engine and push the pilot shutoff
lever to LOCK position.
Engine Oil--Replace

CAUTION: Care must be taken to ensure

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

CAUTION: High-temperature lubricant 3. Loosen the engine oil drain valve at the
can cause personal injury. Replace the bottom of engine oil pan to drain the oil into
lubricant only when the lubricant is warm and suitable container. Replace the engine oil
the impurity is floating. filter.

Replace the engine oil at the first 50 hours,

replace the engine oil every 250 hours later on.
118
Maintenance Manual
Important Maintenance Procedures

4. Close the oil drain valve and replenish clean
engine oil from the oil filler till the engine oil is
at H on the oil dipstick. Run the engine at idle
speed to check the engine oil filter and oil
drain valve for leakage.
3. Clean the surface of the gasket of the
support with a clean cloth. If old O-ring
adheres to the support, remove it.
Clean the support

5. Stop the engine and wait for about 10

minutes, let the engine oil fully return to the
oil pan, check the engine oil level again, if
insufficient, replenish engine oil to the H on
the dipstick.

Check engine oil level

4. Install new O-ring, replenish the oil filter with

clean engine oil, and apply a coat of clean
engine oil on the gasket surface.

Install new engine oil filter

CAUTION: 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

Replace the engine oil filter at the first 50 hours,

replace the engine oil filter every 250 hours later
on.
1. Clean the area around the support of the
engine oil filter.
2. Remove the engine oil filter with a belt
spanner.
CAUTION: 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.
5. 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.

CAUTION: Excessive tightening the

engine oil filter could result in damage to the
thread or the seal of engine oil filter element.
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Engine Valve Lash--Adjust

WARNING: Adjustment of the engine

valve lash must be performed by the trained
person with special tool.

More information about the adjusting procedure

of the engine valve lash refer to the Operation
and Maintenance Manual of the Engine.

Engine Air Intake System--Check

This step mainly check the air intake system for

cracked hose, loose clamps or holes. Tighten or
replace the parts to ensure the air intake system
has no leakage.

Engine Belt--Check

Visually check the belt of the engine for cracked

surface.
If the belt cracks in its lengthways or flake
material fall off, replace it with a new belt. More
information of replacing procedure, refer to the
Operation and Maintenance Manual of the
Engine.

Engine Tensioner Bearing and Fan Hub-

-Check

Check the tensioner to ensure it can turn freely.

Check the fan hub, it must rotate without any
wobble or excessive end play.

Fan Belt Tension--Check/Adjust

As for the adjustment procedures of the fan belt

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

CAUTION:Loose fan belt could cause

inappropriate battery charging, engine
heating and quick or abnormal wear. Over
tightened fan belt also will cause bearing and
belt damaged.
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Important Maintenance Procedures

Gear Oil

Gear oil table

Interval (Hour)
Components Q'ty
8 50 100 250 500 1000 2000
Check oil level —
1.Swing reduction gear
Replace 3.4L ★★★
Check oil level —
2.Travel reduction gear
Replace 5.4L × 2 ★★★

★★★ The first service time

Gear oil filing position

1. Swing reduction gear

2. Travel reduction gear

Swing Reduction Gear Oil Level--Check
CAUTION: Too much or too little gear oil
will cause damage to the swing reduction
gear.
1. Park the machine on flat ground and lower
the bucket onto ground.
2. Shut down the engine and take out the key.
3. Push the pilot shutoff lever to LOCK position.
4. Take out dipstick (1), the oil level should
reach the position between L and H.
L H
5. If the oil level is below L, then open oil filler
cap (3) to replenish gear oil.
6. If the oil level is above H, then loosen drain
plug (2) at the end of the exhaust pipe to
drain the excessive gear oil.
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Swing Reduction Gear Oil--Replace
CAUTION: Care must be taken to ensure
that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before disassembling any
component containing fluids or dismounting
any hydraulic lines. Dispose of all fluids
according to local regulations.
CAUTION: Drain the gear oil only after
the machine stops working for a period of
time, when the lubricant is warm and any
impurities is floating.
Replace the gear oil at the first 500 hours and
replace it every 1000 hours after that.
1. Park the machine on flat ground and lower
the bucket onto ground.
2. Shut down the engine and take out the key.
3. Push the pilot shutoff lever to LOCK position.
4. Unscrew the drain plug (2)at the bottom of
the exhause pipe to drain oil and collect with
a container.
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Travel Reduction Gear Oil Level--Check

CAUTION: When refilling or draning gear

oil of the travel reduction gear, pay attention
to the oil splash.

Park the machine on flat ground. Wipe off each

filling position before checking. Slowly drive the
machine at low speed to locate the oil drain plug
(4) of the travel motor (1) to the lowest position.
The oil drain plugs on left and right travel motor
will not be at the lowest position at the same
time, so check the oil level of the left and right
travel motor.
1. Move the machine slowly until oil level plug
The gear oil temperature might be very high. (2) is located to level mark.
Wear a protective device and handle carefully
to avoid personnel injuries.

5. Install the drain plug. 3

6. Open the oil filler cap(3) and replenish gear
oil to correct level. Check the oil level for 5 2
minutes after replenishing. Make sure the oil
level stays stable.
1

4 5

1. Travel motor
2. Oil level plug
3. Air exhaust plug
4. Oil drain plug
5. Oil level mark
2. Lower the bucket onto ground.

3. Shut down the engine and take out the key.

4. Push the pilot shutoff lever to LOCK position.
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Important Maintenance Procedures

5. Unscrew air exhaust plug (3) slowly to 2. Move the machine slowly until the oil drain
release pressure after the gear oil cools plug (4) is at lowest position.
down completely.

3
The gear oil temperature might be very high.
Wear protective device and handle carefully 2
to avoid personnel injuries

6. Unscrew plug (2) to check oil level. If oil 1

overflows out of the plug hole, it indicates a
full oil level. 4 5
7. Tighten plug (2) and (3) to a torque of
49N.m(5kgf.m). 1. Travel motor
2. Oil level plug
8. Check the gear oil level of another travel 3. Air exhaust plug
motor as above. 4. Oil drain plug
5. Oil level mark
Travel Reduction Gear Oil--Replace 3. Lower the bucket onto ground.

CAUTION: Care must be taken to ensure

that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before disassembling any
component containing fluids or dismounting
any hydraulic lines. And dispose all fluids
according to local regulations.
4. Shut down the engine and take off the key.
CAUTION: Drain the gear oil only after
the machine stops working for a period of 5. Push the pilot shutoff lever to LOCK position.
time, when the lubricant is warm and any 6. Loosen air exhaust plug (3) to release
impurities is floating. pressure.

Replace the gear oil at the first 500 hours and

replace it every 1000 hours after that.
1. Park the machine on flat ground. Wipe off all The gear oil temperature might be very high.
the filling position. Wear protective device and handle carefully
to avoid personnel injuries.

7. Unscrew oil drain plug (4) to drain oil.

8. Tighten plug(4) and wrap the thread and bolt
with tape. Install the bolt and tighten the bolt
to a torque of 49N.m(5kgf.m).
9. Unscrew oil level plug (2).
10. Refill oil until the oil flows out of the bolt.
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Important Maintenance Procedures

11. Wrap the oil level plug and air exhaust plug
with tape, tighten the plug to a torque of
49N.m(5kgf.m).
12. Replace the gear oil of another travel
reduction gear as above.
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Maintenance Manual
Important Maintenance Procedures

Hydraulic System

Interval (Hour)
Components Q'ty
8 50 100 250 500 1000 1500 2000 2500
1. Check hydraulic oil level 1
2. Replace hydraulic oil 230L ★★★
3. Clean suction oil filter 1 When replace oil
4. Replace return filter of hydraulic tank 1
5. Replace pilot oil filter 1

★★★ The first service time.

Main hydraulic components

1 2 3

1. Hydraulic tank
2. Suction filter of hydraulic tank
3. Return filter of hydraulic tank
4. Pilot oil filter
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Maintenance Manual
Important Maintenance Procedures

Hydraulic System Air--Purge 2. Retract and extend all of the cylinders to the
maximum stroke end for 3-4 times.
CAUTION: If hydraulic components is 3. Finally, retract and extend all of the cylinders
repaired or replaced, or the hydraulic circuit to the maximum stroke end for 4-5 times to
is removed or installed, purge the air in the purge air completely.
circuit to avoid damage to the hydraulic
components. 3. Swing Motor Air--Purge
1. Pump Air--Purge 1. Start the engine at low speed, loosen the
connector (1) and check for leakage.
1. Park the machine on flat ground and lower
the bucket onto ground, push the pilot shutoff
lever to LOCK position.
2. Shut off engine and remove the key.
1
3. Unscrew air exhaust plug (1) and check
2
whether oil flows out.

2. If no leakage is found, shut down the engine

4. If no oil flows out, then refill hydraulic oil to
the pump.
5. Start and run the engine at idling speed. If no
bubble comes out from air exhaust plug (1),
tighten the plug and finish exhausting air.
and remove hose (2) at the top of the swing
motor to refill hydraulic oil.
3. After purging the air, tighten hose (2).
4. Run the engine at low speed, slowly swing
the revolving frame left and right at least
twice, air will be purged automatically.
CAUTION: If air is not purged from the
swing motor, the bearing of the swing motor
will be damaged.

CAUTION: Running the pump without 4. Travel Motor Air--Purge

enough oil could produce abormal heat and
cause the pump wear prematurely. CAUTION: After travel motor gear oil is
replaced, purge air from the travel motor.
2. Cylinder Air--Purge

1. Start the engine at low idling speed. Retract

and extend the cylinder to 100mm from the
stroke end for 4-5 times.

CAUTION: Do not retract and extend the

cylinder to the maximum stroke end,
otherwise the air in the cylinder will damage
the seals of the piston.

1. Start the engine and run it at low speed.
Loosen air exhaust plug (1) to check for
leakage. If oil flows out, tighten the plug.
2. Run the engine at low speed, swing the work
implement 90° to locate it vertically with any
one track.
3. Support the machine by the work implement
to raise the track above ground, then rotate
the track under an unloaded condition for 2
minutes.
4. Repeat this operation for left and right track.
Rotate the track forward and backward
evenly.
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Maintenance Manual
Important Maintenance Procedures
5. Attachment Air--Purge(If equipped)
1. If a hydraulic hammer or other attachment is
installed, run the engine at low speed and
depress the auxiliary pedal repeatedly for
about 10 times until the air purges from the
attachment lines.
1. Auxiliary pedal
NOTICE: Purge the air according to the
procedures that are stipulated by the
manufacturer if there are any.
2. After finishing air purging, shut down the
engine and hold the machine for 5 minutes to
purge the bubble in the cylinder.
3. After finish air purging, check the oil level.
Refill if the oil level is low.
Maintenance Suggestion
There are four sealing types for the hydraulic
system.
1. Plane-type O-ring (ORS device)
1. This O ring is used for the connection of
hoses and connectors to prevent oil leakage.
128
Maintenance Manual
Important Maintenance Procedures
2. Make sure that there is no dirt or defects on
the sealing face.
3. When reassembling this unit, replace O-ring
(1).
a. Press the device by hands first to ensure that
O-ring (1) is kept in the sealing slot (3).
b. Tighten the nuts until they reach the torque
values as shown. Do not distort the hose
when tightening nuts.
2. Flange-type plane O-ring
1. Make sure that there isno dirt or defects on
the sealing face.
2. When reassembling this unit, replace O-ring
2.
a. Lubricate the O- ring. Stick the O-ring to the
seal slot of joint 4 by using vaseline.
b. Use bolt 1 to install plate 3 partially, then
install the joint 4 with O-seal ring 2 onto the
fitting surface, finally, install plate 3
completely.
c. Tighten bolts alternately. Tighten bolt M10-
10.9 to a torque of 72 ± 6N·m. and bolt
M12-10.9 to 120 ± 10N·m.
3. Angle-type O-ring
These units are used for the connection of tubes
and oil port.
1. Make sure that there is no dirt or defects on
the sealing face.
2. When reassembling this unit, replace O-ring
2.
4. 24°Cone Seal Device(with O-ring)
This unit is used for hoses and connectors
connection. Tape face (2) and (3) form a seal
face that can prevent oil leakage. O-ring (4)
works as another seal to prevent oil leakage.
1. Make sure that there is no dirt or defects on
the taper face (2)and (3).
2. When reassembling this unit, O-ring (4) can
be reused, if it is undamaged.
3. If O-ring (4) is damaged, replace it by
pushing nut (5) backward, then put a new O-
ring into the slot. (Consult the dealer for the
tools for replacing O-rings.)

4. When assembling this unit, mate taper
surface (2) and (3) tightly, then tighten nut
(5).
5. Tighten the nut to a specified torque. When
tightening the nut, hose twisting is not
allowed.
Hydraulic Oil Level--Check
1. Park the machine on a flat ground.
2. Position the machine with arm cylinder and
bucket cylinder fully retracted, and lower the
bucket onto ground.
3. Shut down the engine and take out the key.
4. Turn the pilot shutoff lever to the LOCK
position.
5. Check the sight glass (1) on the hydraulic oil
tank. The oil must be between low and high
mark.
1
129
Maintenance Manual
Important Maintenance Procedures
6. If the oil level is low, loosen the breather
cap(2)counterclockwise and slowly to release
pressure and open the cover carefully.
2
7. Refill oil, and check the sight glass again.
8. Install the breather cap (2).
Hydraulic Oil and Suction Filter--
Replace
CAUTION: Care must be taken to ensure
that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before disassembling any
component containing fluids or dismounting
any hydraulic lines. And dispose all fluids
according to local regulations.
CAUTION: When hydraulic hammer is
equipped and use frequency of the hydraulic
hammer is 50%, replace the hydraulic oil and
suction filter every 1000 hours; when the use
frequency is 100%, replace the hydraulic oil
and suction filter every 600 hours.
130
Maintenance Manual
Important Maintenance Procedures

1. Swing the revolving frame to 90 ° and park 8. Slowly loosen the breather cap counter-
the machine on flat ground. clockwise to release pressure, then open the
cap carefully.

2
1

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

minutes, repeatedly raise or lower the boom,
tilt back or dump or bucket for several times
to raise the hydraulic oil temperature.
3. Position the machine with arm cylinder and
bucket cylinder fully retracted.
4. Lower the bucket onto ground.
1. Hydraulic tank cover
2. Breather cap
9. Open the hydraulic tank cover.
10. Clean the oil outlet of hydraulic tank and
unscrew oil drain plug to drain oil. Collect the
oil with a container.

5. Shut down the engine and take out the key.

6. Push the pilot shutoff lever to LOCK position. 3

7. Clean the top of hydraulic tank to prevent
dust coming into the hydraulic oil system. 3. Oil drain plug

CAUTION: The hydraulic oil may be

under hot temperature, wear protective
devices and handle carefully to avoid
personnel injury.
 131
Maintenance Manual
Important Maintenance Procedures

11. Remove suction filter and rod group. 17. Unscrew the air exhaust plug from the top of
the pump. Fill oil to the pump through the
2 plug opening and then install the air exhaust
plug.
1

7
6
5

1. Hydraulic tank cover

2. Breather cap
4. Suction filter
5. Rod group 7. Air exhaust plug
6. Nut
12. Clean the internal surface of the suction filter CAUTION: Starting the engine without
and hydraulic oil tank. Take out the screen to injecting the hydraulic pump with oil will
wash. If it needs to be replaced with a new cause damage to the engine easily.
filter, install the new filter onto the rod.
Tighten the nut to a torque of 14.7 to 18. Start the engine and run it at idle speed. Put
19.6N·m. a ''DO NOT OPERATE'' tag to the pilot
shutoff lever. Make sure the pilot shutoff lever
13. Install suction filter and rod group. Ensure the
is at LOCK position.
filter is installed in the correct position.
14. Wash the hydraulic oil tank with clean
hydraulic oil. Wipe it with a clean and dry
towel. Install and tighten the oil drain plug.
G
IN
N
AR
W

er ot
!

CAUTION: Pay attention to the hydraulic

op o n

e
at
d

oil cleanness during handling in order to

prevent foreign matter from coming into the
r:
te
ra
pe
O

:
ate
D

hydraulic system.

15. Refill hydraulic oil to the level between low
and high mark.
16. Install the hydraulic oil cover. Ensure the
suction filter and rod are fixed to correct
position. Tighten the bolt to a torque of 49
N·m.
19. Loosen the breather cap to release the air
until the oil flows out of the opening. Tighten
the cap.
20. Run the engine at a speed of 1200 rpm.
Operate the control lever slowly for about 15
minutes to exhaust the air from the system.
21. Position the machine with arm cylinder and
bucket cylinder fully retracted.
132
Maintenance Manual
Important Maintenance Procedures

22. Lower the bucket onto ground. 4. Slowly loosen the breather cap counter-
clockwise to release pressure.

2
1

23. Shut down the engine and take out the key.
24. Push the pilot shutoff lever to the LOCK
position.
1. Hydraulic tank cover
25. Check the sight glass of the hydraulic oil 2. Breather cap
tank. Refill hydraulic oil if necessary. 5. Open hydraulic tank cover carefully.

Hydraulic Return Filter--Replace CAUTION: Spring force exists at the

CAUTION: When using hydraulic
hammer and the use frequency is 50%,
replace the hydraulic return filter every 500
hours; when the use frequency is 100%,
replace the hydraulic return filter every 300
hours.
bottom of the hydraulic tank cover. Secure
the cover by hand when removing the two
bolts.
6. Secure the cover by hand to overcome the
spring force when removing the last two
bolts. Open the cover.

1. Park the machine on flat ground and lower 7. Remove the spring and the return filter.
the bucket onto ground.
1

2. Shut down the engine and take out the key.

1. Hydraulic tank cover
3. Push the pilot shutoff lever to the LOCK 3. Return filter
position. 4. Spring
8. Replace with a new return filter.
9. Install a spring, cover and O-ring.
 133
Maintenance Manual
Important Maintenance Procedures

Pilot Oil Filter--Replace 5. Operate the hand control lever repeatedly to

release accumulator pressure.
The pilot oil filter is located under the valve on
the front side of hydraulic oil tank. 3

2 4

1. Valve
2. Pilot oil filter
1. Park the machine on flat ground.
2. Lower the bucket on to ground.
2
3. Turn the start switch key to ON position to
turn on the power. 2. Pilot oil filter
3. Hand control lever
4. Accumulator
6. Open the filter housing.
7. Move the filter forwards and backwards to
remove the filter.
8. Replace O-ring and filter parts.
4. Push the pilot shutoff lever to the UNLOCK 9. Clean the O-ring of filter head and filter parts.
position.
10. Coat a thin layer of clean grease on the new
O-ring, and install the O-ring into the head of
the filter. Be sure the O-ring is installed to the
correct position.
11. Coat a thin layer of clean grease around filter
head where the new component will be
installed. Slowly mount the new filter
components.
134
Maintenance Manual
Important Maintenance Procedures
Electrical System
Battery
Never let burning cigarette or open fire close
to the batteries.
Wear safety glasses and rubber gloves when
touching batteries during work. Also wear
protective clothes as the vitriol in the battery
can result in blind or burn.
See the doctor at once if you touch the vitriol
carelessly.
Stop the engine before working with
batteries.
The battery is located in the battery box on the
rear left side of machine.
A maintenance-free battery is provided in this
machine. Obey the following procedures when
operating.
Battery--Install
WARNING: The battery plate will become
loose due to the machine vibration after
operating the machine for a period of time.
Check the tightness of the nut located in the
middle of the plate. Tighten it if it is loose.
WARNING: The battery terminals and the
cable connectors may not have a good
connection due to the machine vibration after
operating the machine for a period of time.
Check the battery terminals and cable
connectors for tightness frequently.
Before installing the battery to the machine,
make sure that the battery hydrometer is green.
1. Turn the start switch (also called ignition
switch) to OFF position then remove the key.
Turn disconnect switch to “O” position.
2. Clean the battery terminals and surface with
a clean cloth and hot water. Do not use petrol
or other organic impregnant or cleanser.
3. When connecting:
(a) Connect the positive post of one battery
to the negative terminal of the other
battery with the cable.
(b) When connecting, connect one end of the
battery positive lead terminal to the
battery positive post, the other end to
start motor.
(c) Connect one end of the battery negative
lead terminal to the battery negative post,
the other end to the battery disconnect
switch.
(d) Connect the battery disconnect switch to
ground cable.
To start motor
5 3
1 To battery
disconnect
switch
2
1. Battery
2. Battery
3. Cable

4. Battery negative lead
5. Battery positive lead
4. Tighten the nut.
5. Turn on the battery disconnect switch. Insert
the key and start the engine.
A wrong installation of the negative and
positive terminal will result in a serious
damage to the battery. Distinguish the
positive (+) and negative terminal (-)
correctly.
Battery--Charge
Long use of the electrical appliances without
starting the engine, a long stop, a long storage,
electricity leakage, or the alternator charging
failure; all these reasons could lead to an
abnormal battery charge and result in an loss of
electrical power. Recharge the battery if this
happens.
Keep ventilated when charging. Charge the
battery under normal temperature.
Do not smoke when charging the battery,
keep any flames away.
Reasons for Battery Electrolyte Loss
1. Abnormal usages, such as the electrical
appliances are turned on for a long time
under unstarted conditions.
2. The batteries is exhausted due to long
running, current leakage, or additional
electrical appliances are used.
3. Frequent starting of the machine.
135
Maintenance Manual
Important Maintenance Procedures
4. Failures of the machine charging system,
such as malfunction of alternator or its
electronic units, low charging voltage, loose
engine belt, etc., which result in abnormal
charging of the batteries, battery electrolyte
loss, black hydrometer, and even starting
failure.
5. The batteries have been stored over six
months before being used.
NOTICE: The batteries under the above-
mentioned condition can work again by
recharging.
The battery can not be charged in the
following situations:
1. If the battery surface is cracked or there is
acid leakage. Discard it.
2. If the terminal cracks. Discard it.
3. Do not charge the battery if it is over-charged
or over-discharged. Discard it.
4. Do not charge the battery with clear
hydrometer. Replace the battery.
Charging procedures:
1. Turn the disconnect switch to “O” position.
2. Remove the battery from the machine. When
removing, first disconnect the negative
terminal of the battery.
CAUTION: When connecting the battery,
first connect its positive terminal; when
disconnecting the battery, first disconnect its
negative terminal.
3. Clean the battery terminals and surface with
a clean cloth, remove the oxidation surface.
4. Connect the positive clamp of the charger to
the positive terminal of the battery, the
negative clamp to the negative terminal
under room temperature. Do not charge the
battery in tandem way (24V).
136
Maintenance Manual
Important Maintenance Procedures

5. It is recommended to use a charger with a
constant voltage of 16VDC (the maximum
voltage cannot exceed 16.2 VDC; if more
than 16.2VDC, a lot of acid will be
decomposed, then its level will decrease and
the hydrometer turns white, then discard it)
and a limited current of 25A. The battery
charge is finished if the hydrometer turns
green.
6. Charge the battery according to the following
specification if the above-mentioned
requirement can not be met
(a) Choose 1/8~1/10 of rated current to
charge. (12~15A for battery 37B0108;
10~12A for battery37B0077)
(b) The voltage should reach but not exceed
16V when charging is finished.(Voltage
below 16 V will cause the hydrometer to
turn black after charging)
(c) If the voltage can not be kept below
16VDC, monitor the battery voltage when
charging, otherwise the battery service
life could be affected due to water loss
caused by an over charge.
(d) Table of charge time and battery voltage
for reference.
Battery Voltage Charge Time
12.55-12.45VDC 2h
12.45-12.35VDC 3h
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
Below11.00VDC 14h
7. Check the hydrometer color after finishing
charging. Green hydrometer indicates that
the battery is fully charged.
(a) If the hydrometer is black, check the
cable connection and connecting points.
Check if the voltage reaches 16VDC after
charging. Measure the voltage after 24
hours. If necessary, charge the battery
again according to the above table.
(b) If the hydrometer is clear, bubble might
exist in the hydrometer. Shake the battery
slightly to remove the bubble. If the
hydrometer is still clear, then electrolyte
loses seriously, discard the battery and
replace with a new one.
8. As for the battery with a voltage under
11.0VDC, it may not be able to be charged at
the beginning. Due to the serious
insufficiency of electricity, the proportion of
acid is close to water, therefore, the battery
resistance is higher. The acid proportion
increases during recharge and the charging
current can get right gradually.
WARNING: Secure the two terminals
tightly. Do not charge the batteries of 24VDC
voltage in serial connection.
WARNING: Stop charging immediately to
check the reason if the batteries discharge
hole spurts acid during the charging process.
9. Stop charging if the battery temperature
exceeds 45°C during the charging process.
Halve the charging current before recharging
after the battery temperature drops to the
ambient temperature.
10. Check the battery voltage every hour during
the charging process. The battery is at full
charge if the hydrometer is green.
CAUTION: If the hydrometer is black,
check for loose cables and clean connecting
terminals. Check whether the voltage has
come to 16VDC. If the hydrometer is clear, it
is likely that air bubbles exist in it. If the
hydrometer is still clear after slight shaking
(indicates an electrolyte loss), replace with a
new battery.

11. It is recommended to apply Vaseline on the
battery terminals to avoid electric corrosion
after charge is completed.
Battery--Maintain
1. Disconnect the negative terminal of the
battery if the machine is stored over 15 days.
2. Check the electrical state of the battery every
3 months.
3. If the voltage exceeds 12.4VDC, the battery
is in normal condition.
4. If the voltage is under 12.4VDC, the battery
lacks a full charge.
5. Recharge if the battery lacks a full charge.
Recharge according to special procedures.
6. For the machine which has not disconnected
the battery terminals, check the battery
voltage state every month. If the voltage is
under12.4V, recharge it according to special
procedures.
7. As for the machine which is stored over 1
year, replace with a new battery and dispose
of the old one if the above- mentioned
requirements can not be followed.
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 a
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 are any) at
a local place.
137
Maintenance Manual
Important Maintenance Procedures
Alternator Maintenance
It is forbidden to check the alternator by
short-circuiting the negative and positive
terminal of the alternator, otherwise the diode
will be burnt and the voltage regulator coulde
be affected.
Keep any metallic conductor away from
termianl B+ and D+ of the alternator.
The alternator is a supporting component of the
diesel engine. The operating voltage for the
excavators less than 10T is 13.5V and for the
excavators more than 10T is 28V. It also has a
built-in electronic voltage regulator. Check the
connections of the alternator terminals
frequently. Connection looseness at either
terminal ''B+''or ''ground'' will result in trouble of
electrical system, even cause serious failure.
Turn off the start switch before checking the
terminal ''B+'' or ''ground''.
CAUTION: The cable of the terminals can
not be incorrectly connected, otherwise the
diode could be burnt and result in serious
failure.
Method of judging whether the alternator works
normally and the handling measures:
1. Turn on the start switch and observe reading
of the voltmeter, and then start the diesel
engine and observe reading of the voltmeter
again. The latter reading should be higher
than the former one.
2. You can also use the 200V DC voltage
position of a multimeter to check. Turn on the
start switch, measure terminal voltage of the
alternator (red meter pen connects D+ of the
alternator while black meter pen connects the
ground), and then write down reading of the
multimeter (in fact, this reading is just the
terminal voltage of the battery and generally
the value is under 26V).
138
Maintenance Manual
Important Maintenance Procedures

3. Start the engine and increase the engine The control box is located near the disconnect
speed to rated speed. Check the voltage of switch.
the alternator again and write down the Control box
reading of multimeter(This reading should be
under 28V if the alternator works
normally).The latter reading should be higher
than the former one.
4. In case the alternator does not work:
(a) Check drive belt of the alternator for
looseness. 1

(b) Turn off the start switch, and then use a 2

wrench to check the connections of 3
alternator terminals.
(c) Check to see whether the alternator
connects correctly to the ground.

Start Motor Maintenance 1. Preheat fuse

2. Start and oil cutoff valve fuse
The start motor is a supporting component of the 3. Power supply fuse
diesel engine. It mainly consists of a solenoid, The control unit is located at the behind of the
DC motor, shifting fork and driving gear. The start cab.
motor converts electrical energy of the battery
into mechanical energy through the DC motor.
Then the driving gear will drive the flywheel of
the engine to start the engine.
After the engine starts, the start motor should
immediately stop. Otherwise, the driving gear
may be damaged, the DC motor may be burnt,
the chock electromagnet may be damaged, and
capacity and service life of the battery may also
be greatly affected.
See the following table for the fuse color:
It is prohibited to allow any metallic conductor to
approach any naked terminal freely. Especially Model Color
Colorless/grey
ensure that the other metallic articles around the BK/ATC-5A
brown
start motor will not contact or rub the naked
BK/ATC-7.5A Brown
terminal after a long and severe shock or
operation of the machine. Otherwise, fire may BK/ATCC-10A Red
occur to the machine. BK/ATC-15A Blue
BK/ATC-20A Yellow
Fuse-Check/Replace
BK/ATC-30A Green
The fuse is used to protect the electrical system
from being damaged by overload of the circuit. CAUTION: Replacing fuses with the
Replace the fuse if is burnt. If a new fuse is burnt same type and size from different brands is
again, check the circuit and repair the circuit if allowed.
necessary.
 139
Maintenance Manual
Important Maintenance Procedures

NOTICE: If it is necessary to replace 4. Alternator output fuse

fuses frequently, an electrical problem may
occur. Contact your Liugong dealer. Alternator output fuse is installed in the double-
way fuse box (37B0079), 70A.
1. Control unit

See following picture for the fuse distribution

inside the fuse box.

1
2

1. Alternator
2. Alternator output fuse

2. Start and oil cutoff valve fuse

The start and oil cutoff valve fuse are installed in

the double-way fuse box (37B0079), 50A for
each.

3. Preheat fuse

The preheat fuse is installed in the double-way

fuse box (37B0079), 200A (=2X100A).
140
Maintenance Manual
Important Maintenance Procedures

Air Conditioning System

Maintenance intervals

Interval (hour)
Components Q’ ty
8 50 100 250 500 1000 1500 2000 2500

1. Check coolant for leakage —

2. Adjust the belt tension of compressor 1

3. Clean external surface of condenser. 1

4. Clean screen of fresh air and recirculating
air.

Refrigerant Leakage-Check

A sight glass is provided on the top of the

Personnel injury or death could result due to
the inhaled refrigerant gas or frog through
lighting the cigarette or other smoking ways.
Never smoke when maintaining the air
conditioner or in the place where refrigerant
gas may exist.
refrigerant receiver. Under normal working
condition, refrigerant can be viewed through the
sight glass. An even and stable refrigerant flow
indicates that the refrigerant capacity is normal. If
bubbles are found in the refrigerant, then
replenish refrigerant because that indicates a
refrigerant leakage in the system.

Wear protective goggles or mask when work 1

with refrigerant, check leakage with 1
instrument, adjust pipe joint, and connect the
high & low pressure combination gauges.

When maintaining the air conditioning

system, personal injury could be resulted 2
due to high pressure , high temperature and 2
chemicals of system. Moving parts and
rotating pulley could also cause harm to
human body.
1. Sight glass
Never bump the refrigerant receiver, a fierce 2. Refrigerant receiver
bumping could cause explosion and
In cold winter, run the compressor for 20 minutes
personnel injury.
every week to avoid refrigerant leakage.
Refrigerant steam could produce poisonous
CAUTION: R134a refrigerant is used in
gas when it contacts a fire, which could
this air conditioning system. Do not use other
cause harm to human body. When the
refrigerant or refrigerant with low quality to
refrigerant content exceeds 25% in the air,
avoid damaging the compressor.
suffocating to death could be resulted.

Do not add excess refrigerant when
replenishing to avoid compressor liquid
impact damage caused by insufficient space
for refrigerant vaporization in the air
conditioning system.
PAG100 refrigeration oil is used in this
system.
CAUTION: If refrigerant leakage is found,
check all the joints that connected to the
hoses for loose condition.
Compressor Belt Tension--Check/
Adjust
The compressor belt tension: apply (W=15N)
force in the center span of the pulleys
(compressor pulley and engine pulley). The
deflation of the belt center distance A should be
5.0 ± 1mm. See the following picture:
Adjust the air conditioner compressor tension as
follows:
1. Loose nut on the tensioner shaft.
2. Tighten the bolt in order to tighten the belt.
3. Tighten the nut on the tensioner shaft.
Replace with a new belt if the belt can not be
tensed. That is, the deflation of the belt center
distance A is more than 5.0 ± 1mm when
applying (W=15N) force in the center span of the
pulleys (compressor pulley and engine pulley).
Replace the belt if the belt fluffs or cracks.
141
Maintenance Manual
Important Maintenance Procedures
Evaporator--Check
1. The evaporator is installed inside the cab.
Keep the air inlet unblocked.
2. Keep the air inlet free from any cotton, paper,
plastic and so on.
CAUTION: A blocked air inlet will cause
unventilation, which could result in electrical
system failure or fire.
Condenser Surface--Clean
1. Check and clean the condenser tube and its
fins surface periodically for contamination.
2. Pay attention to the condenser fins. Do not
damage them. Adjust the pins by clamps if
they are twisted.
Fresh Air/Recirculating Air Filter--Clean
The cab air filters consist of recirculating air
strainer and fresh air strainer. The clogging of the
filters is entirely dependent on the working
environment of the machine.
Recirculating air filter--Clean
If the recirculating strainer is blocked, the air
flow rate will be reduced, and the effect of
cooling and heating will be weakened. The
fresh air will reduce if the fresh airstrainer is
be blocked.
It may be dangerous when stricken by the
compressed air or high-pressured water, or
use the compressed air or the high-
pressured water to clean dust or dirty
materials. Do wear protective glasses, shield
or other protective devices.
142
Maintenance Manual
Important Maintenance Procedures

1. The recirculating air strainer is located at the 5. Replace the recirculating air strainer every
rear left of the driver's seat. 2000 hours. Make sure the new strainer
meets the standard of ISO10263-2.

Fresh air strainer--Clean

Fresh aire strainer is only used to filtrate the

dust and dirt in the air, not for poisonous gas!

A blocked strainer could cause the fresh air

reduced.

2. Remove the four mounting bolts (1)with tools,
remove cover(3)and strainer(2).
1 materials. Do wear protective glasses, shield
3
It may be dangerous when stricken by the
compressed air or high-pressured water, or
use the compressed air or the high-
pressured water to clean dust or dirty
or other protective devices.
The fresh air strainer is located at the rear of the
cab. Service the fresh air strainer every 250
hours, or it can be serviced according to the
actual work envionment to shorten or extend the
service intervals.

2 If the machine is operated in dusty environment,

clean the fresh air strainer more frequently.
1. Remove bolt (2) on cover(1).

3. Clean the filter with compressed air or soft 1

brush. If the filter is too dirty or too oily, wash
it with neutral detergent. Dry the filter
completely before reuse.

CAUTION: Cleaned by compressed air or

water, the strainer could be blocked or
damaged, replace with a new one.

4. Install the cleaned strainer, tighten the four

bolts of the cover. Install the strainer
correctly.
 143
Maintenance Manual
Important Maintenance Procedures

2. Rotate the cover and strainer as the shaft

direction, then remove strainer (3).

3. Clean the strainer with compressed air. If the

filter is too dirty or too oily, wash it with
neutral detergent. Dry the filter completely
before reuse.

CAUTION: Cleaned by compressed air or

water, the strainer could be blocked or
damaged, replace with a new one.

4. Install the cleaned strainer along the track in

the cover. Install it after it is completely
placed into the track. Rotate the cover to
installation position. Align the cover and the
bolt hole before tightening the bolt.
5. Replace the fresh air strainer every 1000
hours. Make sure the new strainer meets the
standard of ISO10263-2.
144
Maintenance Manual
Important Maintenance Procedures

Others

Other maintenance intervals

Interval (hour)
Components Q'ty
8 50 100 250 500 1000 2000
1. Inspect for damage and looseness of bucket teeth —

2. Replace bucket 1 When required

4. Remove the travel control lever 1 When required

5. Check the track tension 2

6. Adjust the track tension 2 When required

7. Check the tightening torque of bolts and nuts — ★★★

8. Refill window washer When required

★★★ The first service time.

1 2

5 6
8
 145
Maintenance Manual
Important Maintenance Procedures

Bucket--Replace Adapter-Replace

Bucket Teeth--Check/Replace Check the bucket teeth. If the adapter and the
tips are severe worn, replace the adapter.

Personal injury or death can result from a

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

Check the bucket teeth everyday. If the bucket

teeth are worn or damaged, replace the bucket
teeth as follows:
1. Park the machine on level ground. Lower the
bucket to ground. Make sure that the bucket
will not move when the bucket pin is 1. Remove dowel pin (1) and take out adapter
removed. (2).

2. Remove the bucket pin to separate the arm

and bucket. Clean the pin and pin bore and
apply grease onto the pin and pin bore.
3. Adjust the arm and replace the bucket. Make
sure the bucket does not move.
4. Install the bucket pin.
5. Install bolt and nut of the pin.
6. Apply grease onto the pin.
7. Start and run the engine at 1200 rpm.
Operate the bucket slowly by tilting back and
dumping to check for failures. Eliminate the
problems if any failures are found.

2
1

1. Dowel pin
2. Adapter
3. Holder
2. Replace adapter (2). When replacing the
adapter, slightly knock the dowel pin(1) to
make it level with the adapter.
146
Maintenance Manual
Important Maintenance Procedures
Travel Control Lever--Remove
If necessary, remove the travel control lever.
1. Park the machine on flat ground.
2. Lower the bucket on ground.
3. Reduce the engine speed to idling speed.
4. Shut down the engine and take out the key.
5. Push the pilot shutoff lever to LOCK position.
6. Remove the bolt from travel control lever
then remove the lever.
7. Install the bolt and tighten it to a torque of
49N.m(5kgf.m)
Track Tension--Check
NOTICE: Check the track tension after
completely cleaning the mud from the track.
As the figure shows, swing the upper structure to
90° and lower the bucket to the ground before
raising the track. Keep the angle of boom and
arm within 90° to 110°, and keep the bucket
bottom contacted to the ground.
Place blocks under the track frame to hold up the
machine. Rotate the track reversely for two
circles, and then rotate the track forward for two
circles. Measure the distance (A) from the
bottom of track frame and the back of track shoe.
The track tension should be within 275 mm to
350 mm.
A
Track Tension--Adjust
CAUTION: Do not remove the valve, keep
your body and face far away from valve to
avoid harm caused by high pressure grease.
If the left track tension is different from the right
one, deflect the machine from the traveling route.
1. Clean the area around the sprocket, track
link and grease fitting.
2. To tension the track, first connect the grease
gun to the grease fitting and then add grease
until the tension is within the recommended
limit.
1 2
1. Valve
2. Grease outlet
 147
Maintenance Manual
Important Maintenance Procedures

3. To loosen the track, turn the valve Window Washer Reservoir-Refill

counterclockwise and slowly. When valve is
loosened for 1 to 1.5 turns, the grease will Refill washer through the water filler inlet of the
flow out from grease outlet. If the grease washer reservoir.
does not flow out smoothly, lift the track
above ground, slowly rotate the track.

CAUTION: If the track is still very tight

after counterclockwise turning, or loose after
filling with grease, this is abnormal. Do not
remove the tensioner of the track, and
contact the service center appointed by
Liugong immediately for repair information.

Torque of Bolts and Nuts--Check

In the first 50 hours, check the tension of bolts

and nuts. Check every 250 hours later.
● If there is any looseness, tighten to the
specified torque.
● Replace the bolts and nuts with new one sof
same quality or higher quality.
● Use torque wrench to check and tighten bolts
and nuts.
● Ensure the threads are clean when mounting
or replacing.
● Apply lubricant to bolts and nuts to maintain
their frictional coefficients.
● If the bolts on the counterweight are loose,
contact your dealer or service center.
Frequently check the washer reservoir to find
whether the water has been used up,
otherwise the normal viewing may be
affected.
The washer reservoir should be emptied or
filled with anti-freeze when the ambient
temperature is below 0 ℃ , otherwise the
washer will not work or even be damaged by
frozen.
Detergent with additive is poisonous and
impotable. Dispose of it according to local
laws and regulations.
148
Maintenance Manual
Important Maintenance Procedures

Maintenance Under Special Conditions

Operating condition Notice of Maintenance

Before operating Check tension of plugs and all the taps.

Muddy area, rainy or
snowy weather Clean and check the machine for cracks, damage, looseness or lost
After operating
parts. Lubricate all the necessary parts strictly on the instructions.

Before operating Check tension of plugs and all the taps.

Coast
Clean completely machine with clean water to remove the salt. Often
After operating
maintain the electronic units to avoid erosion.

Air filter Clean the units in short intervals.

Clean the radiator surface very often to prevent the core from being
Radiator
restricted.
Dusty
Fuel system Often clean filter element and screen in short interval

Electronic units Often clean the terminals of alternator and the start motor

Operate carefully when checking for cracked, damaged or lost bolts

Track
and nuts. The track slack is larger than usual.
Rocky ground The standard bucket could be damaged when digging a rocky
Implement ground. Before using the rock bucket, strengthen the standard
bucket.

Fuel Use high quality fuel that is fit for low temperature

Lubricant Use high quality and low viscosity hydraulic oil and engine oil

Freezing weather Engine coolant Make sure anti-freeze has been used.

Charge the battery very often to make sure the battery is fulled of
Battery
electrolyte. Otherwise, the electrolyte might be frozen.
Keep the track clean. Park the machine on hard ground to avoid the
Track
track from being frozen in the mud.
Offer protection to cab if necessary to protect the machine from
Falling rock Cab
being damaged by falling rock.
 149
Maintenance Manual
Troubleshooting

Troubleshooting

Electrical System

Problem Causes Solutions

No power in battery Charge or replace
Disconnect switch is not turned on Turn on disconnect switch

Machine does not work (no Disconnect switch is damaged Replace disconnect switch
sound from the power relay Fuse Replace fuse
and when turning on start
switch and no power to the Trouble in start switch Replace start switch
machine) Power relay Replace relay
Poor connection of battery cable Tighten cable
Poor connection of harness connector Connect harness connector
Loose connection or corroded Clean and tighten or replace the battery
Loose alternator belt Tighten or replace with a new belt
Battery lack of power Alternator fails to charge Contact your dealer
Fuse Replace fuse
Trouble with start switch key Replace start switch key
Burnt power relay contactor Replace power relay
After turning off the key
switch, electric system still Damaged key switch Replace the start switch
has power
Damaged choke electromagnet Replace choke electromagnet
Short circuit of electromagnet coil Replace choke electromagnet
Turn on the key switch, fuse
of the key switch is burnt at Short-circuited power relay coil Replace power relay
once Wire grounded due to wear or other
Repair wire.
causes
Battery lack of power or damaged Charge or replace battery
Poor connection of battery cable Clean the connection and tighten
Broken fuse Replace fuse
Key switch Contact your dealer
Start motor does not work
Start relay Contact your dealer
Start motor solenoid Contact your dealer
Start motor Repair or replace start motor
Pinion of start motor is stuck in flywheel Repair or replace start switch
Poor connection of battery or start motor Clean the connection
Electromagnetic vibration of Low battery power Charge or replace battery
start switch
Electromagnetism of start motor restricst
Contact your dealer
oil from starting
150
Maintenance Manual
Troubleshooting
Start motor works but
engine does not work
Engine fails to start or start
difficulty
Start motor runs continu-
ously after engine starting
Charging indicator turns on
with engine running
Engine overheats
Commutator has contamination or wears
Alternator fails to work or
low voltage from the alterna- Remanence coil breaks
tor
Remanence disappears
Noisy alternator
Pinion of start motor can not mesh with fly-
wheel gear
The moving mechanism of pinion is
blocked or failed
Pinion teeth cracked
Flywheel teeth cracked or broken
Battery is damaged or lacks for power
The battery or start motor cable loose or
corroded
Start switch is damaged
Poor connection of circuits or circuit
breaks
Start motor solenoid or fork is damaged
Start motor stator is burnt
Power relay and start relay are burnt
Too low ambient temperature
Start motor relay blocked
Start motor coil blocked
Start motor can not open
Start switch key trouble
Loose or slipping alternator belt
Low engine rpm
Overload caused by attachment
Loose or corroded connection on battery,
ground cable, start motor or alternator
Low battery voltage
Alternator
Indicator has loop
Bearing is worn or lacks for lubricant
Commutator or the coil is short-circuited
Drive belt is worn
Pulley is worn
Leveling failture of pulley
Alternator bearing
Contact your dealer
Contact your dealer
Contact your dealer
Contact your dealer
Replace a new battery or charge the battery
Clean and tighten the connectors and cables
Replace the start switch
Check and repair
Check the coil, contactor, fork and spring for
good condition. Repair if necessary.
Replace the start motor
Replace the relay
Install a cold starting acid device
Contact your dealer
Contact your dealer
Contact your dealer
Contact your dealer
Check the belt. Replace if it slips and tension if
it is loose.
Adjust rpm to specified speed
Remove the attachment or install a high output
alternator
Check, clean or tighten the connections
Charge or replace the battery
Contact your dealer
Contact your dealer
Replace bearing or refill lubricant
Remove the alternator to check the commutator
and armature to check
Clean with gasoline by cloth or sand by 00
sandclotch
Check external magnetic filed and check mag-
netization loop with a bulb.
Charge magnetic or replace with a new alterna-
tor
Replace the belt
Replace the pulley and belt
Adjust the alternator installation/alignment
Loosen alternator belt, rotate the pulley by
hand, repair the alternator if any problems are
found.
 151
Maintenance Manual
Troubleshooting

Fuse Replace fuse

Coolant temperature gauge Gauge Contact your dealer

does not work Sensor Check the coolant temperature sensor
Harness Contact your dealer
Instrument is damaged Replace the instrument
Sensor is damaged Replace the sensor
Instrument indicators fail to
work Sensor harness is loose Retighten the harness
Check the alternator or the battery voltage for
Alternator or battery problem
normal condition or value
Fuse Replace the fuse
Fuel level gauge does not
Gauge Contact your dealer
work
Harness Contact your dealer

Engine

Refer to the Diesel Engine Operator and Maintenance Manual for the troubleshooting.

Control Lever

Problem Cause Solutions

Difficult to move
Can not work
Can not return NEUTRAL
Excessive clearance
Control lever is not vertical
when in NEUTRAL
Corroded connector Contact your dealer
Worn thruster Contact your dealer
Worn thruster Contact your dealer
Pilot valve Contact your dealer
Pilot valve Contact your dealer
Worn pivot joint Contact your dealer
Pilot valve Contact your dealer
152
Maintenance Manual
Troubleshooting

Hydraulic System

Problem Cause Solutions

Low oil level Add oil to oil tank to the full mark
Run the engine to preheat hydraulic sys-
Cold oil
tem
Wrong hydraulic oil Use the correct oil
Hydraulic components works
slowly Slow engine speed Contact your dealer
Pilot oil loops Contact your dealer
Worn pump Contact your dealer
Restricted pump suction pipe Contact your dealer
Wrong hydraulic oil Use the correct oil
Air leakage in pump suction pipe Contact your dealer
Oil pipes are restricted Contact your dealer
Low oil level Add oil to oil tank to the full mark
Clogged filter Replace with a new filter
Worn pump Contact your dealer
Hydraulic oil overheats
Clogged radiator or oil cooler Clean or rearrange the radiator fins
Oil cooler bypasses Contact your dealer
Relief valve Contact your dealer
Unclean oil Drain oil and refill
Travel motor Contact your dealer
Improper adjustment for the hydraulic compo-
Contact your dealer
nents
Repair the leakage or contact your
Air leakage at the tube from oil tank to pump
dealer
Twisted oil pipe Check the tube
Oil bubbles
Wrong hydraulic oil Use the correct oil
Water in oil Replace oil
Oil level is too high or too low Correct oil level
Wrong oil Use the correct oil
Improper adjustment for the hydraulic compo-
Contact your dealer
nents
Low pressure or no oil pres-
sure No oil in the hydraulic system Add the correct oil to the fullmark
Worn cylinder Contact your dealer
Relief valve Contact your dealer
 153
Maintenance Manual
Troubleshooting

Hydraulic pump Contact your dealer

No hydraulic function (noises Lack of oil Refill oil to the fullmark

from pump) Suction tube or hose damaged Contact your dealer
Suction filter is clogged Clean
Worn pump Contact your dealer
Low pressure of main relief valve Contact your dealer
Cylinder can work but can
Low oil level Add oil to the fullmark
not lift
Clogged screen Clean the filter and the system
Pump suction pipeline leaks Check suction pipeline
Low pressure of relief valve Contact your dealer
Tube or hose damaged Repair or replace
Hydraulic components loose Tighten
One of control levers does
O-ring is damaged when assembled Replace with a new O-ring
not work
Hydraulic ump Contact your dealer
Pilot valve Contact your dealer
Pilot lines Repair or replace
Shaft of control valve damaged or polluted by
Contact your dealer
dust
Tube or hose damaged Repair or replace
One of cylinders does not Hydraulic components loosen Tighten
work
O-ring of hydraulic components damaged Replace with a new O-ring
Pilot valve Contact your dealer
Pilot pipeline failure Repair or replace
Seal of piston leaks Contact your dealer
Piston rod damaged Contact your dealer

One of cylinders does not Pilot pipeline Repair or replace

work or almost loses power Pilot valve Contact your dealer
Pipeline trouble Contact your dealer
Pump Contact your dealer
Two travel motors do not
Center swivel joint trouble Contact your dealer
work
Travel motor Contact your dealer

One of travel motors does Brake pedal not released Contact your dealer
not work Pilot valve Contact your dealer
Pilot circuit Repair or replace
154
Maintenance Manual
Troubleshooting

Adjustment of track Adjust the track tension

Idler or rollers damaged Contact your dealer
Unsmooth travel Travel frame twisted Contact your dealer
Stone or mud jams the travel frame Remove the rock, mud and repair
Brake pedal not released Contact your dealer
Swing brake release valve Contact your dealer
Can not swing Swing motor Contact your dealer
Pilot valve Contact your dealer
Swing gear Contact your dealer
Unsmooth swing Swing bearing Contact your dealer
Lack of grease Apply grease
Engine flameouts when mov- Poor connection of contactor Repair or replace
ing travel control lever or
hand control lever Poor installation of pipelines Contact your dealer

Air Conditioning System

Problem Cause Solutions

Good cooling effect at first, but poor

Frequent running on a poor road sur-
cooling effect after a period. Bubbles Find leakage with a leak detector, care-
face, loose joint due to vibration and
in sight glass of refrigerant receiver. fully tighten the loose parts.
leakage
Low reading in the low & high gauge.

System doesn't refrigerate, hot air at

air outlet, no temperature difference Replace expansion valve and charge
Improper closure the valve hole.
at the expansion valve inlet and out- with R134a.
let, too low readings at low gauge.

Start the cooling system intermittently

No cooling air at air outlet, high com-
pressor temperature. Rapid lowering
of gauge pointer and close to zero,
excessive high readings.
Foreign matters in the system,
and remove the temperarory block, or
blocked expansion valve screen.
remove the expansion valve and wash
Frost or bead on the expansion valve
with alcohol, then drain out the system
surface.
and charge with R134a again.

Poor cooling capacity, frosted evap- Drain out the system, replace the expan-
Orifice at the expansion valve
orator. Low readings in low and high sion valve and charge with R134a
doesn’ t work.
pressure gauge. again.

Cooling capacity reduced after a Saturated moisture

period, too high reading at the high inside the refrigerant receiver. Throt- Drain the system, replace the refrigerant
gauge and reading is below 0.4Mpa tle of expansion valve is blocked by receiver and charge with R134a again.
at low gauge. ice.
 155
Maintenance Manual
Troubleshooting

Only fan, no cooling air comes out Poor connection of thermostat switch Check thermostat switch for damage
after cooling is actuated. No reading or damaged electromagnetic clutch with a multimeter. Replace electromag-
changes in high & low gauges. coil on compressor. netic clutch of the air compressor.
156
Maintenance Manual
Troubleshooting

Engine Fault Diagnosis Stop indicator display example:

The flash mode of diagnostic code is available
through the diagnostic ON/OFF key：
Enter the flash mode of diagnostic code through
the diagnostic ON/OFF switch.
Turn the start switch to ON position and stop the
engine.
The stop indicator will flash to show the first fault
code automatically after turning on the diagnostic
ON/OFF key.
1
2 please contact your dealer and provide the
3 analysis.
Code 244 (displayed by stop indicator) can be
explained as follows:
The stop indicator flashes twice → pause →
continues to flash for four times → pause →
continues to flash for four times again. A
diagnostic code display progress is completed
through the above order and the diagnostic code
will be displayed continuously. The diagnostic
code will be : 244
Press the diag inc or diag dec switch up and
down in order to change the engine fault codes if
there are more than two faults codes. The fault
code also will be displayed through the stop
indicator.
CAUTION: If the stop indicator flashes
fault diagnostic code during operation,
fault code to the dealer to have a specific

1. Dia inc key

2. Dia dec key
3. Diagnostic ON/OFF key

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
111 Red Engine Control Module Critical internal failure - Bad intelligent Device or Component

Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic pickup
115 Red
sensor - Data, Erratic, Intermittent, or incorrect

122 Amber Intake Manifold Pressure Sensor Circuit – Voltage Above Normal, or Shorted to High Source

123 Amber Intake Manifold Pressure Sensor Circuit – Voltage Below Normal, or Shorted to Low Source

Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to
131 Red
High Source

Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low
132 Red
Source

Remote Accelerator Pedal or Lever Position Sensor Circuit – Voltage Above Normal, or
133 Red
Shorted to High Source

Remote Accelerator Pedal or Lever Position Sensor Circuit – Voltage Below Normal, or
134 Red
Shorted to Low Source

135 Amber Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source
 157
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
141 Amber Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

Oil Pressure Low – Data Valid but Below Normal Operational Range - Moderately Severe
143 Amber
Level

144 Amber Coolant Temperature Sensor Circuit – Voltage Above Normal, or Shorted to High Source

145 Amber Coolant Temperature Sensor Circuit – Voltage Below Normal, or Shorted to Low Source

Coolant Temperature High - Data Valid but Above Normal Operational Range - Moderately
146 Amber
Severe Level

Accelerator Pedal or Lever Position Sensor Circuit – Abnormal Frequency, Pulse Width, or
147 Red
Period

Accelerator Pedal or Lever Position Sensor Circuit – Abnormal Frequency, Pulse Width, or
148 Red
Period

Coolant Temperature Low - Data Valid but Above Normal Operational Range - Most Severe
151 Red
Level

Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High
153 Amber
Source

Intake Manifold Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low
154 Amber
Source

Intake Manifold Air Temperature High – Data Valid but Above Normal Operational Range -
155 Red
Most Severe Level

187 Amber Sensor Supply Voltage #2 Circuit – Voltage Below Normal, or Shorted to Low Source

195 Amber Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High Source

196 Amber Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

197 Amber Coolant Level - Data Valid but Below Normal Operational Range - Moderately Severe Level

211 None Additional Auxiliary Diagnostic Codes logged - Condition Exists

212 Amber Engine Oil Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted to High Source

213 Amber Engine Oil Temperature Sensor 1 Circuit - Voltage Below Normal, or Shorted to Low Source

Engine Oil Temperature - Data Valid but Above Normal Operational Range - Most Severe
214 Red
Level

221 Amber Barometric Pressure Sensor Circuit – Voltage Above Normal, or Shorted to High Source

222 Amber Barometric Pressure Sensor Circuit – Voltage Below Normal, or Shorted to Low Source

227 Amber Sensor Supply Voltage #2 Circuit – Voltage Above Normal, or Shorted to High Source

231 Amber Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source

232 Amber Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source
158
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
Coolant Pressure - Data Valid but Below Normal Operational Range - Moderately Severe
233 Amber
Level

234 Red Engine Speed High - Data Valid but Above Normal Operational Range - Most Severe Level

235 Red Coolant Level Low - Data Valid but Below Normal Operational Range - Most Severe Level

237 Amber External Speed Input (Multiple Unit Synchronization) - Data Erratic, Intermittent, or Incorrect

238 Amber Sensor Supply Voltage #3 Circuit – Voltage Below Normal, or Shorted to Low Source

241 Amber Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect

242 Amber Vehicle Speed Sensor Circuit tampering has been detected – Abnormal Rate of Change

245 Amber Fan Control Circuit - Voltage Below Normal, or Shorted to Low Source

249 Amber Ambient Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

256 Amber Ambient Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

Engine Fuel Temperature - Data Valid but Above Normal Operational Range - Moderately
261 Amber
Severe Level

Engine Fuel Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted to High
263 Amber
Source

265 Amber Engine Fuel Temperature Sensor 1 Circuit - Voltage Below Normal, or Shorted to Low Source

268 Amber Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

High Fuel Pressure Solenoid Valve Circuit – Voltage Below Normal, or Shorted to Low
271 Amber
Source

High Fuel Pressure Solenoid Valve Circuit – Voltage Above Normal, or Shorted to High
272 Amber
Source

Fuel Pumping Element (Front) – Mechanical System Not Responding Properly or Out of
275 Amber
Adjustment

High Fuel Pressure Solenoid Valve #1 – Mechanical System Not Responding Properly or
281 Amber
Out of Adjustment

Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit - Voltage Below Normal,
284 Amber
or Shorted to Low Source

285 Amber SAE J1939 Multiplexing PGN Timeout Error - Abnormal Update Rate

286 Amber SAE J1939 Multiplexing Configuration Error – Out of Calibration

SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error - Received
287 Red
Network Data In Error

SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error - Received Network
288 Red
Data In Error
 159
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Above Normal, or Shorted to High
293 Amber
Source

Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Below Normal, or Shorted to Low
294 Amber
Source

295 Amber Barometric Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

296 Red Auxiliary Pressure Sensor Input 1 - Special Instructions

Auxiliary Pressure Sensor Input # 2 Circuit - Voltage Above Normal, or Shorted to High
297 Amber
Source

Auxiliary Pressure Sensor Input # 2 Circuit - Voltage Below Normal, or Shorted to Low
298 Amber
Source

319 Maint Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect

322 Amber Injector Solenoid Cylinder #1 Circuit – Current Below Normal, or Open Circuit

323 Amber Injector Solenoid Cylinder #5 Circuit – Current Below Normal, or Open Circuit

324 Amber Injector Solenoid Cylinder #3 Circuit – Current Below Normal, or Open Circuit

325 Amber Injector Solenoid Cylinder #6 Circuit – Current Below Normal, or Open Circuit

331 Amber Injector Solenoid Cylinder #2 Circuit – Current Below Normal, or Open Circuit

332 Amber Injector Solenoid Cylinder #4 Circuit – Current Below Normal, or Open Circuit

334 Amber Coolant Temperature Sensor Circuit – Data Erratic, Intermittent, or Incorrect

Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Above Normal, or Shorted
338 Amber
to High Source

Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Below Normal, or Shorted
339 Amber
to Low Source

341 Amber Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect

342 Red Electronic Calibration Code Incompatibility - Out of Calibration

Engine Control Module Warning internal hardware failure - Bad Intelligent Device or
343 Amber
Component

351 Amber Injector Power Supply - Bad Intelligent Device or Component

352 Amber Sensor Supply Voltage #1 Circuit – Voltage Below Normal, or Shorted to Low Source

386 Amber Sensor Supply Voltage #1 Circuit – Voltage Above Normal, or Shorted to High Source

Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit - Voltage Above Normal,
387 Amber
or Shorted to High Source

415 Red Oil Pressure Low – Data Valid but Below Normal Operational Range - Most Severe Level
160
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
Water in Fuel Indicator High - Data Valid but Above Normal Operational Range – Least
418 Maint
Severe Level

422 Amber Coolant Level - Data Erratic, Intermittent, or Incorrect

425 Amber Engine Oil Temperature - Data Erratic, Intermittent, or Incorrect

428 Amber Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to High Source

429 Amber Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

431 Amber Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Intermittent, or Incorrect

432 Red Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration

433 Amber Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

434 Amber Power Lost without Ignition Off - Data Erratic, Intermittent, or Incorrect

435 Amber Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Battery #1 Voltage Low - Data Valid but Below Normal Operational Range – Moderately
441 Amber
Severe Level

Battery #1 Voltage High - Data Valid but Above Normal Operational Range – Moderately
442 Amber
Severe Level

Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit - Voltage Below Normal,
443 Amber
or Shorted to Low Source

Fuel Pressure High - Data Valid but Above Normal Operational Range – Moderately Severe
449 Red
Level

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High
451 Amber
Source

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low
452 Amber
Source

Intake Manifold 1 Temperature - Data Valid but Above Normal Operational Range -
488 Amber
Moderately Severe Leve

497 Amber Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or Incorrect

523 Amber OEM Intermediate (PTO) Speed switch Validation - Data Erratic, Intermittent, or Incorrect

527 Amber Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High Source

528 Amber Auxiliary Alternate Torque Validation Switch - Data Erratic, Intermittent, or Incorrect

529 Amber Auxiliary Input/Output 3 Circuit - Voltage Above Normal, or Shorted to High Source

Accelerator Pedal or Lever Idle Validation Circuit - Voltage Below Normal, or Shorted to Low
551 Amber
Source

Injector Metering Rail #1 Pressure High – Data Valid but Above Normal Operational Range -
553 Amber
Moderately Severe Level
 161
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
554 Amber Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect

Injector Metering Rail #1 Pressure Low – Data Valid but Below Normal Operational Range -
559 Amber
Moderately Severe Level

584 Amber Starter Relay Circuit - Voltage Above Normal, or Shorted to High Source

585 Amber Starter Relay Circuit - Voltage Below Normal, or Shorted to Low Source

Turbocharger #1 Speed High - Data Valid but Above Normal Operational Range –
595 Amber
Moderately Severe Level

Electrical Charging System Voltage High – Data Valid but Above Normal Operational Range
596 Amber
- Moderately Severe Level

Electrical Charging System Voltage Low – Data Valid but Below Normal Operational Range
597 Amber
- Moderately Severe Level

Electrical Charging System Voltage Low – Data Valid but Below Normal Operational Range
598 Red
- Most Severe Level

649 Maint Change Lubricating Oil and Filter – Condition Exists

Turbocharger #1 Speed Low - Data Valid but Below Normal Operational Range –
687 Amber
Moderately Severe Level

689 Amber Primary Engine Speed Sensor Error – Data Erratic, Intermittent, or Incorrect

Turbocharger #1 Compressor Inlet Temperature Sensor Circuit – Voltage Above Normal, or

691 Amber
Shorted to High Source

Turbocharger #1 Compressor Inlet Temperature Sensor Circuit – Voltage Below Normal, or

692 Amber
Shorted to Low Source

ECM Internal Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High
697 Amber
Source

698 Amber ECM Internal Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal, or Shorted to High
719 Amber
Source

Extended Crankcase Blow-by Pressure Circuit - Voltage Below Normal, or Shorted to Low
729 Amber
Source

Engine Speed/Position #2 mechanical misalignment between camshaft and crankshaft

731 Amber
sensors - Mechanical System Not Responding Properly or Out of Adjustment

753 Amber Engine Speed/Position #2 Camshaft sync error - Data Erratic, Intermittent, or Incorrect

757 Amber Electronic Control Module data lost - Condition Exists

778 Amber Engine Speed Sensor (Camshaft) Error – Data Erratic, Intermittent, or Incorrect

779 Amber Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) - Root Cause Not Known
162
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
951 None Cylinder Power Imbalance Between Cylinders - Data Erratic, Intermittent, or Incorrect

1117 None Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect

1139 Amber Injector Cylinder #1 - Mechanical System Not Responding Properly or Out of Adjustment

1141 Amber Injector Cylinder #2 - Mechanical System Not Responding Properly or Out of Adjustment

1142 Amber Injector Cylinder #3 - Mechanical System Not Responding Properly or Out of Adjustment

1143 Amber Injector Cylinder #4 - Mechanical System Not Responding Properly or Out of Adjustment

1144 Amber Injector Cylinder #5 - Mechanical System Not Responding Properly or Out of Adjustment

1145 Amber Injector Cylinder #6 - Mechanical System Not Responding Properly or Out of Adjustment

Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Above Normal, or Shorted to
1239 Amber
High Source

Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Below Normal, or Shorted to
1241 Amber
Low Source

1242 Red Accelerator Pedal or Lever Position Sensor 1 and 2 - Data Erratic, Intermittent, or Incorrect

1256 Amber Control Module Identification Input State Error - Data Erratic, Intermittent, or Incorrect

1257 Red Control Module Identification Input State Error - Data Erratic, Intermittent, or Incorrect

Injector Metering Rail 1 Pressure - Data Valid but Above Normal Operational Range - Most
1911 Amber
Severe Level

2111 Amber Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted to High Source

2112 Amber Coolant Temperature 2 Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Moderately
2113 Amber
Severe Level

Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Most Severe
2114 Red
Level

2115 Amber Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted to High Source

2116 Amber Coolant Pressure 2 Circuit - Voltage Below Normal, or Shorted to Low Source

Coolant Pressure 2 - Data Valid but Below Normal Operational Range - Moderately Severe
2117 Amber
Level

2185 Amber Sensor Supply Voltage #4 Circuit – Voltage Above Normal, or Shorted to High Source

2186 Amber Sensor Supply Voltage #4 Circuit – Voltage Below Normal, or Shorted to Low Source

2195 Red Auxiliary Equipment Sensor Input 3 Engine Protection Critical - Special Instructions

Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range -
2215 Amber
Moderately Severe Level
 163
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational Range –
2216 Amber
Moderately Severe Level

2217 Amber ECM Program Memory (RAM) Corruption - Condition Exists

Injector Metering Rail 1 Pressure - Data Valid but Below Normal Operational Range - Most
2249 Amber
Severe Level

Fuel Priming Pump Control Signal Circuit – Voltage Above Normal, or Shorted to High
2265 Amber
Source

Fuel Priming Pump Control Signal Circuit – Voltage Below Normal, or Shorted to Low
2266 Amber
Source

Fuel Inlet Meter Device - Data Valid but Above Normal Operational Range - Moderately
2292 Amber
Severe Level

Fuel Inlet Meter Device flow demand lower than expected - Data Valid but Below Normal
2293 Amber
Operational Range - Moderately Severe Level

2311 Amber Fueling Actuator #1 Circuit Error – Condition Exists

2321 None Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect

2322 None Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect

2345 Amber Turbocharger speed invalid rate of change detected - Abnormal Rate of Change

Turbocharger Turbine Inlet Temperature (Calculated)- Data Valid but Above Normal
2346 None
Operational Range – Least Severe Level

Turbocharger Compressor Outlet Temperature(Calculated) - Data Valid but Above Normal

2347 None
Operational Range – Least Severe Level

2362 Amber Engine Brake Actuator Circuit #1 – Voltage Below Normal, or Shorted to Low Source

2363 Amber Engine Brake Actuator Circuit #2 – Voltage Below Normal, or Shorted to Low Source

2366 Amber Engine Brake Actuator Circuit #1 – Voltage Above Normal, or Shorted to High Source

2367 Amber Engine Brake Actuator Circuit #2 – Voltage Above Normal, or Shorted to High Source

2377 Amber Fan Control Circuit - Voltage Above Normal, or Shorted to High Source

2384 Amber VGT Actuator Driver Circuit - Voltage Below Normal, or Shorted to Low Source

2385 Amber VGT Actuator Driver Circuit - Voltage Above Normal, or Shorted to High Source

2555 Amber Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source

2556 Amber Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source

2557 Amber Auxiliary PWM Driver #1 - Voltage Above Normal, or Shorted to High Source

2558 Amber Auxiliary PWM Driver #1 - Voltage Below Normal, or Shorted to Low Source
164
Maintenance Manual
Troubleshooting

Engine fault code

FAULT LAMP CUMMINS DESCRIPTION

CODE COLOR
Engine Coolant Temperature High - Data Valid but Above Normal Operational Range - Least
2963 None
Severe Level

Intake Manifold Temperature High - Data Valid but Above Normal Operational Range - Least
2964 None
Severe Level

2973 Amber Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

INDEX
A D
A/C Panel ........................................................58
Air Conditioner System .................................140
Air Conditioning System ................................154
Air Filter--Clean .............................................111
Air Filter--Main Element and Safety Element--
Replace .........................................................112
Air Pre-filter--Clean .......................................110
Alternator Maintenance .................................137
Application ......................................................35
Application and Specification ..........................35
Attachment Cautions .......................................24
Avoid Improper Operation ...............................83
B Electrical System .......................................... 134
Battery ...........................................................134
Battery Disconnect Switch ..............................42
Battery--Charge ............................................135
Battery--Install ...............................................134
Battery--Maintain ...........................................137
Battery--Recycle ...........................................137
Before Operation .............................................41
Bucket--Replace ...........................................145
Burn Prevention ..............................................21
C
Cautions about Machine Maintenance ............31
Cautions about Machine Operation ................25
Cautions for Safe Operation ...........................71
Check Before Starting the Engine ...................73
Choose Proper Track Shoe ............................76
Compressor Belt Tension--Check/Adjust ......141
Condenser Surface--Clean ...........................141
Control Lever ................................................151
Coolant Level--Check ...................................107
Coolant--Replenish .......................................108
Crushing and Cutting Prevention ....................20
195
INDEX
Daily Inspection ............................................ 101
Diesel Engine System .................................. 106
Digging Operation ........................................... 82
Display ............................................................ 51
Display Interface ............................................. 51
Display-Adjust ................................................. 58
Door Lock ....................................................... 69
Downhill Operation ......................................... 78
E
Electrical Storm Injury Prevention .................. 23
Electrical System .......................................... 149
Engine .......................................................... 151
Engine Air Intake System--Check ................. 119
Engine Belt--Check ....................................... 119
Engine Fault Diagnosis ................................. 156
Engine Oil Filter--Replace ............................ 118
Engine Oil Level-Check ................................ 116
Engine Oil--Replace ..................................... 117
Engine Starting ......................................... 73, 74
Engine Tensioner Bearing and Fan Hub--Check
119
Engine Valve Lash--Adjust ........................... 119
Evaporator--Check ....................................... 141
F
Fan Belt Tension--Check/Adjust ................... 119
Fire &Explosion Prevention ............................ 22
Fire Extinguishers and First-aid Kit ................. 23
Fresh Air Strainer--Clean .............................. 142
Fresh Air/Recirculating Air Filter--Clean ....... 141
Fuel Filter and Fuel Pre-filter--Replace ........ 115
Fuel Level--Check ........................................ 113
Fuel Pre-filter and Fuel Filter--Water and
Impurity--Remove ......................................... 115
Fuel Tank Water and Impurity--Remove ...... 114
Fuel Tank--Clean .......................................... 113
Fuel--Heat ..................................................... 116
196
INDEX

Fuel---Replenish ...........................................113 M
Fuse-Check/Replace ....................................138

Machine Operation ......................................... 80

G Main Components ............................................ 3
Main Specifications ......................................... 36
Gear Oil .........................................................120 Maintenance Guidance ................................... 91
General Hazard Information ............................17 Maintenance Manual ...................................... 91
Maintenance Suggestion .............................. 127
Maintenance Under Special Conditions ....... 148
H Mechanical Suspension Seat ......................... 66
Menu of the Display ........................................ 53
Moving Machine from Storage ........................ 86
Hand Control Lever .........................................45
Horn Button .....................................................47
Hydraulic Hammer(Optional) ...........................70 O
Hydraulic Oil and Suction Filter--Replace .....129
Hydraulic Oil Level--Check ............................129
Hydraulic Return Filter--Replace ...................132 Oil Change Interval and Refill Capacities ..... 100
Hydraulic System ..................................125, 152 Operating in Water or Mud ............................. 81
Hydraulic System Air--Purge .........................126 Operating on Soft Ground .............................. 81
Operation during Cold Weather ...................... 84
Operation Information ..................................... 76
I Operation Manual ........................................... 41
Operation Techniques .................................... 76
Operator Controls ........................................... 44
Important Maintenance Procedures ..............101
Operator Controls and Instrument Panels ...... 42
INDEX ...........................................................165
Operator Station ............................................. 24
Instrument Panel and Radio ...........................48
Others ........................................................... 144

K
P
Key Spare Parts to be Periodically Changed ..34
Pilot Oil Filter--Replace ................................. 133
Keyboard .........................................................53
Pilot Shutoff Lever .......................................... 44
Pneumatic Suspension Seat (Optional) .......... 68
L Position Direction ............................................ 71
Power Boost Button ........................................ 48
Preface ............................................................. 1
Latch ...............................................................69
Preparation for Operation ............................... 80
Latch and Latch Handle ..................................69
Proper Position ............................................... 70
Latch Handle ...................................................69
Leaving the Machine .......................................85
Leveling Operation ..........................................81 Q
Lift the Machine ...............................................88
Lifting Operation ..............................................82
Quick Coupler(Optional) ................................. 69
Lifting Single Track with Boom and Arm .........80
Lighter .............................................................50
Lubricant--Apply ............................................102 R
Lubrication Specifications .............................100
Radiator--Clean ............................................ 110
 197
INDEX

Rearview Mirrors .............................................65 W

Refrigerant Leakage-Check ..........................140

Warm-up Operation ........................................ 75

S Warning indicator ............................................ 51
Window Washer Reservoir-Refill .................. 147
Safety Decals and Decal Locations ..................5 Work Implement--Lubricate .......................... 103
Safety Information .............................................5
Safety Signs ......................................................5
Safety Symbol ...................................................5
Seat Belt .........................................................68
Service Hour Meter .........................................51
Spare Switches ...............................................50
Special Protective Devices .............................24
Start Motor Maintenance ...............................138
Start Switch .....................................................42
Steering Operation of the Machine .................79
Stopping the Engine ........................................85
Storage of the Machine ...................................85
Swing Bearing--Lubricate ..............................104
Swing Gear--Lubricate ..................................104
Swing Reduction Gear Bearing --Lubricate ...105
Swing Reduction Gear Oil Level--Check .......121
Swing Reduction Gear Oil--Replace .............121
Switch Assembly .............................................50
Switch Box ......................................................48

Throttle Switch ................................................49

Torque of Bolts and Nuts--Check ..................147
Towing Information .........................................89
Track Tension--Adjust ...................................146
Track Tension--Check ...................................146
Transportation Information ..............................86
Transportation of the Machine ........................86
Travel Control Lever and Travel Pedal ...........47
Travel Control Lever--Remove ......................146
Travel Reduction Gear Oil Level--Check ......122
Travel Reduction Gear Oil--Replace .............123
Traveling Operation of the Machine ................76
Troubleshooting ............................................149
Type and Serial Number of the Machine and
Parts ..................................................................4