0% found this document useful (0 votes)

80 views326 pages

Cargador Clg877h (Cummins t4f&v) Om 202009007-En

Uploaded by

rhernandezhc2412

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

80 views326 pages

Cargador Clg877h (Cummins t4f&v) Om 202009007-En

Uploaded by

rhernandezhc2412

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 326

202009007

CLG877H WHEEL LOADER

CUMMINS POWER Tier 4F / ZF WET-AXLE & ZF 4WG260 GEARBOX
CUMMINS POWER Stage V / ZF WET-AXLE & ZF 5WG260 GEARBOX
( 英语 )

OPERATION AND
MAINTENANCE MANUAL
Important Safety Information

Most accidents related to product operation, maintenance and repair are caused by ignoring basic safety
rules or protective measures. If you are aware of potential hazards, you can prevent accidents before
they occur. Personnel must be familiar with potential hazards and possess the necessary training and
skills to troubleshoot problems.
Improper operation, lubrication, maintenance, and repair are all dangerous, and may lead to death in
severe cases.
Do not perform any operation, lubrication, maintenance, or repair of the machine until you have read and
understood the relevant instructions in this manual.
Safety precautions and warnings can be found both in this manual and on the product itself. Ignoring
these warnings may result in death.
Hazards are marked with “Safety Warnings” that contain “Signal Words” such as “Danger”, “Warning”,
and ”Caution”, etc. The safety warning label “Warning” is shown below:

This meaning of this safety warning label is as follows:

Caution! Pay attention! Your safety is at stake!
The safety hazard is explained using text or diagrams below the warning label.
Operations that could cause damage to the machine are marked both in this manual and on the machine
itself using the labels “Caution” or “Warning”.
LiuGong cannot predict every hazard in the work environment; therefore the warnings in this manual and
on the machine should not be considered exhaustive. When using a tool, procedure, working method, or
operation technique that is not explicitly recommended by LiuGong, you must pay special attention to the
safety of yourself and others. You should ensure that the operation, lubrication, maintenance, or repair
procedure does not damage the machine or create unsafe conditions.
The instructions, values, and illustrations in this manual are based on the most current information
available at the time of writing. Continuous improvements in the design of this machine may cause
variations in some details, which may not be reflected in this manual. For the latest information on the
machine, or for questions about the information in this manual, please contact LiuGong or a LiuGong
distributor.
CALIFORNIA
Proposition 65 Warning
WARNING: Operating, servicing and maintaining a passenger vehicle or off-road
vehicle can expose you to chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your vehicle in a well-
ventilated area and wear gloves or wash your hands frequently when servicing your
vehicle. For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
1
September 4, 2020 CONTENTS
CLG877H

CONTENTS

Preface Operation Manual

Before Operation ............................................. 49
Safety Information
Operator Controls and Instrument Panels ....... 50
Safety Decals and Decal Locations ...................7
Engine Starting .............................................. 139
General Hazard Information .............................21
Operation Techniques ................................... 141
Crushing and Cutting Prevention .....................25
Transportation Information ............................ 156
Burn Prevention ...............................................25

Fire & Explosion Prevention .............................26 Maintenance Manual

Fire Extinguishers and First-aid Kit ..................27 Maintenance Guidance .................................. 224

Electrical Storm Injury Prevention ....................28 Run-in ............................................................ 226

Tire Explosion Prevention ................................28 Maintenance Interval Schedule ..................... 227

ROPS/FOPS ....................................................29 General Torque Specifications ...................... 231

Operator Station ...............................................29 Tire Inflation Information ................................ 232

Steering Frame Lock ........................................29 Lubrication Specifications .............................. 233

Information on Attachments .............................29 Important Maintenance Procedures .............. 236

Cautions about Machine Operations ................30

INDEX
Cautions about Machine Maintenance .............37

Sound and Vibration ........................................39

Key Spare Parts to be Periodically Changed ...40

Applications and Specifications

Applications ......................................................42

Main Specifications ..........................................43

2
CONTENTS September 4, 2020
CLG877H
1
September 4, 2020 Preface
CLG877H

Preface Safety

The safety section lists basic safety precautions.

In addition this section identifies the text and
This manual includes important instructions locations of warning signs and labels used on the
concerning operation, lubrication, checking machine.
testing, adjusting the machine and permanent
key components. Read and understand the basic precautions
listed in the safety section before operating or
This manual should always be kept safe, clean performing lubrication, maintenance or repairs
and with the machine where it is convenient to on this machine.
find for operators to use. This manual should not
be separated from the machine even when Operation
reselling or leasing.
Some photographs and illustrations in this The operation section is a reference for the new
manual show details of attachments those may operator and a refresher for the experienced
be different from your machine. Guards and operator. Read, understand and reference it
covers may have been removed for the purpose whenever necessary. This section includes a
of illustration. description of gauges, machine controls,
switches and other controls at the operators’
Read this manual carefully and follow all station. It also provides transportation and towing
instructions for proper operation and information.
maintenance of this machine. Instructions in this
manual should help the reader avoid possible Photographs and illustrations guide the operator
personal injury or damage to the machine. The through correct procedures of checking, starting,
operator should proficiently and correctly operate operating and stopping the machine.
the machine to ensure safety. Operating techniques outlined in this publication
Use this machine only for the purpose described are basic. Skill and techniques develop as the
in this manual. Contact your Liugong dealer for operator gains knowledge of the machine and its
approval before making any modifications or capabilities.
adding attachments to the machine. The addition
of any unauthorized attachment may cause Maintenance
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi The maintenance section is a guide for
Liugong accepts no liability for any damage equipment care. The illustrated, step-by-step
resulting from the use of unapproved instructions are grouped by servicing intervals.
attachments or working practices. Items without specific intervals are listed under
the "When Required" service interval. Items in
Only trained or experienced personnel should be the "Maintenance Intervals" are referenced to
allowed to operate or maintain this machine. detailed instructions that follow.
Correctly record the machine type, serial
number, engine serial number and all major For the replacement of environment-friendly key
component serial numbers for your reference parts and components when maintaining an
when ordering parts or in the event of theft. engine, please use the OEM parts and
Record the correct numbers to both the components of the same type and the same
operator’s manual and a secure place outside specifications. Otherwise, LiuGong accepts no
the machine. legal liability for any consequence resulting from
the use of unapproved parts.
2
Preface September 4, 2020
CLG877H

Maintenance Intervals

Use the service hour meter to determine

servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 10 service hours or daily.
All the information, figures, tables and
specifications are the latest product information
obtainable at the time of publication. Guangxi
Liugong Company will reserve the right to make
change without notice.
3
September 4, 2020 Preface
CLG877H

Main Components

1 18
17

3
4
5
6
16
15
14
13

10 11 12
9
8
7

FRONT
19 RIGHT

LEFT
20
21
REAR
1. Cab 7. Boom 12. Rear wheel 17. Engine hood
2. Front work lights 8. Front wheel 13. Rear fender 18. Hydraulic oil tank
3. Front combination lights 9. Front fender 14. Rear frame 19. Rear work lights
4. Tilting cylinder 10. Ladder 15. Fuel tank 20. Rear combination lights
5. Bucket lever 11. Pressure centralized 16. Counterweight 21. Front frame
6. Bucket testing area
4
Preface September 4, 2020
CLG877H

Type and Serial Number of the Machine and Parts

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

Type of the Machine

Serial Number of the Machine

Type of Engine

Serial Number of Engine

Type of Transmission

Serial Number of Transmission

Type of Front Axle

Serial Number of Front Axle

Type of Rear Axle

Serial Number of Rear Axle

Type of Hydraulic Pump

Serial Number of Hydraulic Pump

Cab Manufacturer

Serial Number of Cab

Note: After receiving the machine the user should fill out the above table according to the specific configuration.
5
September 4, 2020 Preface
CLG877H

CE Marking, EMC Directive The EU EMC directive on "Electromagnetic

Compatibility", 2014/30/EU, provides a general
description of what demands can be made on
CE Marking the machine out of a safety point of view, where
permitted limits have been determined and given
(Declaration of Conformity) according to international standards.

(Only applies to machines A machine or device which meets the

marketed within the EU/EEA) requirements should be CE marked. Our
machines have been tested particularly for
This machine is CE marked. This means that electromagnetic interference. The CE marking of
when delivered the machine meets the EU the machine and the declaration of conformity
Machinery Safety Directive 2006/42/EC, also cover the EMC directive.
Electromagnetic Compatibility Directive 2014/30/ If other electronic equipment is fitted to this
EU and Noise Emission Directive 2000/14/EC. machine, the equipment must be CE marked and
Any person carrying out changes that affect the tested on the machine with regard to
safety of the machine, is also responsible for the electromagnetic interference.
same.
CE marking on nameplate (Only applies to
As proof that the requirements are met, the machines marketed within the EU/EEA)
machine is supplied with an EU Declaration of
Conformity, issued by LiuGong CE for each This CE marking is located on the right side of
separate machine. This EU declaration does not the front frame.
cover attachments manufactured by LiuGong.
The LiuGong attachments is declared by
manufacturer. The documentation is a valuable
document, which should be kept safe and
retained for at least ten years. The document
should always accompany the machine when it
is sold.
If the machine is used for other purposes or with
other attachments than described in this manual,
safety must at all times and in each separate
case be maintained. The person carrying out
such action is also responsible for the action
which, in some cases, may require a new CE
marking and the issue of a new EU Declaration
of Conformity.

The EU EMC Directive

The electronic equipment of the machine may in

some cases cause interference to other
electronic equipment, or suffer from external
electromagnetic interference, which may
constitute safety risks.
6
Preface September 4, 2020
CLG877H

DECLARATION OF CONFORMITY

THE FOLLOWING EQUIPMENTS:

MODEL PRODUCT IDENTIFICATION NUMBER

CLG877H (Tier 4f)
CLG877H (Stage V)

DECLARATION OF CONFORMITY. GUANGXI LIUGONG MACHINERY CO., LTD. HEREBY

CERTIFIES THAT THE ABOVE MENTIONED WHEEL LOADERS (SKID STEER LOADERS) MEET
THE FOLLOWING EC DIRECTIVES: MACHINERY DIRECTIVE 2006/42/EC AND
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2014/30/EU AND COMPLY WITH NOISE
EMISSION DIRECTIVE 2000/14/EC, AMENDED BY 2005/88/EC AND THE FOLLOWING
HARMONIZED STANDARD HAVE BEEN COMPLIED WITH:
EN 474-1:2006+A4:2013+AC:2014
EN 474-3:2006+A1:2009
MODEL: CLG877H (Tier 4f) MEASURED: 108dB GUARANTEED: 108dB
MODEL: CLG877H (Stage V) MEASURED: 105dB GUARANTEED: 106dB
RESPONSIBLE FOR MARKING THIS DECLARATION IS THE:
MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■
MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD.
MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA.
AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.
AUTHORIZED REP'S ADDRESS P.J. OUDWEG 4, 1314 CH, ALMERE, THE NETHERLANDS

PERSON RESPONSIBLE FOR COMPILING AND KEEPING THE TECHNICAL FILES ESTABLISHED
WITHIN THE EU:
SURNAME, NAME XIAO YUANXIANG
ADDRESS HEFBRUGWEG 6,1332 AN ALMERE, THE NETHERLANDS

PERSON RESPONSIBLE FOR SIGNING THIS DECLARATION:

SURNAME, NAME LIN MINGZHI
POSITION/TITLE CHIEF DIRECTOR

AMSTERDAM,
THE NETHERLANDS
(PLACE) (DATE) (COMPANY STAMP AND LEGAL) SIGNATURE)
7
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Safety Information Safety Decals and Decal

Locations
Safety Warning Symbols Safety decals can be found on the machine. This
section describes the locations of these decals
Safety warning symbols are important and explanations of the safety hazards they
safety messages that can appear on indicate. Please make time to familiarize yourself
machinery, safety signage, or in with these safety markings.
manuals, etc. When you see this Ensure that the warning decals can be read
symbol, you should follow the indications in the easily. If the text or illustrations of the warning
safety message and be alert to the possibility of decals cannot be read clearly, replace the decals
personal injury or death. or clean them with cloth and soapy water. Do not
use harsh cleansers or fuel to clean the warning
Safety Warning Labels decals.
Damaged, missing, or otherwise illegible warning
"Danger", "Warning" and "Caution" are defined decals must be replaced. When replacing
as follows: equipment or components that have warning
decals attached, make sure that the new
components have the corresponding warning
decals.

● Danger: This term indicates an immediate

hazard that, if not avoided, will result in death
or serious personal injury.

● Warning: This term indicates a potential

hazard that, if not avoided, will result in death
or serious personal injury.

● Caution: This term indicates a potential

hazard that, if not avoided, will result in minor
or moderate personal injury.
“Caution” is also used to alert you to safety
concerns regarding unsafe practices that may
result in personal injury. “Danger” indicates the
most severe safety hazards. “Danger” and
“Warning” labels are placed near specific safety
hazards. General precautions are listed on
“Caution” labels.
8
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Location (Used for ISO market)

12 13 14 15 16
11
10 17
9 18
8
7
6
5 19
4
3
2
1

41 39 38 37 35 34 33

39 44 43 42 40

C
D D
E

45 40 46 47 48
1. WARNING DECAL 15. NOTICE DECAL 29. DECAL 43. SYMBOL
2. DANGER DECAL 16. NOTICE DECAL 30. WARNING DECAL 44. DECAL
3. DANGER DECAL 17. DECAL 31. WARNING DECAL 45. SYMBOL
4. SYMBOL 18. WARNING DECAL 32. DECAL 46. NOTICE DECAL
5. SYMBOL 19. WARNING DECAL 33. DECAL 47. DECAL
6. WARNING DECAL 20. DECAL 34. DANGER DECAL 48. WARNING DECAL
7. WARNING DECAL 21. DECAL 35. WARNING DECAL 49. NOTICE DECAL
8. WARNING DECAL 22. CAUTION DECAL 36. DECAL 50. DECAL
9. SYMBOL 23. SYMBOL 37. DECAL 51. SYMBOL
10. DECAL 24. WARNING DECAL 38. WARNING DECAL 52. WARNING DECAL
11. WARNING DECAL 25. DECAL 39. DANGER DECAL 53. WARNING DECAL
12. SYMBOL 26. DECAL 40. WARNING DECAL 54. DECAL
13. DECAL 27. DECAL 41. DECAL 55. WARNING DECAL
14. WARNING DECAL 28. DECAL 42. DECAL
9
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Decal Location (Used for ISO market)

20 19 21 22 23 24 25 26 3 2 1
ROTATE TO VIEW C

MOD EL
R AT ED P OW ER
OP ER A TIN G MASS
P ROD U CT IO N D ATE

37 4 5 31 38 39 30 29 7

28 27 36 32
E-E ROTATE
VIEW A D-D

49 50 51

F-F

52 53 54 55

1. WARNING DECAL 15. NOTICE DECAL 29. DECAL 43. SYMBOL

2. DANGER DECAL 16. NOTICE DECAL 30. WARNING DECAL 44. DECAL
3. DANGER DECAL 17. DECAL 31. WARNING DECAL 45. SYMBOL
4. SYMBOL 18. WARNING DECAL 32. DECAL 46. NOTICE DECAL
5. SYMBOL 19. WARNING DECAL 33. DECAL 47. DECAL
6. WARNING DECAL 20. DECAL 34. DANGER DECAL 48. WARNING DECAL
7. WARNING DECAL 21. DECAL 35. WARNING DECAL 49. NOTICE DECAL
8. WARNING DECAL 22. CAUTION DECAL 36. DECAL 50. DECAL
9. SYMBOL 23. SYMBOL 37. DECAL 51. SYMBOL
10. DECAL 24. WARNING DECAL 38. WARNING DECAL 52. WARNING DECAL
11. WARNING DECAL 25. DECAL 39. DANGER DECAL 53. WARNING DECAL
12. SYMBOL 26. DECAL 40. WARNING DECAL 54. DECAL
13. DECAL 27. DECAL 41. DECAL 55. WARNING DECAL
14. WARNING DECAL 28. DECAL 42. DECAL
10
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Information(Used for ISO market)

Fig.1 WARNING DECAL

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

74A3167

Fig. 2 DANGER DECAL

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

74A3153

Fig. 3 DANGER DECAL

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

74A3165
11
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 6 WARNING DECAL

(Located near the articulation joint)
CRUSH HAZARD. Engage articulation lock
before service or transport.

74A4507

Fig. 7 WARNING DECAL

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

74A3163

Fig. 8 WARNING DECAL

(Located near the high pressure pipe joint
and high pressure valve)
Pressurized system. Relieve pressure before
maintenance.
74A3170
12
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Information(Used for ISO market)

Fig. 11 WARNING DECAL
(Located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations. Operate only from
operator’s seat. Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral. Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator’s compartment, park on level
ground, lower attachmentsto ground, make
sure hydraulic control lever is in lockout
position. All control levers are in neutral.
Engage parking brake. Never operate
machine downhill with stalled engine and
gear in neutral. Avoid contacting overhead
obstacles when operating or hauling
machine. 74A4777
13
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 14 WARNING DECAL
(Located in the cab)
Improper engagement of worktools could
result in serious injury or death. Do not
operate this machine until you have positive
indication that:1. Tool is firmly attached to
coupler.2. Handle of diverter valve is in Aux
position as pictured.3. Mechanical lock on
control lever of coupler is in locked
position.Never operate machine withoutlocks
in locked position. To change tool, turn
hydraulic diverter valve to Coupler position.
Ensure that work area is clear of personnel.
Tool must be in rolled back position and
indicators visible to operator. Release
mechanical interlock on control lever and
withdraw locking pins. Lower tool to ground
and roll forward to release. When attaching
tool, roll back fully and extend locking pins.
Check attachment by rolling tool forward
against ground. Tool should remain
attached. Bucket engaged, indicators point
towards each other at top. Bucket
disengaged, indicators point away from each
other at top. Relock the mechanical interlock
on the coupler control lever and reset the
hydraulic diverter valve to Aux position. Do
not operate machine with a faulty coupler or
with the menchanicalinterlock on the control
lever not engaged at all times. 74A4779

Fig. 15 NOTICE DECAL

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

74A4769
14
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Information(Used for ISO market)

Fig. 16 NOTICE DECAL

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

Fig. 18 WARNING DECAL

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

74A3183

Fig. 19 WARNING DECAL

(Located near the engine belt)
ENTANGLEMENT HAZARD. Keep clear or
stop engine before servicing.

74A3171
15
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 22 CAUTION DECAL

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

74A3168

Fig. 24 WARNING DECAL

(Located in the cab)
CRUSH HAZARD. Use seat belt. Do not jump
if machine tips.

74A4778

Fig. 26 DECAL
(Located in the cab)

74A2875
16
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Information(Used for ISO market)

Fig. 30 WARNING DECAL

(Located on the high pressure gas container)
CONTAINS HIGH PRESSURE GAS
To avoid exposion and personal injury, do not
expose to fire, do not weld, do not drill.
Relieve pressure before discharging.
74A3075

Fig. 31 WARNING DECAL

(Located near the crush area)
RUNOVER HAZARD. Block wheels to
prevent machine movement before
disengaging parking brake for repair or
maintenance.

74A3173

Fig. 34 DANGER DECAL

(Located near the battery)
Fumes given off by batteries are combustible.
Keep flame and sparks away, do not store
tools or metal objects near batteries. Risk of
explosion if metal objects cause a short
circuit. Sulphuric acid contained in batteries is
poisonous, do not allow acid to contact skin,
clothing or your eyes. If you spill acid on
yourself, immediately: Flush your skin with
water. Apply a neutralizing agent such as
lime. Flush eyes with water for 10-15 minutes.
Immediately seek medical attention.
74A4506
17
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 35 WARNING DECAL
(Located near the battery)
Only attempt to use jumper cables from an
operating machine with a 24 volt negative
ground system, failure to observe could result
in serious injury. Follow this procedure when
attaching jumper cables. 1. Connect a jumper
cable to positive terminal (+) of disabled
machine and connect other end to positive
terminal (+) of operating machine. 2. 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. 3. Start operating machine and start
disabled machine from operator seat only. 4.
Once disabled machine is started remove
jumper cables in reverse order. 74A4510
Fig. 37 DECAL
Refer to the manufacturer plate on the
machine for the machine mass.
The steering frame lock must be in place for
lifting.
Use proper rated cables and slings for lifting
.position crane for level machine lift.
Spreader bar witch should be sufficient to
prevent contact with machine. 74A4255

Fig. 38 WARNING DECAL

(Located near the ladder)
Whenever mounting or dismounting machine,
face machine and maintain 3 points of
contact. Never jump from machine. Ensure
steps are clean.

74A4508
18
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Information(Used for ISO market)

Fig. 39 DANGER DECAL

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

74A4509

Fig. 40 WARNING DECAL

(Located on the engine hood )
Do not step on this surface.

74A4511

74A2868

Fig. 46 NOTICE DECAL

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

74A2863
19
September 4, 2020 Safety Information
CLG877H Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 48 WARNING DECAL

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

74A4512

Fig. 49 NOTICE DECAL

(Located near the fuel filler)
Only fill the DEF tank with approved DEF
solution. Do not fill with diesel fuel or water.

74A9063

Fig. 52 WARNING DECAL

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

74A3178

Fig. 53 WARNING DECAL

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

74A3161
20
Safety Information September 4, 2020
Safety Decals and Decal Locations CLG877H

Decal Information(Used for ISO market)

Fig. 55 WARNING DECAL
(Located near the joint of coupler)
CRUSH HAZARD. Inspect coupler locking
pins extension before operating. Bucket
engaged, indicators point towards each other
at top. Bucket disengaged, indicators point
away from each other at top. Improperly
locked attachment could release and cause
serious injury. Failure to comply could result
in death or serious injury. Only use
attachments specifically degigned for and
approved for use with the coupler fitted.If the
attachment is damaged or can not be secured
to the coupler it must not be used. Never
move the machine with attachments not
secured. 74A3184
21
September 4, 2020 Safety Information
CLG877H 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. When you

remove springs or resilient parts, add acid/

r:
te
ra
pe

electrolyte to batteries, you should wear a full

:
ate
D

face protective mask. When carrying out welding

Do not wear loose fitting clothing, dangling operations or gas cutting operations with a
jewelry or long hair that can catch on controls or welding torch, wear specific safety goggles
in other moving parts of the machine. suitable for the task being performed. Consult
your welding equipment dealer for more
information.
22
Safety Information September 4, 2020
General Hazard Information CLG877H

Pay attention when opening fluid compartments

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

When working under high noise conditions, wear

appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high Know the appropriate worksite hand signals and
noise on your hearing. who gives them. Accept signals from one person
only.
Do not smoke or allow open flames near the
machine while performing maintenance on the
air conditioner or if refrigerant gas is present.
Refrigerant gas coming in contact with a burning
cigarette or open flame could produce toxic
vapors that must not be inhaled. Inhaling these
toxic vapors can cause serious injury or death.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
Make sure all protective guards and covers are
handling harmful articles such as lubricants,
secured in place on the machine. Always replace
fuels, coolants, solvents, filters, batteries and
protective guards and covers removed for
other materials.
servicing or maintenance. Repair damaged
guards and covers before operation. Use all cleaning solutions with care. Do not use
any flammable material to wash components, for
Keep the machine, especially the panels,
example, diesel oil or gasoline. They may easily
accesses, step and ladders, free of foreign
catch fire.
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.
23
September 4, 2020 Safety Information
CLG877H General Hazard Information

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

Compressed Air

Compressed air can cause personal injury. When

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

High-pressure Fluid

Avoid injury from high-pressure oil. When

repairing hydraulic lines, ensure that
system pressure is completely released Disposal of Waste Fluids
before beginning the repair. Hydraulic oil
under pressure contacting the skin could Improper handling of the waste fluid will cause
cause serious injury or damage. pollution of the environment. Obey all local
regulations for disposal of waste fluids.
Use caution before disconnecting hydraulic lines
or connectors. High pressure oil that is released Collect all waste fluids when performing
can cause a hose to whip. inspections, maintenance, testing, adjusting and
repairs to the machine.
Always support attachments and release
residual pressure before attempting to Prepare to collect fluids with suitable containers
disconnect hydraulic lines. Pressure applied by before opening any compartment or
loads on attachments could cause hydraulic oil to disassembling any component that contains
spray when lines are removed. fluids.
24
Safety Information September 4, 2020
General Hazard Information CLG877H

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

Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
● Never use compressed air to clean up
asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.
Cautions about Accumulators ● A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
High-pressure nitrogen is contained in the can also be used.
accumulators making them dangerous articles.
Read the following requirements and pay ● Do not grind materials that contain asbestos.
attention to the proper use of accumulators. ● Operate the machine on the windward side of
Check accumulators before charging with the asbestos as far as possible.
nitrogen. Safe use cannot be guaranteed if there ● Obey environmental regulations for the
is not a nameplate attached to the accumulator. disposal of asbestos.
Never charge accumulators that have an
incomplete nameplate or that are of an ● Shower after contact with asbestos.
unidentified type. ● Wear an approved respirator if there is no
Accumulators are charged with nitrogen. The other way to control the dust.
use of oxygen, compressed air or other
flammable air in the accumulator could cause an
explosion and possible injury, death and damage
to the machine.
When charging accumulators with nitrogen, care
should be taken not to damage the diaphragm.
The accumulator's valve should be installed
facing vertically upward. Do not attempt to fix
accumulators by welding them.
Do not drill any hole in the accumulator or close
a hole by welding.
Do not weld a boss on the accumulator.
Accumulators are high-pressure vessels and
should be repaired only by trained specialized
personnel.
25
September 4, 2020 Safety Information
CLG877H Crushing and Cutting Prevention

Crushing and Cutting If the machine must be repaired with engine

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

Burn Prevention

Some parts of the machine become hot during

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

Keep hands and objects away from moving fan

blades. They can throw or cut any object that
contacts the moving blades.
Check the coolant level only after the engine has
Never attempt adjustments while the machine is been stopped and the coolant filler cap is cool
moving or the engine is running unless otherwise enough to remove with your bare hand.
specified.
Remove the cooling system filler cap slowly to
relieve pressure.
26
Safety Information September 4, 2020
Fire & Explosion Prevention CLG877H

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

Oil

Hot oil and components can cause personal

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

Fire & Explosion Prevention

All fuels, most lubrication and some coolant

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

Batteries
Clean and tighten all electrical connections.
Batteries give off flammable fumes which can Check daily for loose or frayed electrical wires.
explode. Have all loose or frayed electrical wires
Batteries and battery terminals may contain lead; tightened, repaired or replaced before operating
do not touch batteries with your bare hands. the machine.
Always wash your hands right after maintaining a Check the electric circuit periodically to avoid fire
battery. caused by overload or short circuit.
Do not smoke when observing the battery Keep all fuels and lubrications stored in properly
electrolyte levels. marked containers and away from all
Electrolyte is an acid and causes personal injury unauthorized persons.
if it contacts skin or eyes. If contact occurs flush Store all oily rags or other flammable materials in
with water and seek medical attention right away. a protective container away from naked flames
or other sources of ignition.
Do not weld or flame cut pipes that contain
flammable fluids. Clean the flammable fluids
before welding or flame cutting on them.
27
September 4, 2020 Safety Information
CLG877H Fire Extinguishers and First-aid Kit

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

A fire extinguisher that meets with all local fire

extinguisher laws and regulations should be
available on the machine.
Maintain the fire extinguisher in accordance with
all local laws and regulations. Contact your local
fire department for further information.
Know how to use the fire extinguisher and first-
Cautions Concerning Lines, Tubes and
aid kit.
Hoses
A first-aid kit should be available at the work site.
Do not bend or strike high-pressure lines. Do not Periodically check the contents of the kit and
install bent or damaged tubes or hoses. replace used medical supplies as necessary.
Tighten any loose fuel or oil pipes, hydraulic Keep telephone numbers of doctors, first-aid
system tubes or hoses. Repair any damaged fuel centers or fire stations etc with you so you can
or oil lines, tubes or hoses. Leaks can cause contact them in case of an emergency. Post the
fires. Contact Liugong or your Liugong Dealer for contact telephone numbers in regulated places.
factory authorized replacement parts. Ensure that all persons know where the
telephone numbers are located and know the
If you see evidence of any of the following
correct contact method.
situations, replace the part before using:
● Connectors damaged or leaking.
● Outer covering frayed or cut and reinforcing
wire exposed.
● Outer covering ballooning.
● Evidence of kinking or crushing.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
28
Safety Information September 4, 2020
Electrical Storm Injury Prevention CLG877H

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

Tire Explosion Prevention

Maintenance, removal, repair and installation of

Dry nitrogen is recommended for inflation of
the tires and wheel rims must be performed with
tires. If the tires were originally inflated with air,
special equipment and a trained repairer.
nitrogen is still preferred for adjusting the
Therefore, it is better to repair and maintain the
pressure. Nitrogen mixes properly with air.
tires in a tire service shop.
Nitrogen inflated tires reduce the potential of a
tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation
of the rubber, deterioration of rubber, and
corrosion of rim components.
Avoid over inflation. Use proper inflation
equipment, and training for using the equipment
is necessary. Improper equipment or using will
result in tire break or rim damage.
Inproper tire and rim maintenance may cause tire
explosion, and such explosion can lead to
serious personal injury or death. Only trained
personnel with proper tools and correct
procedure can maintain the tires and wheel rims.
29
September 4, 2020 Safety Information
CLG877H ROPS/FOPS

ROPS/FOPS Any modifications or aditional equipment added

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

Information on Attachments

Installation and adjustment of attachments must

be performed by qualified personnel. Operators
should be trained to operate and maintain
attachments in strict accordance with the
relevant manuals.
When installing or using replacement
attachments, read the relevant instructions in the
Operator Station attachment manual as well as this manual.
Improper installation of attachments or
This machine is equipped with a cab that meets accessories will not only cause safety hazards,
with industry standard: ISO 3411. but will also adversely affect the machine’s
operations and the service lifespan of the
equipment.
Do not use any attachments that are not
authorized by LiuGong. Use of unauthorized
attachments may cause safety hazards and
adversely affect the machine’s normal operation
and its service lifespan.
30
Safety Information September 4, 2020
Cautions about Machine Operations CLG877H

Without authorization, any modification of Understand the purpose of all control systems,
attachments is strictly prohibited. instruments and indicators.
LiuGong is not responsible for any injuries, Understand the rated load, speed range, the
accidents, or damage to the machine caused by characteristics of braking and steering, turning
the use of unauthorized attachments. radius and the space clearance for operation.
Remember that rain, snow, ice, gravel and soft
Cautions about Machine earth may change the performance of the
machine.
Operations
Understand the safety signs on the machine
(Danger, Warning, Caution) and any other signs.
Mounting and Exiting the Machine
Understand Your Working Area
Clean any oil or mud from the handrails and
steps before mounting or exiting the machine. Before starting, inspect the area where you will
Any damaged parts must be repaired, and loose be working. You should check: adequate
bolts must be tightened. ventilation, the position of any slopes, visible
Only step on parts of the machine that have ditches, falling or hanging objects, conditions of
steps or handrails. soils (soft or hard), accumulated water and
swamp areas, rocks or stumps, hidden
Face the machine when getting on and off. Hold groundwork, posts or the outer limits of walls, the
the handrails, step on the steps, and maintain outer limits of the areas where garbage is buried
three points of contact (two feet and one hand or or that are filled in with earth, holes or openings,
two hands and one foot). 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

Never jump off the machine. Inspect the machine carefully before starting the
Never get on or off the machine while it is engine, ensure all systems are in good
moving. operational condition. Make sure nobody is on or
around the machine before starting the engine.
Never use any control lever as a handrail while
getting on or off the machine. Keep the steps and handrail clean. Clear any dirt
and sand from your shoes before mounting the
Do not climb onto or off of the machine while machine.
carrying tools or other items. Use rope to lift the
required tools onto the operating platform. Check all structural members, covers and
fenders for deformation or damage.
Understand Your Machine Check the condition of safety items such as
doors, guards and covers. Repair any damage
Be able to operate all the equipment on your as necessary.
machine.
31
September 4, 2020 Safety Information
CLG877H Cautions about Machine Operations

Check the hydraulic system for oil leakage. Engine Starting

Check the condition of hoses and pipes.
Do not start the engine if there is a DO NOT
Check all fasteners for security.
OPERATE or similar tag attached to the start
Check the condtion of the electrical wiring switch or control levers.
harness and fuses, replace or repair as
neccessary. Also check the connectors for good
connection.

G
Check the fuel level and fuel system for normal

IN
N
AR
W
condition, drain any water or sediment in the

er ot
!

op o n

e
water/fuel separator. Dispose of fluids in

at
d
accordance with local regulations.

r:
te
ra
pe
O
Replace all damaged or lost parts and carry out

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

the RELEASED position.

32
Safety Information September 4, 2020
Cautions about Machine Operations CLG877H

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

Before working the machine, you should operate

the machine slowly to an open area, check for
proper operation of all control levers and all
protective devices.
Before Operating the Machine
Note any needed repairs during machine
Make sure the machine is clear of personnel and operation such as an abnormal noise, vibration,
fasten the seat belt before operation. smell, wrong reading of gauges, gas or oil
leakage, etc., stop what you are doing and report
any needed repairs.
33
September 4, 2020 Safety Information
CLG877H Cautions about Machine Operations

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

If driving or operating the machine with a bad

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

Avoid bumping the obstacles on top of the

machine when operating it.
34
Safety Information September 4, 2020
Cautions about Machine Operations CLG877H

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

When driving the machine on a slope, make it

straight up and down and neither make turn on
the slope nor drive it transversely on the slope to
prevent tipping. The distance between bucket
and ground should be 200-300mm (7-12in).
If the engine stops accidentally when operating
the machine across the slope, depress the
service brake pedal immediately and lower the
bucket to the ground, then pull up the parking To prevent the machine from tipping over or
brake button (or parking brake handle) to stop damaging the attachment due to overloading,
the machine from moving. never exceed the machines rated capacity.
If the machine begins to sideslip on a slope,
immediately remove the load and turn the
machine downhill.
When going down a slope, use the brake power
of the engine and drive in low speed. At the
same time, use the service brake to control the
travel speed if necessary. Do not shut down the
engine or push the lever to NEUTRAL position
when machine goes down the slope, so as to
prevent serious accident or personal injury. Do not use the bucket or boom for lifting. The
machine can only be used within its capability.
Any operation beyond its capability will bring
damage to the machine. Refer to the
Applications and Specifications section for the
specific capacities.
Never hoist heavy articles by directly hanging
slings on the bucket teeth.
35
September 4, 2020 Safety Information
CLG877H Cautions about Machine Operations

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

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

● Alert all personnel to keep away from the Consider environmental conditions such as the
machine. posibility of flooding, heavy snow fall, electrical
storms and exposure to wind and cold. Any of
● If you can, drive the machine away to these conditions may cause damage to the
disconnect the contact point and separate machine.
the high voltage wire from the machine and
leave. Do not cause an obstruction, consider the site
access and other emergency conditions the
● If you can not disconnect the contact point, machine may obstruct.
stay inside the cab until the Electricity
Company cuts off the power and you are
informed to go out.
● If a fire occurs, hold your feet as close as
possible and jump off the machine without
touching ground with your hands. Try to jump
into a safe place.
36
Safety Information September 4, 2020
Cautions about Machine Operations CLG877H

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

Lowering the Attachment/ Implement with

Engine Stopped

Understand and obey all regulations relating to

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

Engage the parking brake.

Keep the engine running at idle speed for five
minutes to let the engine cool down gradually.
Stop the engine, and take out the key from the
switch.
Turn the battery disconnect switch to OFF
position to avoid battery discharge.
37
September 4, 2020 Safety Information
CLG877H Cautions about Machine Maintenance

Store Accessories Safely Transportation Information

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

Cautions about Machine

Maintenance 1. Wedge
2. Block
3. Angle (Max. angle is 15°)
Prepare the Working Area 4. Distance between the ramps
5. Ramp
Please choose a clean and flat area with Use loading ramps appropriate for the machine
adequate space, enough light, and good being moved. Consider: size, strength, departure
ventilation to carry out any repair work. Clean the angle and proper height. Make sure that the
ground surface, wipe up fuel, lubricating oil and loading ramp is anti-slip and free of mud and
water, and spread sand or other absorptive snow.
materials on the slippery ground. Keep the work
area clean and dry. Use chains and blocks to secure the machine to
the trailer.
Support the Machine Correctly Keep the bystanders away.

Lower to the ground or support any attachments Place all the working equipment in the
with stands or other methods. Ensure that any transportation position, secure all the equipment
attachment can not move during maintenance or and attachments or additional equipment with
repair work, use wheel chocks or other devices chains or other secure methods to prevent
to prevent machine movement. accidental movement.

Do not work under any part of the machine or Lifting the Machine
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use Refer to the machine nameplate for the machine
stands or other measures that are secure and mass.
can support the weight being applied to them.
38
Safety Information September 4, 2020
Cautions about Machine Maintenance CLG877H

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

Clean the Equipment Periodically

To avoid possible injury or damage to the

machine, all the oil and scraps accumulated
should be removed. The engine, radiator,
storage battery, hydraulic hose, fuel tank and cab
should be kept clean.
Welding Operation
When carrying out the cleaning operation, wear
Any personnel engaging in welding operations suitable PPE. Consider exposure to: chemicals,
must have occupational certificates and carry out slippery surfaces, high pressure water spray and
the operation at a place with appropriate devices material splash.
equipped, When carrying out the welding
operation, the personnel must follow the
instructions below:
Before carrying out the welding operation, turn
off the battery isolator switch, disconnect the
battery, disconnect the controllers, GPS and
other electrical parts.
Remove all paint from the place to be welded, so
as to prevent harmful gas from being produced.
Do not inhale smoke produced by burning paint.
Never weld pipes, close to rubber hose and Do not spray the water directly onto sensors,
electrical wires. connectors or instruments of the electrical
Always remove residual pressure from the system. If water enters the electrical system
machine. Never weld pipes that are fitted to the malfunction may occur.
machine.
Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
of the operation being performed.
Ensure good ventilation.
39
September 4, 2020 Safety Information
CLG877H Sound and Vibration

Sound and Vibration

Sound

The sound performance offered for this machine

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

Vibration Level

Whole body vibrations generated by

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

This machine is equipped with an operator's

seat, which meets the criterion in standard ISO
7096. This seat is tested with the input spectral
class EM3 and has a Seat Amplitude
Transmissibility factor SEAT=0.95.
The hands and arms are exposed to a weighted
root mean square acceleration that is less than
2.5 m/s2.
The whole body is exposed to a weighted root
mean square acceleration that is less than 0.5 m/
s2.
Measurements are obtained on a representative
machine using the procedures in the following
standards:
“ISO 2631-1”
“ISO 5349-1”
“ISO 5349-2”
40
Safety Information September 4, 2020
Key Spare Parts to be Periodically Changed CLG877H

Key Spare Parts to be Periodically Changed

No. Key spare parts to be periodically changed Q’ty Changing intervals

Every year or every 2000h (To see which
1 Filter element of hydraulic oil tank 1
one comes earlier)
2 Fuel hose (fuel tank—diesel prefilter) 1
3 Fuel hose (diesel prefilter—diesel filter) 1
4 Fuel hose (diesel filter—high-pressure pump) 1
5 Fuel hose (fuel return line) 1
6 Turbo-charger oil return pipe 1
7 Hose (steering pump to flow boost valve P port) 1
8 Hose (flow boost valve to steering cylinder) 2
9 Steering cylinder seals 2
10 Hose (hoses between two steering cylinders) 2
11 Hose (flow boost valve to metering pump R port) 1
12 Hose (flow boost valve to metering pump L port) 1
13 Hose (flow boost valve to metering pump P port) 1
14 Hose (steering pump to shuttle valve) 1
15 Hose (shuttle valve to flow boost valve LS port) 1
16 Hose (shuttle valve to metering pump LS port) 1
17 Hose (control valve to flow boost valve) 1
18 Hose (work pump to flow-converging square block) 1
Hose (flow-converging square block to control valve P Every 2 years or every 4000h (To see
19 1
port) which one comes earlier)
Hose (hoses from the steel tubes of boom cylinder head
20 4
and cylinder rod to the control valve steel tubes)
Hose (hoses from the bucket cylinder head and cylinder
21 2
rod to the bucket steel tubes)
22 Hose (shuttle valve to control valve LS port) 1
23 Hose (work pump to shuttle valve) 1
24 Hose (secondary steering pump to priority valve) 1
25 Hose (priority valve to steering pump check valve) 1
26 Brake hose (brake pump to high pressure oil filter) 1
27 Brake hose (high pressure oil filter to service brake valve) 1
28 Brake hose (service brake valve—accumulator outlet I) 1
29 Brake hose (service brake valve—accumulator outlet II) 1
30 Brake hose (service brake valve—accumulator outlet III) 1
31 Brake hose (service brake valve—front axle) 1
32 Brake hose (service brake valve—rear axle) 1
33 Brake hose (service brake valve to parking brake) 1
34 Brake hose (cooling pump to solenoid valve) 1
35 Brake hose (solenoid valve to fan motor) 2
41
September 4, 2020 Safety Information
CLG877H Key Spare Parts to be Periodically Changed

No. Key spare parts to be periodically changed Q’ty Changing intervals

Every 3 years or every 6000h (To see
36 Accumulators 3
which one comes earlier)
1. To ensure the safety of the machine during usage, the user must adhere to replace the parts listed in the above table
regularly due to the important of these parts in the security and fire prevention.
2. The materials of these parts will degenerate along with the passage of time, or more easy to wear, corrosion.
Moreover, it is very difficult to determine the state of these parts simply according to the regular maintenance.
Therefore, no matter what usage state they are, it is necessary to change these parts regularly in order to ensure their
performance.
3. If the parts not work properly even less than the time for replacement, they should be repaired or replaced immediately.
4. If the pipe folder of the fixed hose has any damage, such as distortion or cracks, it should be replaced together with the
hose.
5. Please replace the O-ring, seals and other parts like these at the same time when replace the hose.
6. Please contact the designated dealer of LiuGong Machinery Co., Ltd. to replace the safety key parts.
42
Applications and Specifications September 4, 2020
Applications CLG877H

Applications and
Specifications

Applications

This machine is a kind of engineering machinery

Air conditioner system

1 Type / Cooling & heating A/C Cooling & heating A/C
2 Heating capacity W 5800 5800
3 Cooling capacity W 5500 5500
4 Refrigerant Model R134a R134a
Electrical system
1 System voltage / DC 24V DC 24V

Refill capacities
1 Fuel tank L 372 417
2 Engine oil L 33 33
3 Cooling system L 36 36
4 Transmission oil L 50 50
Front: 60 Front: 60
5 Drive axle oil L
Rear: 60 Rear: 60
6 Hydraulic oil L 220 300
7 Brake oil L / /
8 Axle cooling system L / /
9 AdBlue L 18 49.2
Other specifications
Variable displacement Variable displacement
1 Cooling pump type /
piston pump piston pump
2 Cooling pump displacement ml/r 45 45
3 Cooling pump flow L/min 67.5 67.5
4 Cooling motor displacement ml/r 45 45
5 Cooling motor flow L/min 67.5 67.5
Nitrogen pre-charge pressure
6 of pilot oil supply valve MPa 1 1
accumulator
Nitrogen pre-charge pressure
7 MPa 2.5 2.5
of ride control accumulator
Work pressure of flow
8 MPa 20.7 20.7
amplifying valve
Nitrogen pre-charge pressure
9 of steering cushion MPa (psi) 3 3
accumulator
Nitrogen capacity of steering
10 L (US gal) 0.5 0.5
cushion accumulator
48
Applications and Specifications September 4, 2020
Main Specifications CLG877H

Note:
1. Continuing improvement and advancement are made to LiuGong products. All the specifications are the latest product
information obtainable at the time of publication. LiuGong will reserve the right to make change without notice.
2. The above parameters are the theoretical values, the tolerance ranges during testing are provided by LiuGong
standard.
49
September 4, 2020 Operation Manual
CLG877H Before Operation

Operation Manual Daily Inspection

For a maximum service life of the machine,

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

Mounting and Dismounting Inspect the area around the machine and under
the machine. Look for loose bolts, trash buildup,
Before mounting or dismounting the machine, hydraulic oil, coolant leakage, broken parts, or
check the condition of handrails, ladders and worn parts.
steps. Clean them of grease, lubricants and dirt Inspect the condition of the implement and the
before use. Repair any damaged parts and hydraulic components.
tighten loose bolts.
Check all of the oil levels, the coolant level and
Mount and dismount the machine only where the fuel level.
there are handrails, steps or ladders.
For additional information, refer to section
Face the machine when getting on or off, grab “Maintenance Interval Schedule”.
the handrails with both hands and step onto the
steps or ladders. Touch three points
simultaneously (two feet and one hand or two
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.
50
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Operator Controls and Disconnect switch--OFF

Instrument Panels To shut down the electrical system, turn the

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

The battery disconnect switch is located on the

right rear side of the rear frame. Open the cover O I
of battery box to get access to it.

The battery disconnect switch and the engine

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

Turn the battery disconnect switch key clockwise

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

O I

In order to make sure the AdBlue pump is

evacuated, it is forbidden to turn off the
battery disconnect switch in 100 seconds
after shutting down the engine.
51
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Engine Start Switch

The start switch (also called ignition switch) is If the engine fails to start, turn the start
located on the right front upright column in the switch to the OFF position before restart or
cab, and it has four positions in clockwise the start switch could be damaged.
direction.
Do not engage the start switch for more than
15 seconds at one time. Wait at least 30
seconds before restarting. Do not exceed
three consecutive attempts before allowing
the starter motor and choke solenoid to cool
down. Failure to comply could result in a
reduction of the service life of the battery as
well as damage to the starter motor and
D choke solenoid.

O——The start switch key can only be inserted

or taken out in this position. The engine is shut
down and the power is cut off. All of the other
electrical appliances can not be turned on except
the lift mechanism.
I——The first position when turning the start
switch key clockwise. The electrical system of
the machine can turn on and work normally.
II——The second position when turning the start
switch key clockwise. It is used for preheating
the engine. It is optional.
III——The third position when turning the start
switch key clockwise. The engine will be started
and work. Release the start switch key after
starting the engine. This position can not hold on
automatically and the key will reset to the I
position automatically after being released.

The battery disconnect switch must be at I

position and the shift control lever must be in
NEUTRAL before starting the engine.
52
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

2. Front left switch panel 6. Sound system
3. Front right switch panel 7. Right instrument panel
4. Right front upright column switch panel 8. Top instrument panel
55
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Central Instrument Panel The right indicator flashes when the

machine turns right, the front & rear
Central instrument panel consists of five pointer right turn signal light will also flash
gauges, one LCD, status indicators and warning simultaneously.
indicators, etc..
877H T4F Speedometer

6 5 1 2 1 3 4 This meter shows the actual speed of

the machine. The external scale
indicates the value in metric system; The interior
scale indicates the value in British system. It is a
meter which has backlight function. Turn on the
meter light switch to open backlight function if it
can not be seen under strong light.

Engine coolant temperature gauge

This gauge shows the coolant

8 7 temperature of the engine. The green
zone shows normal work temperature; the yellow
877H Stage V zone shows low temperature and the red zone
6 5 1 2 1 3 4 shows high temperature.

Stop the engine and park the machine on a

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

8 7
1. Turn indicators When checking the engine fan, belt and water
2. Speed meter tank level, be extremely careful to avoid
3. Engine coolant temperature gauge injury. Keep away from the moving parts to
4. Torque converter oil temperature gauge avoid being injured and keep away from hot
5. Fuel level gauge
6. AdBlue gauge parts to avoid being burnt.
7. Service hour meter
8. LCD screen

Turn indicators

The left indicator flashes when the

machine turns left, the front & rear left
turn signal light will also flash
simultaneously.
56
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Torque converter oil temperature LCD screen

gauge
This LCD can display the engine rotating speed,
This gauge is used to indicate the oil system voltage, engine fault code and so on, the
temperature of the torque converter. The green unit of the display can be switched between
zone shows normal work temperature; the yellow metric unit and English unit.
zone shows low temperature and the red zone
shows high temperature.

Whether “X10m3” will illuminate depends on

the specification value.
When the pointer of the torque converter oil
temperature gauge points to the red zone, 1. Engine rotating speed
park the machine on a safe and convenient “RPM” will illuminate when machine is travelling.
place for repair. Check the transmission and Engine rotating speed will display on the LCD
transmission oil level. Never go on working screen, e.g: 1800rpm. The normal work range is
or operate the machine before eliminating 950~2200rpm, and the speed at maximum
the problem. torque is 1400rpm.

Fuel level gauge

This gauge indicates the fuel level of

the machine. “1” indicates the high fuel
level. “0” indicates the low fuel level. Add fuel in
time when the fuel level is lower than “0.2”.

AdBlue gauge
2. System voltage
This gauge indicates the level of System voltage will display on the LCD screen
AdBlue. Green zone indicates the when “Volts” illuminates, e.g: 27.3V.
normal volume range, red zone indicates that the
AdBlue level is very low. Add AdBlue in time
when the gauge pointer points to red zone.

Service hour meter

Service hour meter indicates the total

work hours of the machine, unit in
hour. The time range of the hour meter is 0 to
9999.99 hours. When turning on the start switch,
the power of the panel is turned on and the
service hour meter starts to time. The LCD
display shows the accumulated work hours of the
machine. The recording value by the service
hour meter can be used to determine the
machine maintenance intervals.
57
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

3. Engine fault code

“SERV. CODE” will illuminate immediately if 9-10
there is a fault when the engine is running. The
engine fault code will display on the LCD screen,
e.g: 1308. 11-13

9. Voltage indicator
The fault codes will display one by one through 10. Seat belt indicator
the LCD screen according to the number 11. Parking brake indicator
12. Brake low pressure alert indicator
sequence for 10s each time when there are two 13. Main fault alert indicator
or more fault codes. At the moment, other items
can only show for 30s by using the screen Voltage indicator
selector switch.
For more information about engine fault code, When the yellow indicator lights, it
refer to “FAULT CODE INDEX FOR ENGINE”. indicates the voltage of the machine is
out of the range of 24.8-29.5V. If the voltage of
Engine rotating speed, system voltage and the machine exceeds 31.5V, the voltage indicator
engine fault code can show in turn by using the and status indicator will light, the buzzer will
screen selector switch on the right front upright sound at the same time.
column in the cab.
Seat belt indicator

The seat belt indicator on the

instrument panel will light to remind the
driver if he doesn’t fasten the seat belt after
starting the machine. The indicator will go out
after fastening the seat belt and starting the
machine, the seat belt alert lamp on the top of
the cab will light to remind the surrounding
people that the driver has already fastened the
seat belt and the machine is going to work.

The screen selector switch is instant type, it will Parking brake indicator
reset to the original position automatically after
being released. When engaging parking brake, the red
indicator turns on. It indicates the
parking brake is working.
58
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Brake low pressure alert indicator Engine intake air filter alert indicator

The illumination of this red alert When the air filter is blocked, this
indicator indicates the hydraulic oil indicator will light. Stop the engine and
pressure of the service / parking brake is too low. maintain the air filter.
Stop the machine to check.
Generator charge indicator
Main fault alert indicator
The indicator indicates if the generator
The main fault alert indicator will flash is generating electric power. When the
to alert if any one of the following alert engine start switch is turned to the ON position,
indicators illuminates: parking brake, brake low this indicator illuminates. When the engine start
pressure, engine oil pressure, engine air filter switch is turned to the START position, the
blocked, centralized lubrication fault, generator reached the electric power generation
transmission oil pressure, transmission fault, state, this indicator goes out.
hydraulic oil temperature, hydraulic oil filter, axle
oil temperature, axle oil pressure and steering Centralized lubrication fault
system fault indicator. The buzzer will sound to indicator
alert if any one of the following alert indicators
illuminates and an engine running signal could When the red indicator flashes, it
be detected: parking brake, brake low pressure, indicates fault of the centralized lubrication
engine oil pressure, and steering system fault system.
indicator. The buzzer will sound if the boom lifting
angle setting indicator illuminated. Transmission oil pressure alert
indicator

The red indicator will flash when

transmission oil pressure is too low. Stop the
engine to check.

14-19

Park the machine on a safe and convenient

place for repair when the transmission oil
pressure alert indicator is flashing. Check the
transmission and transmission oil level.
14. Engine oil pressure alert indicator Never go on working or driving the machine
15. Engine intake air filter alert indicator before correcting the fault.
16. Generator charge indicator
17. Centralized lubrication fault indicator (optional)
18. Transmission oil pressure alert indicator Transmission fault alert indicator
19. Transmission fault alert indicator
The red transmission fault alert
Engine oil pressure alert indicator indicator will light when the
transmission controller detects a fault.
Engine oil pressure alert indicator will
flash to alert when the engine oil
pressure is too low, and the buzzer will sound at
the same time (the buzzer alerts only when the
engine is running). Stop the engine to check.
59
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Hydraulic oil filter alert indicator

877H T4F
The red indicator indicates that the
return oil filter element of the hydraulic
oil tank has been polluted seriously, which needs
to be replaced.

20-25 Start the machine under low temperature,

the hydraulic oil filter alert indicator will
flash momently, and go out when the
temperature raises after a period of time.
20. Hydraulic oil temperature alert indicator
21. Hydraulic oil filter alert indicator Translational lifting indicator
22. Axle oil temperature alert indicator (red) (not
available)
23. Axle oil temperature alert indicator (yellow) (not The green indicator illuminates when
available) the translational lifting function is
24. DEF low indicator
25. Steering system fault indicator
activated.

877H Stage V Axle oil temperature alert indicator

(red)

When the drive axle oil temperature

reaches 120°C, the red indicator will illuminate.
The yellow indicator will go out when the red
indicator illuminates, and the buzzer will sound at
the same time.

20-25 Axle oil temperature alert indicator

(yellow)

When the drive axle oil temperature is

20. Hydraulic oil temperature alert indicator 105°C, the yellow indicator will illuminate, and
21. Translational lifting indicator (optional) the buzzer won’t sound.
22. Axle oil temperature alert indicator (red) (not
available)
23. Locking state indicator
Locking state indicator
24. DEF low indicator
25. Steering system fault indicator When the locking state indicator is
light, the engine will be locked and the
Hydraulic oil temperature alert engine rotating speed will decrease from the
indicator highest speed.

The red indicator will light to alert when DEF low indicator
the hydraulic oil temperature is too high. Stop the
engine to check. DEF low indicator lights when the
AdBlue level is lower than 10%, and
flashes when the AdBlue level is lower than 5%.
Add AdBlue in time when the indicator lights.
60
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Steering system fault indicator

This red indicator is controlled by the

instrument system. The indicator will
light and the secondary steering motor will start
when the instrument detects a fault in the
31-36
steering system.

26-27

28-30
31. DPF regeneration disabled (inhibit) lamp (mandatory)
32. DPF high exhaust system temperature lamp
(mandatory)
33. DPF particle filter lamp (mandatory)
34. Automatic triggered detection mode indicator
35. Secondary steering indicator
36. Clutch cut-off indicator

DPF regeneration disabled (inhibit)

26. Auto-dig record mode indicator lamp (mandatory)
27. Ride control indicator (optional)
28. Fan reverse indicator
29. Front floodlight high beam indicator The DPF regeneration disabled
30. Centralized lubrication indicator (Inhibit) switch was activated when this indicator
illuminates, therefore, the automatic or manual
Auto-dig record mode indicator regeneration cannot occur.
Operation: this lamp illuminated as a
The green indicator illuminates when
confirmation/ acknowledgement from the ECM to
the auto-dig record mode is working.
indicate that the regeneration disabled (inhibit)
switch is turned on.
Ride control indicator
DPF high exhaust system
The green indicator illuminates when
temperature lamp (mandatory)
the ride control is working.
The DPF (diesel particulate filter) high
Fan reverse indicator
exhaust system temperature (HEST) lamp
indicates the exhaust system temperature is or is
The yellow indicator illuminates when
about to increase above normal operating
the fan of radiator is reversing.
temperatures for the operating mode of the
engine. The increased temperature can be from
Front floodlight high beam indicator
residual heat from a previous operating condition
or from an automatic regeneration of the
The blue indicator indicates the front
Cummins Particulate Filter. The HEST lamp will
floodlight is at high beam.
also illuminates during a manual regeneration.
Centralized lubrication indicator

The green indicator illuminates when

the centralized lubrication system is
working.
61
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Operation: when a manual regeneration is 4. If the DPF lamp turns off, but the red stop
initiated or the exhaust temperature exceeds a indicator illuminates, this indicates that the
programmable value the HEST lamp will particulate filter can no longer regenerate.
illuminate in a solid ON state. The HEST lamp Operator will need to disable all operations
stays ON during the entire manual regeneration. and service call is required. Depending on
The HEST lamp will then turn OFF when the the soot level, particulate filter may be
temperature falls below a second programmable removed and cleaned in an approved
temperature. The HEST lamp signal uses a machine. This lamp will also turn off to
Switched Source Driver Output which exists in acknowledge an effective assistance for
one of two states: Source or OFF. The Source regeneration. However, if assistance has not
state provides battery voltage to illuminate the been sufficiently long to complete
lamp, while OFF state turns off the lamp. regeneration, the DPF lamp will be
illuminated according to the appropriate
Diesel particulate filter (DPF) lamp stage.
(mandatory)

The DPF lamp notifies the operator

that the particulate filter is becoming filled and
HEST lamp, regeneration disabled lamp are
needs assistance from operator to regenerate
not connected with the fault code.
within the next several hours of engine operation.
Assistance can be provided by the following
methods. Automatic triggered detection mode
indicator
1. Increase engine load/speed and allow engine
to run until regeneration is completed. The green indicator illuminates when
2. Initiate a manual regeneration. the automatic triggered detection mode is
working.
The DPF indicator has two states: SINK and
OFF. The DPF indicator illuminates at SINK state Secondary steering indicator
and goes out at OFF state. The indicator flashes
according to flash modes. When the secondary steering button is
Operation: at ON position or the diesel engine
stops accidentally, the secondary steering motor
1. At first, if the lamp illuminates frequently, it starts and the yellow secondary steering
indicates the particulate filter need to indicator lights.
regenerate. Depending on the equipment
duty cycle, the operator may allow the Clutch cut-off indicator
equipment to complete a typical shift of
operation before providing assistance for The machine is at clutch cut-off state
regeneration. when the yellow indicator lights. The
2. If the situation becomes more and more machine is out of clutch cut-off state when the
emergent, the lamp will flash. At this time, if indicator goes out.
still no increase the engine load/speed, it
needs to initiate a manual regeneration.
3. If the situation becomes serious, the lamp will
flash continuously and the engine self-check The clutch cut-off function can be used only
indicator will illuminate. At this time, the when the machine is in gear F1, F2 or R1, R2.
operator must initiate a manual regeneration.
62
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

The machine may be setup to display fault codes

877H T4F using the stop indicator. If the machine is set up
to display fault codes on the stop indicator, the
stop indicator will flash to indicate the fault code.
For more information on using the stop indicator
to display fault codes, refer to the “Engine Fault
Codes” section.

37-41
If the stop indicator flashes a fault code
during operation, contact a dealer and
provide the fault code to the dealer.
37. Stop indicator
38. Warning indicator Warning indicator
39. Wait to start indicator
40. Water-In-Fuel indicator
41. Automatic pile detection mode indicator The yellow warning indicator provides
important maintenance information of
877H Stage V the machine. If the warning indicator flashes for
0.5 seconds and continues to flash for 30
seconds, the engine should be serviced. Refer to
the Cummins™ engine maintenance manual
provided with this machine.
The warning indicator is also used to indicate a
system fault and supplies secondary emergent
information. If the indicator flashes during work
37-42 or traveling, the engine system has a non-
serious fault. The machine can continue work or
travel but inspection must be performed later on.
The diagnostic code can be displayed through
37. Stop indicator the warning indicator. The display method is
38. Warning indicator similar to the diagnostic code flash of the stop
39. Handle steering function operation indicator
indicator.
40. Wait to start indicator
41. Automatic pile detection mode indicator
42. FNR state indicator (not available) Handle steering function operation
indicator
Stop indicator
The handle steering function operation
The stop indicator illuminates red indicator illuminates green when the handle
indicating that the machine must be steering function is activated. At the same time,
stopped and the engine must be turned off due to the handle steering function operation indicator
a fault. flashes when the travel speed exceeds 13 km/h
(8.1 mph).
The engine will be damaged to different degrees
according to the severity of the fault if the
machine has not been stopped and turned off in
time.
63
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Wait to start indicator The operator does not need to move the bucket
controls during automatic loading. Lower the
When the operating temperature inside bucket to the ground. Drive the machine into the
the machine tested by the system is pile. Do not move any of the controls. The auto-
below -18°C, the machine automatically starts dig system will automatically load the bucket.
the cold starting aid device to help the engine to
preheat quickly, then the wait to start indicator
will be on. When the indicator goes out, the
temperature has reached the preset requirement
Even in the Automatic Pile Detection Mode,
and the engine can be started.
pressing the auto-dig trigger switch button
activates the auto-dig system.
Water-In-Fuel indicator

When the water in the fuel tank covers

the WIF sensor at the bottom of the
fuel filter, WIF indicator will light automatically.
Drain the water in the fuel tank if WIF indicator
lights. WIF indicator will go out when the water is
completely drained or the fuel covers the WIF
sensor completely.

The above indicators are the special

indicators of the diesel engine. Turn the
start switch to I position and keep the
diagnostic ON/OFF switch disconnected,
then all of the indicators will go out within
about 2 seconds in sequence. This indicates
that the engine is in normal work condition.
Do not start the engine when any indicator
lights.

Automatic pile detection mode

indicator

The auto-dig system will be set to the

automatic pile detection mode upon initial
activation. This means that the loading cycle will
automatically begin when the bucket contacts the
pile. The automatic pile detection mode indicator
will light.
64
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Front Left Switch Panel Hazard flasher switch

After turning on the hazard flasher

switch, all the turn signal lights (four
lights) will flash simultaneously. They function as
warning lights when the machine stops in case of
danger and emergency.
1

3 The left and right turn lights switch will not

work after turning on the hazard flasher
switch. Therefore, turn off the hazard flasher
1. Position light and front floodlight switch
switch before starting the machine.
2. Hazard flasher switch
3. Front work light switch Front work light switch
Position light and front floodlight
The front work light switch controls on or
switch
off of the font work lights on the top of
the cab simultaneously. The work lights won’t
This switch controls the on and off of the
work if the engine isn’t started or the generator
position lights, front floodlights and
has fault.
license plate light (if equipped).
When press the upper of the switch, the four Front Right Switch Panel
position lights, front floodlights and license plate
light (if equipped) of the machine will be turned
on. At the same time, the backlight lamp and the
relevant switch indicator will be turned on.
Press the switch to the middle position, the four
2 1
position lights and license plate light (if equipped)
of the machine will be turned on and the front
floodlights will be turned off. At the same time,
the backlight lamp and the relevant switch
indicator will be turned on. 3
Press the switch to the inferior position, the four
position lights, the front floodlights and license
plate light (if equipped) of the machine will be 1. Rear work light switch
turned off. 2. Diagnostic ON/OFF switch
3. Lighter

Rear work light switch

The rear work light switch controls on or

off of the rear work lights on the top of
the cab and the two work lights on the engine
hood (if equipped) simultaneously.
65
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Diagnostic ON/OFF switch Lighter

DIAG
When this switch is at the OFF position, Push down the lighter, the lighter will
the idle/diag (diagnostic) inc /dec switch be turned on and begins to heat. The
will function as the idle speed setting switch. lighter will spring out when it is hot enough. Pull
out the lighter for smoking. Return the lighter to
ON socket after use.

The lighter will automatically spring out in 10-

18 seconds. If the lighter does not spring out
OFF in this time, the lighter will heat continuously
and the lighter wiring terminal or jacket may
If a fault code is found from the engine and this be burnt; Immediately drawout the lighter if it
switch is switched on, the fault code will be does not automatically spring out exceed 25
displayed through the stop indicator on the seconds.
central instrument panel and the code
conversion will be finished by the idle/diag The socket of the lighter can be used as a power
(diagnostic) inc /dec switch. supply interface of 24 volts DC, the maximum
power supply current is 10 Amp.

Right Front Upright Column Switch

Panel
If a lock buckle is provided on the diagnostic
ON/OFF switch; press the buckle downwards 877H T4F
before locking or unlocking the switch.
Otherwise the switch will be damaged.
This switch should be normally kept at the
OFF position.
4 1
Refer to section “Engine Fault Diagnosis” for
detailed instructions of the engine fault code
display. 2

1. DPF lamp/regeneration disabled (Inhibit) Lamp switch

2. Fan motor reverse switch (manual)
3. Idle/ diag (diagnostic) inc /dec switch
4. Rearview mirror defroster switch (optional)
66
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

DPF lamp/regeneration disabled

877H T4F (Inhibit) Lamp switch

The regeneration disabled (Inhibit)

switch disallows any automatic or
manual (non-mission) regeneration of
5 7 the diesel particulate filter. This may be used by
operator to prevent regeneration when the
machine is operating in a hazardous
6
environment and the OEM is concerned about
8
high temperature.
The regeneration disabled (Inhibit) switch has
9 two positions: Open (not grounded) and Closed
(grounded). An open switch allows automatic
and manual (non-mission) regeneration of the
Cummins Particulate Filter. A closed switch
5. Screen switching switch inhibits automatic and manual (non-mission)
6. Rear windshield wiper switch regeneration of the Cummins Particulate Filter.
7. Defroster switch
8. Rear washer switch Automatic and manual (non-mission)
9. Intelligent clutch cut-off switch (ICCO switch) regeneration remains inhibited until switch is
opened.
877H Stage V
Fan motor reverse switch (manual)

Fan motor reverse switch must be

used when the engine runs at idle
12 1 speed. Press this switch to make the fan reverse
to clear the dirt on the surface of the radiator.
This switch is a momentary switch, a locking
4 device is provided on the switch. Push the red
2
locking buckle forward before switching on the
switch. The switch and locking buckle can reset
automatically after being released to avoid
10 misoperation.
13
Idle/diag (diagnostic) inc/dec switch

3 11 When the diagnostic ON/OFF switch is

at the OFF position, pressing the idle/
1. DPF lamp/regeneration disabled (Inhibit) Lamp switch diag (diagnostic) inc/dec switch (instant reset
2. Fan motor reverse switch (manual) switch) up and down can adjust the engine idle
3. Idle/ diag (diagnostic) inc /dec switch
4. Rearview mirror defroster switch speed within a range from 600 rpm to 1200 rpm.
10. Handle steering system cut-off switch (optional) When the diagnosis ON/OFF switch is in the ON
11. Transmission interlock function control switch
12. Hydraulic lock switch position and there are two or more faults on the
13. Ride control mode select switch engine, pressing the switch up and down can
convert the engine fault code and display it
through the stop indicator on the central
instrument panel.
67
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Rearview mirror defroster switch Intelligent clutch cut-off switch

(ICCO switch)
This switch controls ON or OFF of the
electrothermal defrost device of the ICCO switch is a snap switch. The
rearview mirrors. Press the switch, the defrost ICCO function of this switch is enabled at the
device starts heating the rearview mirrors and default state. The operator doesn’t need to press
remove the frost on the mirror surface. the switch when operating the machine. The
electrical control module of the transmission will
Screen switching switch automatically compute and intelligently judge
whether to cut off the power output of the
This switch is located on the right front transmission according to the current gear, load
upright column in the cab, it is used for torque and the angle of service brake pedal, etc.
the switching of drive speed, system voltage,
engine fault codes and other items displayed on
the LCD screen on the central instrument panel.
When the machine is at manual shift mode,
Rear windshield wiper switch
the clutch cut-off function can be used in F1,
F2 or R1, R2. When the machine is at high
There are three positions of the rear
speed, to ensure safety operation, even if the
windshield wiper: OFF, LOW and HIGH.
ICCO switch is at default state, the shift
The wiper can reset automatically at OFF
control electronic box will not cut off power
position.
output of the transmission when braking.
Defroster switch

The defroster switch controls ON or

OFF of the defrost device. During normal operation or driving of the
machine, the operator should keep the ICCO
Rear washer switch switch at default state. Otherwise the
performance of the brakes, service life of the
The washer will work and spray water brake system and the transmission will be
from the reservoir to the windshield by affected.
pressing the switch, and the washer will stop
spraying when the switch resets automatically Steering handle cut-off switch
after being released. For more information, refer
to section “Window Washer Reservoir--Fill”.
ON

OFF

A lock buckle is provided on the switch; unlock

this buckle by turning it downward before
pressing the switch, otherwise the switch will be
damaged.
68
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

When the switch is on, the driver can perform A lock buckle is provided on the switch; unlock
related operations of the handle steering system, this buckle by turning it downward before
including steering, FNR, KD, horn and other pressing the switch, otherwise the switch will be
functions. damaged.
When the switch is off, the handle steering When the switch is turned to UNLOCK position,
system is in the locked state and no operation the work implement works when the driver
can be performed. This can prevent accidents operates the work implement control levers.
caused by accidentally touching the steering When the switch is turned to LOCK position, the
handle. work implement is unable to work when the
driver operates the work implement control
Transmission interlock function control levers. Thus, it is able to prevent accident
switch causing by misoperation of the work implement
control lever.

Disengaged
UNLOCK

Engaged
LOCK

The transmission interlock function control switch Ride control mode select switch
is used to control whether the transmission
interlock function is enabled.
Manual
When the switch is in the engaged position, the
transmission controller will comprehensively
determine whether to engage the lock-up clutch
Neutral
according to the working condition, gear and
other parameters. When the lock-up clutch is
engaged, the pump impeller of the torque
Automatic
converter is rigidly connected with the turbine,
and the torque converter has the highest
efficiency. When the switch is in the disengaged
In the automatic mode, the ride control function
position, the lock-up clutch will never be
is enabled when the machine speed is greater
engaged.
than 11km/h or in reverse gear. In the manual
mode, the ride control function is always
Hydraulic lock switch
enabled. In the Neutral position, the ride control
function is not enabled.
The machine with electronic control
valve in hydraulic system uses
hydraulic lock switch to control the work
hydraulic system. When the switch is at LOCK
position, the work implement is unable to work.
69
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Right Instrument Panel Quick coupler switch

When the quick coupler switch is at

5 4
UNLOCK position, the quick coupler
3 cylinder will be at unlocked state, then the work
1
attachment can be installed or removed.

UNLOCK

LOCK

1. Engine datalink connector

2. Auto-dig trigger switch button When the quick coupler switch is at LOCK
3. Quick coupler switch position, the quick coupler cylinder will be at
4. Rear wiper intermittent switch locked state. It is unable to install or remove the
5. Parking brake switch (suitable for 877H stage V) work attachment at this time.
Engine datalink connector

This is the datalink connector only used by

CUMMINS engines. Use of the special software A lock buckle is provided on the quick
of CUMMINS can test the parameters and fault coupler switch; unlock this buckle by turning
codes of the engine. it downward before pressing the switch,
otherwise the switch will be damaged.
Auto-dig trigger switch button
Make sure that the quick coupler switch is at
LOCK position before operating the machine.
The operator may desire to start the auto-dig
system manually.
Rear wiper intermittent switch
1. Rotate dig mode switch in order to select the
desired model. Press this switch to turn on the rear
2. Toggle operating mode switch in order to wiper intermittent function.
place the system in the operator triggered
mode. The automatic triggered detection
mode indicator will light.
3. With the auto-dig system in the operator
triggered mode, drive into the pile. Press the
trigger switch in order to activate the loading
cycle.
70
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Parking brake switch Top Instrument Panel

877H T4F
Disengaged 1 2 3 4 5

Engaged
877H Stage V
1 2 3 6 7 4 5
Press the front end of the parking brake switch to
disengage the parking brake; press the rear end
of the switch to engage the parking brake. The
default position is the engaged position.

1. Dig mode switch

2. Auto-dig operating mode switch
A lock buckle is provided on the switch; 3. Work device kickout set switch
unlock this buckle by turning it downward 4. Transmission shift mode selection switch
before pressing the switch, otherwise the 5. Shift mode switch
6. Fan motor reverse mode select switch (automatic)
switch will be damaged. 7. Engine override switch

Dig mode switch

1 2 3

1. Manual dig mode

2. Auto-dig mode
3. Auto-dig record & playback mode
1. Manual dig mode
The machine is in manual dig mode when the dig
mode switch is in this position, the auto-dig
function is turned off.
71
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

2. Auto-dig mode a. Place dig mode switch into the record or

playback mode position.
Auto-dig mode switch allows the operator to
select different settings for different types of b. Toggle the operating mode switch. The
material for loading. Rotate the switch automatic pile detection mode indicator
counterclockwise in order to load light material. and automatic triggered detection mode
Rotate the switch clockwise in order to load indicator will illuminate. This indicates that
heavy material. the system is in the record mode.
3. Auto-dig record & playback mode c. Running in Automatic Pile Detection Mode
or Operator Triggered Mode.
Only when the dig mode switch is turned to this
position, the record or playback of a load cycle
can be realized.
(1) Record Steps The auto-dig system can only be activated in
a. Place dig mode switch into the record or gear 1 or 2.
playback mode position. At any time, the operator may take control by
b. Toggle the operating mode switch. The moving the work implement control levers.
record mode indicator will illuminate. This The playback position can no longer be set
indicates that the system is in the record back to the default parameters after the
mode. record mode has been utilized.
c. Position the machine in front of the pile
with the bucket in the dig position. Auto-dig operating mode switch
d. In order to begin recording, press the auto-
dig trigger switch button. A loading cycle
must be performed within 20 seconds of
pressing the trigger switch. 1
e. Enter the pile and load the bucket
manually. While the bucket is being
loaded, the record mode indicator will 2
flash. The record mode will capture the
loading process. This loading process will
be used during the playback mode.
1. Auto-dig operating mode switch
f. After loading the bucket, press the auto-dig 2. Boom height setting switch
trigger switch button to complete recording
1. Auto-dig operating mode switch
of the loading cycle. Loading the bucket
plus pressing the switch must be done The operating mode selection can be carried out
within 20 seconds. If the trigger switch is only when the dig mode knob is in auto-dig mode
not pressed in this time, the loading cycle or record & playback mode.
will go back to the previously recorded
Press the top of the switch for ~0.3s and release
cycle or the default.
it, the machine enters the relative mode after a
g. If the commands were recorded beep, the related operation mode indicator
successfully, the auto-dig system will illuminates at the same time.
automatically return to the automatic pile
2. Boom height setting switch
detection mode. Two beep indicates an
unsuccessful recording. The stop position of boom after finishing auto-dig
(2) Playback Steps operation.
72
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Press the bottom of the switch and hold ~0.3s, if To set the lower height, first lower the boom to a
the boom kickout height has been set height below 35% of the kickout height, press the
successfully, one beep will be heard; if the top of the switch for ~0.3s and release it, one
kickout height setting is unsuccessful, two beeps beep will be heard if the kickout height has been
will be heard. set successfully.

There is requirement for the lowest position After the setting is successful, the system
of the boom height, if the boom height is set will store the boom height until it is set again
below the requirement, the system default next time.
lowest position will be the kickout height, two
Only when the auto-lift/ lower function is
beeps will be heard at the same time.
activated, the boom can automatically lift or
lower to the set height.
Work device kickout set switch
(1) Boom auto-lift
Pull the boom control lever backwards to its
limit position, and then release it quickly to
1 Neutral position after a moment's pause, at
this time, the boom will automatically lift to
the set height with the fastest speed and
2 stop.
(2) Boom auto-lower
Push the boom control lever forwards to its
1. Boom kickout height setting switch limit position, and then release it quickly to
2. Bucket angle setting switch Neutral position after a moment's pause, at
this time, the boom will automatically lower to
1. Boom kickout height setting switch the set height with the fastest speed and
stop.
Boom kickout height setting includes the settings
of rising direction and descent direction.
Press the top of the switch for ~0.3s and release
it, if the kickout height has been set successfully, Do not let hand leave the boom control lever
one beep will be heard. to prevent it from bouncing back and causing
unsafe factors when the control lever returns
To set the kickout height, first lift the boom to a
to Neutral position.
height above 35% of the kickout height, press
the top of the switch for ~0.3s and release it, one The boom auto-lift/ lower function won’t be
beep will be heard if the kickout height has been activated if the boom control lever is kept too
set successfully. long or too short in its limit position, and the
boom will stop after the control lever
returned to Neutral position. If the boom
control lever is pushed or pulled away from
the Neutral position by >6° in the boom lifting
or lowering process, the boom will stop after
the control lever returned to Neutral position.
73
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

● Calibration and emergency exit of bucket f) Long press the boom kickout height
positioning and bucket tilt-back setting switch for more than 5s, one beep
will be heard when it is released. Pull the
(1) Calibration of bucket positioning and bucket
boom control lever to finish the boom
tilt-back
auto-lift operation in 2s (pull the boom
a) Power on and start the machine. control lever to the limit position, and
release it quickly to Neutral position in 1s
b) Lower the bucket flatly on the ground.
after a moment's pause), the machine
c) Turn the shift control lever to Neutral enters into auto-calibration, no further
position 4. operations are required.
g) Slowly lift the boom to the highest
position → Slowly lower the boom to the
start position.
h) Always keep the bucket tilting back to the
end → Slowly lift the boom to the highest
position → Dump the bucket to the flat
position → Slowly lower the boom to the
start position → Calibration is completed.
i) If the calibration has been set
successfully, one beep will be heard; if
the calibration failed, two beeps will be
d) Turn the shift mode switch to MANUAL heard.
position.
(2) Emergency exit of bucket positioning and
bucket tilt-back

The calibration will exit immediately if any of

the following conditions are not met:
1. The boom control lever should be pushed
forward or backward by more than 6°.
2. The bucket control lever should be pushed
forward or backward by more than 6°.
e) Do not depress the accelerator pedal 3. The engine speed changed greatly.
during calibration, the engine speed will 4. The shift control lever isn’t in Neutral
be around 1000rpm automatically after postion 4.
the calibration is activated, and reduce to
idle speed automatically after the 5. The work implement lock switch is turned
calibration. on.
74
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

the set position with the fastest speed at this

time and stop.

Before the calibration, the bucket and boom

displacement will affect the operation
accuracy of the intelligent shovel. Make sure Do not let hand leave the bucket control lever
the bucket is level on the ground before to prevent it from bouncing back and causing
calibration. unsafe factors when the control lever returns
to Neutral position.
2. Bucket angle setting switch The bucket auto-leveling function won’t be
activated if the bucket control lever is kept
(1) Bucket angle position setting too long or too short in its limit position, and
Press the bottom of the switch for ~0.3s and the bucket will stop after the control lever
release it, if the bucket angle has been set returned to Neutral position. If the bucket
successfully, one beep will be heard. control lever is pushed or pulled away from
the Neutral position by >6° in the bucket auto-
leveling or auto-rotating process, the bucket
will stop after the control lever returned to
After the setting is successful, the system Neutral position.
will store the angular position of the bucket
● Bucket dumping position calibration and
in this boom state until it is set again next
emergency exit
time.
(1) Bucket dumping position calibration
Only when the bucket auto-leveling function
is activated, the bucket can automatically a) Power on and start the machine.
rotate to the set angle. b) The bucket is at the maximum dumping
(2) Bucket auto-leveling function position, and the boom is lowered to the
lowest position that can be reached.
After finishing dumping (the bucket is below
the leveling position), pull the bucket control c) Turn the shift control lever to Neutral
lever backwards to its limit position, and then position 4.
release it quickly to Neutral position after a
moment's pause, the bucket will tilt back
automatically to the set position with the
fastest speed at this time and stop.
When the bucket is above the leveling
position, push the bucket control lever
forward to its limit position, and then release
it quickly to Neutral position after a moment's
pause, the bucket will level automatically to
75
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

d) Turn the shift mode switch to MANUAL (2) Bucket dumping position emergency exit
position.

The calibration will exit immediately if any of

the following conditions are not met:
1. The boom control lever should be pulled
backward by more than 6°.
2. The bucket control lever should be pulled
backward by more than 6°.
3. The engine speed changed greatly.
4. The shift control lever isn’t in Neutral
e) Do not depress the accelerator pedal postion 4.
during calibration, the engine speed will 5. The work implement lock switch is turned
be around 1000rpm automatically after on.
the calibration is activated, and reduce to
idle speed automatically after the
calibration. Transmission shift mode selection switch
f) Adjust the height of the boom so that the
It is a selection switch for the transmission shift
lowest position of the bucket is slightly
point. Shifts under a certain specific
higher than the ground when the bucket
instantaneous velocity range, the instantaneous
is in the maximum dumping state. Then
velocity is the shift point. Two shift modes are
tilt the bucket back to the flat state.
available: shift mode “L” and shift mode “M”.
g) Long press the bucket angle setting
switch for more than 5s, one beep will be
heard when it is released, and the engine
speed will automatically increase to L
around 1000rpm. The bucket dumping
position calibration will be entered soon.
No further operations are required.
M
h) Always keep the bucket at maximum
dumping state → Slowly lift the boom to
the highest position → Calibration is
completed. Shift mode “L”: the transmission shifts in
advance at low engine rotating speed to get
i) If the calibration has been set faster vehicle speed. This mode is suitable for
successfully, one beep will be heard; if light load working condition.
the calibration failed, two beeps will be
heard. Shift mode “M”: the transmission shifts at
intermediate engine rotating speed to get bigger
power. This mode is suitable for general working
condition and heavy duty working condition.
76
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Shift mode switch Fan motor reverse mode select switch

(automatic)
There are three positions on this switch:
MANUAL, AUTO 1-4 and AUTO 2-4.
Mode 2
1 2 3

Mode 1

OFF

Press this switch can make the fan reverse

automaticly to clear the dirt on the surface of the
radiator.
Fan motor reverse mode 1: the cooling fan
reverses once every 15 minutes for 30s each
time;
1. MANUAL
2. AUTO 1-4 Fan motor reverse mode 2: the cooling fan
3. AUTO 2-4 reverses once every 30 minutes for 30s each
When MANUAL is selected, the travel speed can time.
only be shifted manually through the shift control
lever. Engine override switch
When selecting position AUTO 1-4, the machine
can automatically shift gradually among gears 1,
ON
2, 3 and 4; when selecting position AUTO 2-4,
the machine can automatically shift gradually
among gears 2, 3 and 4, there isn’t gear 1.
The operator can choose switch position
according to the working condition during
operation. Generally, position 1-4 should be OFF
selected in heavy load working condition,
position 2-4 should be selected in light load
working condition. Gear will be automatically When the engine emission no longer meets the
increased or reduced gradually according to the requirements of the regulations due to a failure,
machine speed and load condition. and the user fails to remove the fault in time, the
engine will upgrade the fault level gradually;
when the most serious level of locked idle is
reached, the engine will no longer respond even
stepping on the accelerator pedal. At this time,
Do not change the switch mode when the
the engine override switch allows the user to
machine is travelling.
operate three times at most. After each
operation, the engine will return to normal
operation for 30 minutes to give the operator the
last chance to drive the machine to a proper
position or a service station for repair.
77
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

A/C Panel Pressing “ ∧ ” switch increases setting air

volume, pressing “ ∨ ” switch reduces setting air
1 2 3 volume. The air volume changes over
4 automatically at AUTO mode.
LCD display and air volume

Symbol Fan speed

Low

9 8 7 6 5

Medium 1
1. OFF switch
2. Temperature setting switch
3. Fan speed setting switch
4. Recirculating & fresh air switch
5. Defrost mode switch Medium 2
6. Air outlet mode setting switch
7. LCD screen
8. AUTO mode switch
9. A/C switch Medium 3

OFF switch

It's used to start or stop the fan and air Medium 4

conditioner. Press OFF switch, setting
temperature and air speed symbol will disappear
from LCD screen. The air conditioning system
High
will stop running.

Recirculating & fresh air

switch
It is unable to turn on the air conditioner
before starting the engine. This switch is used to change mode over
between recirculating air and fresh air. Fresh air
Temperature setting switch mode and recirculating air mode will switch
automatically under AUTO mode.
To set temperature in the cab.
Fresh air mode
Pressing “ ∧ ” switch increases
temperature, pressing “ ∨ ” switch drops When the indicator lights, the fresh air
temperature. mode works, the fresh air outlet will
The temperature is set between 18° to 32°, open to let fresh air come into the cab.
commonly the service temperature is 25°. This function is suitable for air exchange and
defrosting.
Fan speed setting switch
Recirculating air mode
To set air volume to the cab from the air
conditioner. When the indicator lights, the
recirculating mode works, the fresh air
78
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

outlet is closed, and air recirculates inside the LCD screen

cab.
LCD screen shows the internal and
This function is suitable for quick cooling, heating
external temperature of the cab, the
or when the outside air is dirty.
setting temperature, fan speed and air outlet
mode etc., and the fault alert and fault code also
Defrost mode switch
can be shown on the LCD screen.
Defrost mode can be activated by two After pressing OFF switch, the setting
ways: temperature, fan speed and air outlet mode
status disappear on the LCD screen, the air
1. Press this switch, the air conditioner will start
conditioner stops running.
up, and then enter the defrost mode.
2. When the air conditioner is working, press AUTO mode switch
this switch to enter the defrost mode.
Press this switch to change manual
Air outlet mode setting switch mode to AUTO mode.
Under normal working condition, press this
To set air outlet mode. Under normal
switch, the indicator of the switch will light and
working condition, press the setting switch
AUTO mode will be selected.
(MODE) of air outlet mode to change over the air
outlet mode. LCD screen will display the change- To change AUTO mode to manual mode, only
over. The air outlet mode is automatically need to reset the fan speed, air outlet mode,
changed over at AUTO mode. recirculating air and fresh air mode, then the
indicator of the switch will go out.
Item Symbol Air outlet mode

Front and rear air outlet and

1
air outlet under the seat
Under AUTO mode, when the air outlet is at
mode 1 or 4, the system will limit the air
2 Front and rear air outlet volume automatically to prevent cool air
blowing out if the engine water temperature
is very low.

3 **Front air outlet A/C switch

This switch is used to control the ON

and OFF of the A/C system cool mode,
4 Air outlet under the seat defrost mode and warm mode.
Press this switch, the air conditioner starts to
work, the LCD screen displays as follows:
** Air outlet under the seat
5
and defroster air outlet

6 **Defroster air outlet

Note: ** indicates this item does work at AUTO mode.

79
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Press this switch again, the air conditioner stops 3. Press OFF switch, the LCD screen doesn’t
working, the LCD screen displays as follows: display the setting temperature and air
volume, the air conditioner stops working.

Under AUTO mode, when the air outlet is at

mode 1 or 2, the system will limit the air
volume automatically to prevent cool air
blowing out if the engine water temperature
is very low.

When the fan isn’t working (no fan speed Operation of Manual Mode
symbol on the LCD screen), the air
conditioner is unable to work. 1. Press A/C switch. The ON or OFF of the A/C
switch can be judged through the LCD
Operation of Auto Mode screen.
2. Press the fan speed setting switch to adjust
1 2 3 4 the air volume. The setting temperature and
air volume can be confirmed through the LCD
screen.
3. Adjust the temperature setting switch to set
proper temperature.
4. Adjust the air outlet mode setting switch to
set the required air outlet.
9 8 7 6 5
5. Press the recirculating & fresh air switch to
1. OFF switch
choose the required air circulation mode.
2. Temperature setting switch 6. Press OFF switch, the LCD screen doesn’t
3. Fan speed setting switch
4. Recirculating & fresh air switch display the setting temperature and air
5. Defrost mode switch volume, the air conditioner stops working.
6. Air outlet mode setting switch
7. LCD screen Operation of head Cooling and foot heating
8. AUTO mode switch
9. A/C switch mode
1. Press AUTO mode switch, the LCD screen Cool air will blow to the operator’s head and
displays the setting temperature and air
warm air will blow to the operator’s feet under
volume.
this mode.
2. Adjust the temperature setting switch to 1. Press the fan speed setting switch to adjust
comfortable temperature. The air conditioner
the air volume. The setting temperature and
will change the air volume, ait outlet mode,
air volume can be confirmed through the LCD
recirculating air and fresh air mode screen.
automatically according to the setting
temperature.
80
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

2. Adjust the air outlet mode setting switch to 4. Adjust the temperature setting switch to set
choose the air outlet mode, the LCD screen proper temperature.
displays the symbol of Mode 1.
Adjust the direction of each air outlet louvre to let
Mode 1 the air blow to the glass. In mould rain season, if
there is water accumulated on the glass or
defrost is needed, turn on the A/C switch to
defrost.

Switch between Celsius degree and

Fahrenheit degree
3. Press A/C switch. The ON or OFF of the A/C
switch can be judged through the LCD
The set temperature can be showed in celsius
screen.
degree or fahrenheit degree.
Adjust the fan speed setting switch, temperature
When the air conditioner system is working,
setting switch, recirculating & fresh air switch to
pressing the temperature setting switch “ ∧ ” & “
proper position.
∨ ” at the same time for more than 5 seconds
can realize the switch between cersius degree
Operation of Defrost Mode
and fahrenheit degree.
1. Press the fan speed setting switch to adjust The temperature unit can not be showed on the
the air volume. The setting temperature and LCD screen, refer to the following table for the
air volume can be confirmed through the LCD value range.
screen.
Item Display value
2. Defrost mode can be activated by the
following two ways: Celsius degree (°C) 18~32
Fahrenheit degree (°F) 63~91
a) Adjust the air outlet mode setting switch
to air outlet mode 5, the LCD screen
displays the symbol of Mode 5. Warm water valve
Mode 5
The heating function of the air conditioning
system can be realized by the coolant flows
through the evaporator of the air conditioning
system to release heat.

b) Directly press the defrost mode switch to

enter the defrost mode, the LCD screen
displays the symbol of Mode 6.
Mode 6

3. Press the recirculating & fresh air switch to

choose the fresh air mode.
81
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

A manual warm water valve is provided Self-diagnosis function

respectively for the water inlet and water outlet of
the engine.(Note: some machine only has one The air conditioner controller can diagnose fault
for the water inlet of the engine). for every sensor and unit that is used in air
conditioning system.
3
2 1. Press OFF switch, the setting temperature,
air volume and air outlet mode disappears,
the air conditioner stops running.
2. Simultaneously press the control button “ ∧ ”
& “ ∨ ”on the temperature setting switch for 3
1 seconds, fault codes will show on the LCD
screen.
Fault code information
1. Warm water valve
2. Warm water valve ON Fault code Description
3. Warm water valve CLOSE
E-- No trouble
During heating operation, the manual warm
E11 Broken wire of the internal air sensor
water valve should be at ON position (the warm
water valve direction is the same with the hoses). E12 Short circuit of internal air sensor
Broken wire of water temperature
E15
sensor
Short circuit of water temperature
E16
sensor
If it is necessary to repair the air conditioning
E18 Short circuit of sunlight sensor
system due to fault, first close the manual
warm water valve (the warm water valve E43 Abnormal air outlet
direction is vertical to hoses) to prevent E44 Air mixture, air door is abnormal
coolant loss.
3. As for the newly-installed air conditioner or
When replacing the engine coolant, open the one that has been eliminated trouble, set the
warm water valve and set the selector switch data again and press the fresh air and
to warm air position to replace the coolant recirculate air switch simultaneously for 3
inside the evaporator together. Make sure the seconds to cancel fault code.
engine coolant level is correct.

The water radiator should be emptied or filled Abnormal use will result in damage and
with antifreeze and the selector switch invalidation of air conditioner system.
should be set to warm air position when the
ambient temperature is below 0°C and the Air conditioner can not be repaired by users
engine stops running, otherwise the radiator themselves. If you need to repair it, connect
lines will be damaged by being frozen. your LiuGong dealer directly.
Although the internal circuit of air
Memo function conditioner system is damp-proof, do not
clean it by water or liquid detergent, or the
When restarting the machine, the system would system will not work.
recover the setting that is used last time
automatically.
82
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Resetting

Resetting is used for newly-installed air

conditioner or used to clear the fault code on the
LCD screen after trouble shooting.
Simultaneously press the control button “ ∨ ” on
the recirculating & fresh air switch and the fan
speed setting switch for 3 seconds, the fault
code will be cancelled.
83
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Control Devices

For machine with electro-hydraulic control levers (877H T4F)

1
3
9

5 4
8

7 10

1. Steering wheel 6. Service brake pedal

2. Steering column 7. Accelerator pedal
3. Horn switch 8. Parking brake button
4. Combination switch 9. Work implement control levers
5. Shift control lever 10. Steering handle (optional)
84
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

For machine with electro-hydraulic control lever and triple valve (877H T4F)

1
3 9

4
5
8

7 10

1. Steering wheel 6. Service brake pedal

2. Steering column 7. Accelerator pedal
3. Horn switch 8. Parking brake button
4. Combination switch 9. Work implement control lever
5. Shift control lever 10. Steering handle (optional)
85
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

For machine with pilot-hydraulic control lever and two-way valve (877H T4F)

1
3 9

4
5 8

7
10

1. Steering wheel 6. Service brake pedal

2. Steering column 7. Accelerator pedal
3. Horn switch 8. Parking brake button
4. Combination switch 9. Work implement control lever
5. Shift control lever 10. Steering handle (optional)
86
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

For machine with electro-hydraulic control levers (877H Stage V)

1
3
9
5 4
8

7
10

1. Steering wheel 6. Service brake pedal

2. Steering column 7. Accelerator pedal
3. Horn switch 8. Parking brake switch
4. Combination switch 9. Work implement control levers
5. Shift control lever 10. Steering handle (optional)
87
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

For machine with electro-hydraulic control lever and triple valve (877H Stage V)

1
3 9

4
5 8

7 10

1. Steering wheel 6. Service brake pedal

2. Steering column 7. Accelerator pedal
3. Horn switch 8. Parking brake button
4. Combination switch 9. Work implement control lever
5. Shift control lever 10. Steering handle (optional)
88
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Steering Wheel Horn Switches

There are two horn switches, one is located at

the end of the steering combination handle, the
other one is located beside or on the work
implement control lever. The functions of these
two switches are the same, the horn will sound
by pressing any one of the switches. The
operators can use the switches according to their
own operation habits.
Steering combination handle

Articulate full-hydraulic power steering is

provided on this machine, the steering wheel is
in the cab and it is connected to the full-hydraulic
metering pump through steering column. In
normal operation, turn the steering wheel
clockwise, the machine will turn right; turn the
steering wheel counterclockwise, the machine
will turn left.
The characteristics of the full-hydraulic power
steering are as follows:
Horn switch
1. The steering angle of the steering wheel is
not the same with the turning angle of the
machine, turn the steering wheel
continuously to increase the turning angle of
the machine until the desired position is
obtained.
2. The faster the steering wheel turns, the faster
the machine turns.
3. The steering wheel can not reset
automatically after being released, and the
machine steering angle will not change. Horn switch (pilot-hydraulic control lever)
Therefore, turn the steering wheel
counterclockwise to let the machine travel in
straight direction after finishing turning.
89
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

High beam/ low beam shift

Horn switch (electro-hydraulic control lever)

The high beam/ low beam can be achieved by

the up and down movement as per the arrow
direction.
Combination Switch
If the front floodlight is at low beam state, push
The combination switch located on the right of the combination switch up and down to change
the steering wheel is an integrated type switch. It the light to high beam and the blue front
has the following functions: steering indication, floodlight high beam indicator on the central
front floodlight high beam / low beam shift, horn instrument panel turns on. Push the combination
control, windshield wiper control, windshield switch up and down again, the front floodlight
washer control etc. high beam will change to low beam.

Steering indication Horn control

Push the combination switch forward when

turning left, the left turn indicator will flash, and
the front & rear left turn signal lights will also turn The horn will sound by pressing the horn button
on simultaneously. Pull it backward when turning at the end of combination switch.
right, the right turn indicator will flash, and the
front & rear right turn signal lights will also turn
on simultaneously. When the hazard flasher
switch is on, the turn signal lights will not work.
90
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Front windshiled wiper control Shift Control Lever

The shift control lever is automatic type. It is

located on the left side of the steering column,
which is used to choose travel direction and
travel speed.

Front windshield wiper switch is located on the

combination switch. There are four positions:
OFF (O), intermittent (J), low velocity (I), high
velocity (II). The position J is not available at When the shift control system has a fault,
present. Rotate the switch to I position, the never remove the transmission system
windshield wiper works at low velocity, rotate it to without authorization. Consult LiuGong
II position, it works at high velocity. dealer or Service Company if the fault can not
be eliminated.
Front washer control
Direction selection

1
R

F: Forward
R: Reverse
N: Neutral
The washer will work by pressing the washer
control switch inwards. The water from reservoir 1. Shift control lever
will be sprayed to windshield window glass. Forward: push the shift control lever to
FORWARD position, the machine will move
The washer will reset to natural position and stop
forward.
spraying after being released.
Neutral: push the shift control lever to NEUTRAL
Refer to section “Window Washer Reservoir--Fill”
position, the machine should not move. Only
for the location and maintenance of the washer
when the shift control lever is in NEUTRAL
reservoir.
position can the engine starts.
Reverse: push the shift control lever to
REVERSE position, the machine will move
backward.
91
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Speed selection Except for the direction and speed change

function, the shift control system also has other
Rotate the shift control lever. The number in the special functions.
arrow direction as illustrated in the picture is the
speed position. This machine has four forward Special functions of the shift control system:
speeds and three reverse speeds. When the shift
control lever is in the R4, actually it is in R3. 1. Neutral locking protection function
Neutral lock switch

1. ''1'' for first speed

2. ''2'' for second speed
3. ''3'' for third speed
4. ''4'' for fourth speed
Push the shift control lever to NEUTRAL, and
push the lock switch to position (N), the shift
1 control lever will be locked at NEUTRAL position.
Push the lock switch to position (D), the shift
control lever will be unlocked, and the machine
2 can be operated normally.
1. Gear Generally, when the machine is in maintenance
2. Gear indication or in parking condition, in order to prevent the
When the shift control lever is in the fourth gear, misoperation, push the lock switch to position (N)
the machine gear can switch freely by increasing to lock the shift control lever at NEUTRAL
or decreasing the throttle, the machine gear and position.
transmission fault code will display on the LCD
Use this switch to prevent misoperation.
screen on the central instrument panel.
The specific travel speed of the machine will
display on the speedometer on the central
instrument panel.
When the shift control lever is locked at
NEUTRAL position, it is forbidden to shift
forward or reverse without releasing the
neutral lock switch, otherwise the shift
control lever will be damaged.

2. Neutral/start interlock protection

functions

The electrical system of the machine has neutral/

start interlock protection function, start the
engine only after the shift control lever is at
NEUTRAL position so as to prevent unexpected
accidents due to sudden actions.
92
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

3. Direct forward/reverse change function KD key (pilot-hydraulic control lever)

The shift control lever of the machine has no

turning interlock function, the driver can directly
change directions according to the driving speed:
At F1 or F2 gear, directly engage the
corresponding reverse (F1 <=> R1 and F2 <=>
R2) any time.
At F3 and F4, the driver should operate the shift
control lever according to the driving speed as
the following rules:
When the machine exceeds the preset speed
(normally 2nd gear is set as the maximum driving KD key (electro-hydraulic control lever)
speed), the system first automatically reduces to
2nd position at the present driving direction and
engages the 2nd position after a while, and
finally changes speed to the preset position.

4. Forced down shift function (Kick down

key)

Two kick down keys (KD key) are available. One

is at the end of the shift control lever, the other
one is located beside the work implement control
lever or on the work implement control lever.
See above picture shows, the arrow direction is
KD keys
the operation direction of the KD key.
When the F2 or R2 is selected, press KD key on
the shift control lever, the transmission can
automatically shift to F1 or R1.
93
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

The KD key function and the direct forward/ 6. System self-protection function
reverse change function have supplied a
convenience for gear shifting when loading When abnormal information occurs (such as
materials. For example, when the machine disconnected wiring, ground short-circuit of the
moves close to the material stack at F2, push electronic control box and odd signal) or power
down the KD key, the gear can shift into F1 supply exceeds the specified limit or there is an
automatically; after loading, press down the key open circuit, the electronic control box changes
↓, the gear will shift to R2 automatically. The to NEUTRAL to lock all output signals so that
machine will leave the material stack at R2 misoperation can be greatly prevented to ensure
speed, so a high working efficiency can be the driving safety.
achieved.
7. Clutch cut off function

Depress the brake pedal after the intelligent

clutch cut-off switch (ICCO switch) is turned to
ON (see the following picture), then the shift
control valve will judge intelligently whether to cut
off the transmission power output.

CLUTCH CUT-OFF

The KD key function will stop automatically when CLUTCH CUT-ON

other position is selected, cancel the KD key
function through the following ways:
● Pressing KD key again.
● Reversing. When the ICCO switch is turned to OFF, the
power cut-off function will be cancelled, the
● Operate the shift control lever to change the
power output of the transmission will not be cut
driving speed.
off even the service brake pedal is depressed.
● The lever is at NEUTRAL position.

5. Start speed limit function

When the machine is at manual shift mode,
To ensure the driving safety, the position is
the clutch cut-off function can be used in
limited at F1, F2 or R1, R2 by the electronic
F1, F2 or R1, R2. When the machine is at
control box when the machine starts. Only after
high speed, to ensure safety operation, even
the speed exceeds the setting value can F3, F4
if the ICCO switch is turned to ON, the shift
be shifted. If the speed doesn’ t reach this value,
control electronic box will not cut off power
the machine only can move in F2 (the road
output of the transmission when braking.
condition determines the running speed) even
shift the gear to F3, F4. Therefore, after the
machine starts, it can move at high speed only
after the driving speed exceeds the setting value.
94
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Accelerator Pedal

During normal operation or driving of the

machine, the operator should turn the ICCO
switch to ON. Otherwise the performance of
the brakes, service life of the brake system
and the transmission will be affected.

Service Brake Pedal

The accelerator pedal is located at the front right

side of the driver's seat. Naturally, the engine is
at idle state. The diesel engine oil supply and the
engine speed will increase by depressing the
pedal while the oil supply and the engine speed
will reduce by releasing it.

Parking Brake Button (for 877H T4F)

The service brake pedal is located at the front left

side of the driver’s seat. Depress the service
brake pedal, the front and rear axle brakes will
engage and the brake lights will turn on
simultaneously. Repair the brake system in time
if it has fault to ensure the machine has enough
brake power.
If the clutch cut-off switch is turned on and the
transmission is at I and II position, depressing the
brake pedal, then the transmission will shift to
neutral automatically to cut off the power output.
If the transmission is at the III and IV position, the
transmission will not shift to neutral even if the
brake pedal has been depressed.
Do not use the parking brake when the
If the clutch cut-off switch is turned off, the machine is traveling unless the service brake
transmission will not shift to neutral even if the failed. Use the parking brake as the service
brake pedal has been depressed. brake in the regular operation will damage
Release the service brake pedal to disengage the brake system seriously.
the serviced brake.
The parking brake button is located on the right
side of the driver’s seat. Pull it up to engage the
parking brake, press it to disengage the parking
brake.
95
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

The parking brake is also used as emergency The parking brake button is located on the right
brake. If an emergency occurs when the side of the driver’s seat. Press the front end of
machine is working, pull up the parking brake the parking brake switch to disengage the
button to engage the emergency brake. If the parking brake; press the rear end of the switch to
machine is at the 1st or 2nd speed, the engage the parking brake. The default position is
transmission will automatically shift to NEUTRAL the engaged position.
simultaneously.
The parking brake is also used as emergency
When the service brake system has faults and brake. If an emergency occurs when the
the accumulator pressure in the service brake machine is working, press the rear end of the
circuit is below 6 MPa, the parking brake will cut switch to engage the emergency brake. If the
off power and the parking brake system will machine is at the 1st or 2nd speed, the
actuate brake automatically. The machine transmission will automatically shift to NEUTRAL
engages the emergency brake to ensure driving simultaneously.
safety.
When the service brake system has faults and
the accumulator pressure in the service brake
Parking Brake Switch (for 877H Stage V) circuit is below 6 MPa, the parking brake will cut
off power and the parking brake system will
actuate brake automatically. The machine
engages the emergency brake to ensure driving
safety.

Disengaged

Engaged

Do not use the parking brake when the

machine is traveling unless the service brake
failed. Use the parking brake as the service
brake in the regular operation will damage
the brake system seriously.
96
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Work Implement Control Lever

The work implement control levers are installed

on the right side of the seat. They are used to
control the boom and bucket. Boom control lever The machine can be started only when the
controls the boom lowering and raising; bucket shift control lever is at N position.
control lever controls the bucket tilting back and
Pay atttention to the following cautions when
dumping. The two control levers are naturally at
using the FNR switch to control the travel
the NEUTRAL position when the engine stops.
direction of the machine:
1 1. FNR function of the FNR switch can be
2 activated only when the shift control lever is
at N position.
3 2. After the FNR function is activated, operate
the FNR switch to select desired travel
4 direction of F, N, R. At this time, gear 2 is the
5 highest travel speed of the machine.

6 Notice: The output change of transmission gear

1 and gear 2 can be carried out promptly through
KD key. When the machine is travelling at F2 or
1. Auxiliary control lever (optional) R2, press the KD key on the shift control lever or
2. Boom control lever
3. Bucket control lever
the KD switch near the bucket control lever, the
4. KD switch travel speed will shift to F1 or R1. If press the KD
5. FNR switch key again, the travel speed will shift to F2 or R2.
6. Horn button When changing the travel direction by FNR key
There are horn button, KD switch and FNR or changing the travel speed by the shift control
switch near the bucket control lever. FNR switch lever, KD function will stop. The transmission will
is used to control the travel direction. F, N, R output at gear 2 (when changing the travel
respectively indicates FORWARD, NEUTRAL direction by FNR switch) or relative gear (when
and REVERSE. changing gear 2 to other gears by the shift
control lever).
When the shift control lever is at N position, the
FNR switch also can be used to control the 3. FNR function will stop when the shift control
FORWARD and REVERSE direction of the lever is not at N position. Then the travel
machine. speed and travel direction will be controlled
only by the shift control lever. Follow the
above procedures if you want to use the FNR
function again.

7. Shift control lever

97
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Boom control Lower

Auto-lifting Push the boom control lever forward,

the greater the angle between the
Pull the boom control lever backward to the limit control lever and the NEUTRAL position, the
position, if the time for releasing the control lever greater the boom lower speed. Release the
back to NEUTRAL position is longer than 100ms control lever back to the NEUTRAL position
and less than one second, the boom will raise without activating the boom float-lowering
automatically with the most rapid speed at this function, the boom will stop.
time and stop after detecting the boom lift kickout
signal. Bucket control
Pull the boom control lever backward to the limit
Dump
position, if hold the control lever over one second
and release it back to NEUTRAL position, there
Push the bucket control lever forward,
isn’t boom auto-lifting function. The boom will
the greater the angle between the
stop after the control lever returned to NEUTRAL
control lever and the NEUTRAL position, the
position.
greater the dump speed. Release the control
In the auto-lifting process, if push or pull the lever back to the NEUTRAL position, the bucket
boom control lever and make its deviation from will stop.
the NEUTRAL position greater than 6 °, and then
release the control lever back to NEUTRAL Tilt back
position, the boom will stop.
Pull the bucket control lever backward,
Float-lowering the greater the angle between the
control lever and the NEUTRAL position, the
Push the boom control lever forward to the limit greater the tilting speed. Release the control
position, if the time for releasing the control lever lever back to the NEUTRAL position without
back to NEUTRAL position is longer than 200ms, activating the bucket positioning function, the
the boom will lower automatically with the most bucket will stop.
rapid speed at this time.
Bucket auto-leveling
In the float-lowering process, if push or pull the
boom control lever and make its deviation from
After finishing dumping (the bucket is below the
the NEUTRAL position greater than 6 °, and then
leveling position), pull the bucket control lever
release the control lever backe to NEUTRAL
backward to the limit position, if the time for
position, the boom will stop.
releasing the control lever back to NEUTRAL
position is longer than 100ms and less than one
Raise
second, the bucket will tilt back automatically
with the most rapid speed at this time and stop
Pull the boom control lever backward,
after detecting the bucket leveling signal.
the greater the angle between the
control lever and the NEUTRAL position, the If the time for releasing the control lever back to
greater the boom raise speed. Release the NEUTRAL position is longer than one second,
control lever back to the NEUTRAL position there isn’t bucket auto-tilting function. The bucket
without activating the boom auto-lifting function, will stop after the control lever returned to
the boom will stop. NEUTRAL position.
98
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

In the bucket auto-tilting process, if push or pull FNR key. The FNR key is used to control the
the bucket control lever and make its deviation travel direction. F, N, R respectively indicates
from the NEUTRAL position greater than 6 °, and FORWARD, NEUTRAL and REVERSE.
then release the control lever back to NEUTRAL
When the shift control lever is at N position,
position, the bucket will stop.
operate the work implement control lever to
If the bucket is above the leveling position, there control the FORWARD, REVERSE direction and
isn’t bucket auto-leveling function. KD key function of the machine.
Pilot-hydraulic control lever

2
3
Push the control lever to LOWER position to 4
lower the work implement onto ground or
trailer if the engine flames out.

Before lowering the work implement, make

sure that no obstacles or personnel is around
the machine to avoid machine damage or
personnel injury or death. Electro-hydraulic control lever
5 7
4 3
Work Implement Control Lever

The work implement control lever is located on

the right side of the driver' seat. It is used to 2
8
control the boom and bucket. Push the control
lever forward and pull it backward to control the
boom lowering and raising; pull the control lever
leftward and push it rightward to control the
bucket tilting back and dumping. The control
lever is naturally at the NEUTRAL position when
the engine stops.

1 6

2. Horn switch
3. Auxiliary control knob (optional)
4. FNR key
1. Work implement control lever 5. KD key
6. Shift control lever
The work implement control lever has a horn 7. Auto-dig trigger switch button
switch, an auxiliary control key, a KD key and a 8. Auxiliary control knob (not available)
99
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Boom lift kickout: pull the control lever backward

until it reaches to the limit position, then the
control lever will stay at this position (it will not
reset after being released); when the boom
The machine can be started only when the reaches its maximum height, the boom lift
shift control lever is at N position. kickout switch works and the control lever will
return to the NEUTRAL position, the boom will
Pay attention to the following cautions when not raise any more.
using the work implement control lever to control
the travel direction of the machine: Lower
1. FNR function of the work implement control
lever can be activated only when the shift Push the control lever forward, the
control lever and FNR key both are at N boom will lower. The control lever will
position. return to NEUTRAL position after being
released.
2. After the FNR function is activated, operate
the work implement control lever to select Float
desired travel direction of F, N, R or select the
KD key function. At this time, gear 2 is the Push the control lever forward until it
highest travel speed of the machine. reaches the limit position, then it will
Notice: The output change of transmission gear stay at that position (the control lever will not
1 and gear 2 can be carried out promptly through reset after being released) and the boom is at
KD key. When the machine is travelling at F2 or FLOAT state.
R2, press the KD key on the shift control lever or When scraping or loading, push the control lever
the work implement control lever, the travel to the FLOAT position, then the bucket will raise
speed will shift to F1 or R1. If press the KD key or lower along with the ground condition to avoid
again, the travel speed will shift to F2 or R2. damaging the road surface.
When changing the travel direction by FNR key
or changing the travel speed by the shift control When lowering the boom, push the control lever
lever, KD function will stop. The transmission will to FLOAT position, and then the boom will lower
output at gear 2 (when changing the travel slowly due to its dead weight.
direction by FNR key) or relative gear (when Pull the control lever to NEUTRAL position to
changing gear 2 to other gears by the shift cancel FLOAT state.
control lever).
3. FNR function will stop when the shift control
lever is not at N position. Then the travel
speed and travel direction will be controlled Do not use FLOAT when lowering the boom
only by the shift control lever. Follow the with a loaded bucket. The quick lowering
above procedures if you want to use the FNR speed of the boom will damage the
function again. machine.
Boom control
Hold
Raise
The control lever will return to the
Pull the control lever backward, the NEUTRAL position after being
boom will raise. released from RAISE or LOWER position, the
boom will stay at the position that is selected.
100
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Bucket control When the bucket is dumping, the control lever

does not have HOLD function. Keep pushing the
Dump control lever rightward and it will reset to the
NEUTRAL position after being released.
Push the control lever rightward
(forward), the bucket will dump
forward.
Push the control lever to LOWER position to
Hold
lower the work implement onto ground or
trailer if the engine flames out.
The control lever will return to the
NEUTRAL position after being
released from DUMP or TILT BACK position, the
bucket will stay at the position that is selected.
Before lowering the work implement, make
Tilt back sure that no obstacles or personnel is around
the machine to avoid machine damage or
Pull the control lever leftward personnel injury or death.
(backward), the bucket will tilt back.
The control lever will hold at the maximum tilting Auxiliary Control Knob (Optional)
position till the bucket reaches the positioning
position. Then the control lever will return to the The auxiliary control knob is located on the work
NEUTRAL position. implement control lever. It is used to control the
operation of attachments. Only when the
Bucket positioning auxiliary control knob lock switch is at UNLOCK
position, the auxiliary control knob can work
When the bucket is at DUMP condition, pull the normally.
control lever leftward to the limit position, then Auxiliary control knob
the control lever will hold at that limit position. It
will not return to NEUTRAL position after being
released. The bucket keeps tilting backward until
it reaches the positioning position. Then the
control lever will automatically return to the
NEUTRAL position and the bucket will hold at
the bucket positioning position.
Pull the control lever leftward to the limit position
again, the control lever will not hold, it will return
to the NEUTRAL position after being released.
Only when pushing the control lever rightward
and the bucket dumping angle exceeds the
bucket positioning position, the bucket positioner
switch will reset and the bucket positioning
function will recover. Push the control lever
leftward to the limit position again, the control
lever will hold at the limit position.
101
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

NEUTRAL--The logging fork will stay at this

Auxiliary control knob lock switch position after releasing the auxiliary control knob.
OPEN--Rotate the auxiliary control knob again,
the logging fork will open. The control knob will
UNLOCK return to NEUTRAL position after being
released.

Snow plow moldboard

LOCK
SWING RIGHT--Rotate the auxiliary
control knob, the moldboard will swing
Side dump bucket right. The control knob will return to
NEUTRAL position after being
DUMP--Rotate the auxiliary control released.
knob, the bucket will dump by side. NEUTRAL--The moldboard will stay at
The control knob will return to this position after releasing the
NEUTRAL position after being auxiliary control knob.
released.
SWING LEFT--Rotate the auxiliary
NEUTRAL--The side dump bucket will control knob again, the moldboard will
stay at this position after releasing the swing left. The control knob will return
auxiliary control knob. to NEUTRAL position after being
TILT BACK--Rotate the auxiliary released.
control knob again, the bucket will tilt
back. The control knob will return to The auxiliary control knob can be used to
NEUTRAL position after being control the replacement of working
released. attachments on the quick coupler device.
Refer to the section of "Quick Coupler Device
(Optional)" for specific operation.

After finish dumping, do not operate other

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

Do not operate the auxiliary control knob

during loading, otherwise the side dump
cylinder will be damaged, the bucket will
loose and dump accidently, serious accident
will be caused.

Logging fork

CLOSE--Rotate the auxiliary control knob, the

logging fork will close. The control knob will
return to NEUTRAL position after being
released.
102
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Auxiliary Control Lever (Optional)

The auxiliary control lever is located on the right

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

Logging fork

CLOSE--Push the auxiliary control lever forward,

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

After finish dumping, do not operate other

control levers until the side dump bucket is The auxiliary control lever can be used to
lowered to ground. control the replacement of working
attachments on the quick coupler device.
Refer to the section of "Quick Coupler Device
(Optional)" for specific operation.
103
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Steering Handle (Optional) Steering handle cut-off switch

The steering handle assembly is installed on the

left armrest of the seat. The steering handle
assembly and the armrest can be adjusted up ON
and down, left and right, front and back. The
steering handle assembly includes KD key, FNR
switch, steering handle, enable key, steering
handle indicator and horn button, which can
realize the functions of low gear change, driving
direction selection, steering, etc. OFF

1
The steering handle cut-off switch is located on
the switch panel on the right front upright column
of the cab.
A lock buckle is provided on the switch; unlock
this buckle by turning it downward before
pressing the switch, otherwise the switch will be
1. Steering handle assembly
2. Armrest damaged.
When the switch is on, the driver can perform
related operations of the handle steering system,
including steering, FNR, KD, horn and other
The function of the steering handle can only functions.
be used when the machine travel speed is
within 20km/h. When the switch is off, the handle steering
system is in the locked state and no operation
The steering handle will only function when can be performed. This can prevent accidents
the steering handle cut-off switch is turned caused by accidentally touching the steering
on. handle.

When the armrest is raised, all keys on the

armrest are disabled.
104
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

When the ECWS controller is powered on, the

KD key is always activated in the off mode.
KD key can work only when the following
3 1 conditions are met at the same time:
1. The ECWS controller is powered on.
2
2. The armrest is lowered.
3. Press the enable key 1 ~ 2s, the blue LED
steering handle indicator illuminates.
As long as any one of the following conditions is
met, the KD key will not work:
1. The ECWS controller is powered off.
2. The armrest is raised.
7 6 5 4 3. Press the enable key 1 ~ 2s, the blue LED
1. KD key
steering handle indicator doesn’t illuminate.
2. FNR switch
3. Steering handle Left-hand FNR switch
4. Enable key
5. Steering handle indicator
6. Horn button
The FNR switch is the direction key used to
7. Reserved button select the driving direction of the machine, where
F, N, R respectively indicates the FORWARD,
KD key NEUTRAL and REVERSE gears of the machine.
When the ECWS controller is powered on, the
The KD key is the function key of forced
left-hand FNR switch is always activated in the
downshift. When the gear is set to the second
off mode of FNR switch.
gear forward (F2) or the second gear reverse
(R2), press the KD key lightly, and the The left-hand FNR switch can work only when
transmission gear can automatically switch to the the following conditions are met at the same
first gear forward (F1) or the first gear reverse time:
(R1) accordingly.
1. The armrest is lowered.
The cooperation between the KD key function
2. The left-hand FNR switch is in NEUTRAL.
and the direct forward/ reverse change function
makes it very convenient for the machine to 3. The shift control lever and the right-hand
change gears frequently when loading materials. FNR switch are both in NEUTRAL.
Once another gear is shifted in, the KD key 4. Press the enable key 1 ~ 2s, the blue LED
function will be stopped automatically. The KD steering handle indicator illuminates.
key function can be cancelled by the following As long as any one of the following conditions is
methods: met, the left-hand FNR switch will not work:
● Press the KD key again. 1. The armrest is raised.
● Change the driving direction. 2. The right-hand FNR switch is not in
● Turn the shift control lever to change the NEUTRAL.
gear.
● Switch to Neutral.
105
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

3. Press the enable key 1 ~ 2s, the blue LED 3. When the handle is released, it will return to
steering handle indicator doesn’t illuminate. the Neutral position automatically, the
machine will stop turning and maintain the
current steering angle.

When the armrest is raised, all keys on the

armrest are disabled. When the armrest is
lowered, the FNR function can work only after The priority is given to the steering of the
the FNR switch returns to the NEUTRAL steering wheel. After the steering wheel
position. stops, the steering handle can work again
only after the handle returns to the Neutral
position.

When the ECWS controller is powered on, the

The priority order of the FNR function: steering handle is always activated in the off
priority is given to the FNR function of the mode of steering.
shift control lever, followed by the right-hand
FNR switch and finally the left-hand FNR The steering handle can work only when the
switch. following conditions are met at the same time:
When using the FNR function of the shift 1. The armrest is lowered.
control lever, the left-hand FNR switch does 2. Press the enable key 1-2s, the blue LED
not work. The left-hand FNR switch can steering handle indicator illuminates.
function again only when the shift control
lever and the left-hand FNR switch are both in 3. No ECWS controller error is detected.
the "N" position. As long as any one of the following conditions is
met, the steering function of the handle will not
Steering handle work:
1. The armrest is raised.
The steering handle is used to control the turning
direction of the machine. Move the handle to the 2. The enable key does not work, and the blue
left to turn the machine to the left. Move the LED steering handle indicator doesn’t
handle to the right to turn the machine to the illuminate.
right. Operation steps of the steering handle:
3. Serious error of the ECWS controller is
1. Once move the handle, the machine will detected.
continue to turn to the limit position.
4. ECWS pressure sensor is not connected,
2. The greater the moving angle of the handle, (K1-D3) current value is lower than 2mA.
the faster the turning speed of the machine.
A steering limit value is set before the machine
leaves the factory. When the actual LS pressure
is detected to be higher than the set value, the
blue LED steering handle indicator will flash
continuously, and the steering function of the
handle is disabled, and the machine enters the
steering standby mode.
106
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

When the actual LS pressure is detected to be Other Devices

lower than the set value, the blue LED steering
handle indicator will illuminate continuously, and
the steering function of the handle will be Steering Column (not adjustable up and
restored. down)

Enable key The steering column of the machine can be

adjusted forward and backward within certain
Enable key is used to control the steering scope to meet different drivers’ operation habit.
handle. When the left-hand and right-hand FNR
There is a pedal on the lower left side of the
switches are at Neutral position at the same
steering column, it is connected with an air
time, press and hold the enable key for 1-2s to
spring.
activate the steering handle, the steering handle
indicator illuminates, and the steering handle can
be used.

Steering handle indicator

The steering handle indicator is on the enable 3

key, press and hold the enable key for 1-2s, and
the blue LED indicator illuminates. When the
steering handle is not activated, the indicator
goes out.

Horn button
2
Press the horn button, the horn will sound.
1
When the ECWS controller is powered on, the
horn button is always activated in the off mode.
The horn button can work only when the
following conditions are met at the same time:
1. Pedal
1. The ECWS controller is powered on. 2. Air spring
3. Adjusting handle
2. The armrest is lowered. Adjust the steering column forward or backward
As long as any one of the following conditions is as follows:
met, the horn button will not work: 1. Depress the pedal, the air spring will be
1. The ECWS controller is powered off. released.
2. The armrest is raised. 2. Keep the pedal unmoved, move the steering
column forward or backward to desired
Reserved button position.
3. Release the pedal, the steering column will
This button is reserved for future use. The wiper be fixed at this position.
function is currently unavailable.
107
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Steering Column (adjustable up and Pilot Shutoff Lever (for machine with
down) pilot-hydraulic control lever)

The steering column can be turned forward and The pilot shutoff lever is located at the bottom of
backward, and the height can be adjusted. the work implement control lever. Two positions
are available: ON and OFF.
1. Press the adjusting handle down and push
the steering wheel forward and backward to
the proper position at the same time, then
release the adjusting handle, the steering
column is fixed to realize the forward and
backward direction adjustment.
2. Lift the adjusting handle up and pull the
steering wheel up and down to the proper
position at the same time, then release the
adjusting handle, the steering column is fixed
to realize the vertical direction adjustment.

Turn the pilot shutoff lever to ON position, the

work implement will move when operating the
control lever; turn the pilot shutoff lever to OFF
position, the work implement will not move when
operating the control lever. This can prevent the
accident caused by misoperation.
1
Pilot shutoff lever at ON

1. Adjusting handle

Adjustment mark on the handle

Pilot shutoff lever at OFF
108
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Lower the bucket to the ground and turn the

pilot shutoff lever to OFF position before The maximum supporting capacity of the
leaving the driver’s seat, otherwise, armrest is 50kg.
misoperation of pilot control lever may lead
to accident. 3. Seat depth adjustment and seat tilting
adjustment
Pneumatic Suspension Seat
Seat depth adjustment 60mm in 15mm
1. Fore-and-aft adjustment increments. Seat tilting angle adjustment 8°.

Fore-and-aft adjustment max. 150mm.

4. Document box

2. Armrest angle adjustment

Height and angle of the armrest is adjustable.

Armrest angle is 40° and height adjustment is
40mm.
109
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

5. Headrest height adjustment 8. Weight adjustment and suspension

function
As shown below, hold the seat headrest with
both hands, pull it upward or downward smoothly Two stroke options are available for this weight
can adjust the height of the seat headrest. adjustment: 60mm and 80mm. Adjust according
to the operator's weight. Weight adjustment is
infinite from 50 kg to130 kg.

6. Backrest angle adjustment

The max. adjusting angle of the seat backrest is

21°. It can be adjusted to meet the need of
different operators. 9. Infinite adjustable lumber support

7. Nonretractable seat belt

110
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

10. 3-step height adjustment by lifting the

seat top

Adjust the seat height according to operator's

height or operating habits. Three increments are
available. The height adjustment 60mm in 20mm
increments.

The seat height can be adjusted up or down by

pulling or pushing the adjuster handle.

Do not adjust the seat while the machine is

traveling, so as to avoid accidents.

2. Fore-and-aft adjustment

Do not adjust the seat while the machine is Hold the pull rod by hand, slide the seat back
traveling, so as to avoid accidents. and forth to the desired position, and then
release the pull rod to lock the seat in place. The
Mechanical Suspension Seat front and back adjustable travel distance of the
seat is 150 mm.
The seat provided for this machine can be
adjusted in the aspects of fore-and-aft direction,
height, backrest angle, armrest angle, headrest
height and weight to meet the needs of different
drivers in various working conditions.

1. Weight and seat height adjustment

The driver must sit on the seat when adjusting

the weight, pull up or press and hold down the
adjuster handle until the green mark appears in
the weight and height indicator. The seat can be
adjusted infinitely between 50-130kg according
to the weight of the driver.

In order to avoid health damage, check and

adjust the setting of the driver's weight
before driving.
111
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

3. Backrest angle adjustment 5. Seat pan angle adjustment

Release the backrest adjustment by lifting the Pull the left handle upwards. Move the seat pan
locking lever up. When releasing the backrest, to the desired position by applying pressure to
do not apply pressure load to the backrest. Apply the front or rear part of it.
pressure through the front or rear part of the seat
cushion to move to the desired position. Release
the locking lever to lock the backrest.

6. Seat depth adjustment

Pull the right handle upwards. Adjust the seat

4. Armrest angle adjustment pan to the desired position by moving it forward
or backward.
The tilt angle of the armrest can be changed by
turning the adjusting knob. When you rotate the
knob outwards, the front of the armrest will rise;
when you rotate the knob inwards, the front of
the armrest will lower down.
112
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

7. Headrest height adjustment Seat Belt

The headrest height can be adjusted separately.
Increase the height of the headrest to the
required position by stretching it upward.
Remove the headrest by pulling it up to the end The machine is equipped with a seat belt by
position. Liugong before transporting it to the
destination. Its quality and installation
instruction has met the standard of
ISO6683.

The seat belt used in this machine can not retract

automatically.
Fasten the seat belt before operating the
machine. Before using the seat belt, check the
seat belt for wear and fastness, replace if
necessary. Contact your LiuGong dealer for the
seat belt replacement.
8. Seat belt Adjust length of the seat belt before use in order
to ensure safety and comfortability. Length of the
seat belt can be adjusted by moving position of
catch on the safety belt.
The buckle of the seat belt is located at the right
rear side of the seat. Insert catch of the safety
belt into the buckle to latch it.

9. Document box

The document box is located behind the seat

back.
113
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

A red button is provided by side of the buckle. Sound System

Press the button, the catch will spring up from
the buckle. The sound system is located inside the cab and
consists of the main unit, loudspeaker and
antenna.

1 2 13 14 15

3 4 5 6 7 8 9 10 11 12

1. Source/mute key
Before using the seat belt, check whether the 2. SRC/SOUND
buckle of the seat belt can lock and release 3. Volume key
normally. 4. Menu key
5. Preset key 2
6. Preset key3
Hand Pad 7. Preset key4/last menu
8. Preset key 5/next menu
There is a hand pad beside driver's seat. The 9. SCAN key
10. Search station forward/last song
driver can place his right arm on it to reduce 11. Auto store station/exit
fatigue. 12. Search station backward/next song
13. Audible signal input
14. USB
1 15. Waveband key

Connect the battery negative terminal only

when the sound system has been installed to
avoid a short circuit.
Make sure you can still hear traffic (horns,
2
sirens and so on) when adjusting the volume.
1. Hand pad
2. Mounting bolt Source/mute key
Loosen the mounting bolt of the hand pad
Press to switch on the power. Press
support and move the hand pad up and down to
this key for more than 2 seconds to
appropriate position then tighten it.
switch off the power. Press this key shortly to
mute or cancel the mute (silence).
114
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Sound adjustment BASS—TREBLE—BAL—FADER—LOUD

BASS--low volume control, -7, +7.
Volume Key
TREBLE--high volume control, -7, +7
Press the VOLUME+/- key to adjust
BAL--left and right balance control. -7-- -0- --7
the volume up or down.
FADER--horn control, -7- -0- 7
Sound LOUD--undertone volume control. Four choices
are available: OFF LOW MID HI.
2. Press VOLUME+/- shortly to adjust the
1. Press SRC/SOUND key for 2 seconds to selection mode.
enter BASS-TRE.

If no other sound mode is selected, BASS/

2. Press VOLUME+/- key shortly to select your TREBLE will show on the display.
own sound style.

The sound system will escape from the

sound mode and memorize the last setting if
● BASS-TRE——Your own settings of bass no further changes within 5 seconds.
and treble.
● FLAT——Original Radio
● JAZZ——Jazz music
Waveband
● VOCAL——Speech
● POP——Pop music Press BAND to select the desired
band.
● CLASSIC——Classical music
● ROCK-Rock music mode
3. The LED display will show the sound type
that has been selected.

Automatic search

No sound mode will be shown on the display

if no sound mode is selected.
● Press '''' to tune to a station of a lower
frequency or '''' to a higher frequency. To
Volume balance adjustment
search for another station, press the key
again.
1. Press the SOUND key continuously to select
the balance modes:
115
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Manual search Do as follows:

● Press '''' or '''' for two seconds to change 1. Insert the memory disc, USB PLUG will show
to manual search. on the display.
● Press '''' to turn to a station of a lower
frequency or '''' to a higher frequency or a
desired frequency.
● The radio will search the station
automatically when you release '''' or ''''
for five seconds.

Store stations Initialization is needed when inserting the

memory disc. It will last for a few seconds by
Press any keys from 1 to 6 to store different memories. Do not take out the
desired stations. memory disc within the initialization process.
● Manual store
2. Press SRC key shortly under radio state to
Press the desired preset key (1 to 6) for more change to USB mode, then the following
than 2 seconds to store the current tuned station. interface will be shown:
● Automatic store (AUTO STORE)
You can automatically store the 6 strongest FM
stations on the FM AST band or 6 strongest MW
(AM) stations on the MW(AM) AST band. When
you use Auto Store, the new stations replace any
3. The display will show the album number
stations previously stored in the FM AST band or
before playing the songs.
the MW (AM) AST band.
4. When playing, the display will show the
Press ''AST'' key to activate auto-store.
song's name and playing time. After finishing,
it will continue to play the next one.
USB 5. Press or to select the last song or the
next song to play.
USB interface is provided on this machine. 6. Press SCAN key during playing, each song in
Features: the same album will play for 10 seconds in
sequence, press SCAN key again to make it
● Support MP3 format only. return to normal playing state.
● Support 32Mbyte~4G memory disc. 7. During playing, press MENU key to show the
● Support MPEG Audio 1, 2 and 2.5. the song sequence in the album, after 2
seconds, it will return to normal playing state.
● Support Layer 3.
● Support FAT16 and FAT 32 partition
memorizing.
● Sampling frequency range: 8k,16k, 32k,
11.025k, 22.05k, 44.1k, 1k, 12k, 24k and
48kHz.
● Bit rate: 8k ~ 320kbps and VBR(MP3 PRO).
116
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

8. In playing state, press 3||, playing will Small Tool Kit

pause, press this key again to continue
playing. There is a small tool kit under the driver's seat,
which is used to store some common small tools.

Do not take out the memory disc when

playing, otherwise the file could be damaged.
It is better to take out the memory disc after
turning off the sound system.

It is recommended not to extend the USB

cable because USB connection has a high
requirement on the length, resistance and
Lights
signal delaying of the cable, other cables may
not meet the requirement, which could result
Lights of the machine consist of front work lights
in a reading failure of the memory disc.
(left & right each), front combination lights (left &
right each), rear work lights (left & right each),
Audible signal input rear combination lights (left & right each), dome
light, and rotating beacon.
A 3.5 mm audible signal input interface
is provided on the sound system,
which can be used to connect other music
players. Press SRC key and select AUX IN 1
mode. The volume can be adjusted under AUX
IN mode.

1. Front work lights

2. Front combination lights
3. Rear work lights
4. Rear combination lights
117
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

The front combination lights consist of front turn

signal lights, front position lights, and front 11
floodlights. The turn signal lights are controlled
by the combination switch.

10 8
6

9
5
8. Rear position lights/ brake lights
9. Reflectors
7 10. Rear turn signal lights
11. Backup lights

12. Rotating beacon

5. Front turn signal lights

6. Front floodlights (high beam/ low beam)
7. Front position lights
The rear combination lights consist of rear
position lights/ brake lights, reflectors, rear turn
signal lights, and backup lights. 13

8 13. Dome light

9
118
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Door Lock Door Positioner

The driver should enter the cab from the left

door, which can be opened inside or outside the
cab. The right door can not be opened.

The machine cab only has one door on the left,

and right side is window, the left door is installed
with a door lock.
Insert the key and rotate it clockwise for 180
degrees then take it out, hold the door lock with
your hand, push the lock pin down with your
thumb, open the door by pulling the door
outward.
Before locking the door, first close it. Insert the
key and rotate counterclockwise to 180 degrees,
then take it out. After the door is locked, the lock
pin can't be pressed down.

After the left door is opened to a particular

opening, it can be opened completely and
positioned automatically by an air spring, which
Before operating the machine, always close
is located on the top of the left door. Pull the
the door first to ensure safety.
inner handrail backward to close the left door.
If it needs to open the left door partly, push the
left door outward and fix it with the stay rod.
Remove the stay rod to close the left door.
119
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Stay rod of left door

When open the door, the pressurization in

the cab will disappear.

Before operating the machine, always close

Extract the fixed pin to unlock the latch and then
the right & left doors and right window first to open the right window completely.
ensure safety.
Fixed pin
Latch

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

If the left door can not be opened at the
emergent situation, leave the machine from the
right window of the cab.
Open the right window from the driver’s cab. Pull
the latch handle and then push it outward to
open the right window partly.
Latch handle

When open the window, the pressurization

in the cab will disappear.
120
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

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

Pull the latch unlocking handle to unlock the

window, and then pull the inner handrail
backward to close the right window.
Latch unlocking handle

Adjustment of Rear View Mirrors

1. Loosen the connecting bolts between the

rear view mirror brackets and the cab, turn
the brackets to adjust the rear view mirrors to
proper position.
2. Loosen the connecting bolts between rear
view mirrors and the brackets, adjust the rear
view mirrors to desired angles.
3. After completing the above-mentioned
adjustment, tighten the bolts.
121
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Engine Hood Lift Device 1. Pull the draw ring of the stop pin outward.

The motor pump of the engine hood lift device is

located in the box on the rear right side of the
machine, open the cover to get access to the lift
control box.

2. Pull the lowering handle along the arrow

direction from position A to position B,
release the draw ring, the lowering handle
will be fixed at this position by the stop pin.

B
A

4 3. Turn the electric switch upward, the lift

mechanism will drive the engine hood to
raise; release the electric switch when getting
the required position, the engine hood will
stop at this position.
2
1

1. Electric switch
2. Lowering handle
3. Draw ring of stop pin
4. Revolving shaft

Open the engine hood

There are two ways to open the engine hood:

electric switch (normal condition), and manual
crank operation (abnormal condition).
122
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

4. When the electric switch doesn’t work, insert 2. Push the lowering handle along the arrow
a crank into the revolving shaft, and rotate direction from position B to position A to
the crank, the engine hood will raise. lower the engine hood. The engine hood
starts to lower slowly when the handle is
getting to the level position, the closer the
handle gets to the level position, the faster
lowering speed of the engine hood.

Close the engine hood

1. Pull the draw ring of the stop pin outward. 3. When the engine hood is fully closed, release
the draw ring of the stop pin, the lowering
handle will be fixed at this level position by
the stop pin.

Do not stand behind the engine hood when it

is tilting forward or backward to avoid injury.
Do not pull the draw ring of the stop pin and
turn the lowering handle at will after the
engine hood is lifted.
The lowering handle must be in position A
when driving the machine (if it isn’t in
position A, when the engine hood vibrates, it
will result in the tension of cylinders and
damage the motor pump and cylinders).
123
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Backup Alarm System (Optional) Steering Frame Lock

The backup alarm is located at the back of the

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

To connect the steering frame lock, the

machine must be in the straight ahead
direction.

The steering frame lock is located at the left or

right side of the machine.

The back-up alarm is close to the radiator,

1
when adjusting the back-up alarm, first stop
the engine and wait until the high
temperature cools down to avoid being burnt.

1. Pin
2. Steering frame lock
Connect the steering frame lock when the
machine is being lifted and transported. Also
connect the steering frame lock if you are
performing service work near the articulation
joint.
Separate the steering frame lock before
operating the machine. Move the steering frame
lock to the rear frame and install the pin.
124
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Centralized Lubrication System 2. Secondly, before the M-end of each pipeline

is connected to the lubrication piont, it is
Check before leaving the factory: necessary to press the “set” key on the
centralized lubrication pump and keep it for 2
Lubrication pump must be checked before seconds. The centralized lubrication system
leaving the factory to ensure that the blockage of will enter the “continuous cycle test”
the red air bleeder in its lower left is removed. operation mode. When there is continuous
flow of lubricating oil at the M-end of all
Cautions when adding grease to lubrication pipelines, it means that the air in the pipeline
pump: has been exhausted. Then close the
“continuous cycle test” operation mode.
1. Make sure no air in when pumping grease by 3. After completing the above steps, connect
a pneumatic pump or a manual grease the M-end of pipeline to the lubrication piont
pump; When pumping grease by a of the pin shaft.
pneumatic pump, make sure that the suction
port is totally sunk in grease, the grease 4. After completing the step1-3, run the
reservoir should be equipped with a follower “continuous cycle test” again and pump oil for
plate; When pumping grease by a manual 30 minutes. Ensure that the lubricating piont
pump, a new grease rod should be placed at each M-end of machine is oil off before
into grease reservoir. delivery, and that there is enough grease in
the groove of the pin shaft and shaft sleeve.
2. Pump grease to proper level when the
grease level of the grease reservoir is low,
that is, the bottom edge of the follower plate
inside the grease reservoir reaches MAX
position. Q-end: the starting end of each separate
pipeline is refer to the end of lubricating
3. Do not use the centralized lubrication pump pipeline connected to the distributor.
when the grease level is extremely low or the
grease reservoir is empty, otherwise, it may M-end: the end of each separate pipeline is
lead to the entering of air in the grease pump, refer to the end of lubricating pipeline
abnormal system pressure, and result in connected to the lubrication piont of the pin
system fault, or even serious damage of shaft.
grease pump.
Centralized lubrication oil pump exhaust
4. The normal pressure range of A/B oil ports
operation:
when system supplies grease normally is
20Mpa to 25Mpa. When system has fault, the
1. Firstly, loosen the A and B pipe joints at the
pressure of A/B oil ports is too high or too
pump outlet (in order to avoid residual
low, system will send out fault code in the
pressure in the pipe, loosen several threads
display through pressure switch signal.
first, and then fully loosen them after no
lubricating grease emerges).
Grease line exhaust operation:
2. Run the “continuous cycle test” operation
When installing lubrication system, mode, ensure that there is continuous flow of
lubricating oil from circulation A and
1. Firstly, ensure that the Q-end of each pipeline circulation B, and then reconnect the main
is connected to the connector on the pipe with the pump.
distributor.
3. Perform two single test cycles to check the
lubrication system for proper function.
125
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Display

The display is located on the front right column of

the cab.
The step is only suitable for case that the
pump occasionally suck in air for a short time
and the system fails to establish pressure.
Pay attention to add clean grease to the
pump in time for daily maintenance. If the
lubricating grease is not replenished in time,
the centralized lubricating oil pump will suck
in air many times or for a long time, which
may cause damage to the entire centralized
lubricating oil pump.
Centralized lubrication system consists of pump,
distributors, circuits, connectors, brackets and After the ignition switch is switched on, the
display etc. This system can lubricate display will indicate the active duty mode within
automatically when the bearing is working, which one minute. Press the switch-button for about 4
can reduce pollution, friction and abrasion, seconds and release, accordingly, the 3-digit
maintenance interval and lubricating effort to display starts flashing. During the flashing, press
prolong the service lift. the switch-button repeatedly until the desired
duty mode shows. Leave the desired duty mode
flashing for at least 6 seconds until the duty
mode comes on. This will confirm the desired
6
duty mode has now changed.
7

6
5 5
4
1
2 2
4 3

1. Grease pump
2. Main grease line A 1
3. Main grease line B
4. Distributor
5. Metering unit
6. Pressure switch
7. Solenoid (connect to grease point) 1. Switch-button
2. 3-digit display
3. Decimal dot
4. System activation indicator LED
5. Low grease level indicator LED
6. Alarm indicator LED
The lubrication time and intervals have been
setup at the factory, do not modify them by
yourself.
126
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Display indications and error codes

Code + LED Explanation of error codes

When ignition switch is switched ON, the 3-digit display forms a rotating clock, indicating
it’s communicating with the pump control unit. After 10 seconds, the preset duty mode
selection appears along with the green LED.

Light duty - Greasing mode with long intervals. (Decreased greasing output)

Medium duty - Greasing mode with medium intervals. (Normal greasing output)

Heavy duty - Greasing mode with short intervals. (Increased greasing output)

Pump performs a single cycle test (LED flashes slow).

Pump performs multiple cycle test (LED flashes fast).

Minimum level in the reservoir has been reached. Resets itself by refilling the reservoir.

System error. Duty cycle selection possible only after the error has been solved.
Possible reason:
1. Grease pressure is insufficient in 10 successive greasing cycles (or successive 10
times for the same grease line). After trouble shooting, pressing the test switch on the
pump for one second to reset. The ignition switch should be switched on at this time.
2. The grease reservoir is empty. Refill the reservoir with grease, and press the test
switch on the pump for one second to reset. The ignition switch should be switched
on at this time.
E11 due to successive no pressure in line-A.
Possible reason:
1. There is leak or crack in line A. Check the related joints and piping along line A, repair
or replace the damaged parts.
2. There is leak due to the damage of certain metering unit. Replace the damaged
metering unit.
3. Air existed in line A. Bleed line A. Perform successive cycle test after removing the
corresponding plugs connected to line A starting from the first distributor.
127
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Display indications and error codes

Code + LED Explanation of error codes

E12 due to successive no pressure in line-B.
Possible reason:
1. There is leak or crack in line B. Check the related joints and piping along line B, repair
or replace the damaged parts.
2. There is leak due to the damage of certain metering unit. Replace the damaged
metering unit.
3. Air existed in line B. Bleed line B. Perform successive cycle test after removing the
corresponding plugs connected to line B starting from the first distributor.
E13 due to successive pressure before cycle in line-A.
Possible reason:
1. There is short circuit inside due to the damage of pressure switch wiring harness.
Replace the switch wiring harness.
2. Pressure switch failed/ broken. Replace the switch.
3. 5/2-way valve did not operate correctly. Replace the 5/2-way valve.
E14 due to successive pressure before cycle in line-B.
Possible reason:
1. There is short circuit inside due to the damage of pressure switch wiring harness.
Replace the switchwiring harness.
2. Pressure switch failed/ broken. Replace the switch.
3. 5/2-way valve did not operate correctly. Replace the 5/2-way valve.
E15 due to empty reservoir.
Possible reason:
1. Reservoir reaches the lowest grease level, the greasing system already carried out
the preset max. pumping times, pump stops working. Refill the reservoir with grease.
2. Integrated error alert of “low grease level” and “no pressure in line-A or line-B”. Refill
the reservoir with grease. Bleeding the pump if it is necessary.
E20 due to successive low supply voltage, and unable to start the electrical motor.
Possible reason:
1. Batteries are old or damaged. Replace the battery.
2. Faulty wiring (bad grounding). Check the wiring, repair or replace when necessary.
3. Corroded pin-contact in connector. Check the connectors of the pump unit, repair or
replace when necessary.
128
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Display indications and error codes

Code + LED Explanation of error codes

E21 due to successive faulty pressure switch circuit. The pressure switch did not close
during a greasing cycle in primary line-A or -B while control unit noticed a deviant
resistance over the pressure switch circuit.
Possible reason:
1. Faulty wiring or loose connectors. Check the connectors or wiring, repair or replace
when necessary.
2. Defective pressure switch. Replace it.
E22 due to successive pump open loads. Control unit detected a too low current draw to
pump motor, in combination with initial “no pressure line-A or B” error.
Possible reason:
1. Interrupted wiring. Check the wiring, repair or replace when necessary.
2. Defective motor. Check motor on wiring faulty, check the resistance of the motor.
Replace when necessary.
3. Defective control unit. Check control unit. Replace or repair when necessary.
E23 due to successive pump over current. Control unit detected a too high current draw
to pump motor and aborted the attempted cycle.
Possible reason:
1. Short circuit in wiring of motor. Check the wiring, repair or replace when necessary.
2. Short circuit in motor. Check the motor on wiring faulty, check the resistance of the
motor. Replace when necessary.
3. Drive shaft blocked. Check the drive shaft on blocking. Replace or repair when
necessary.
4. Extreme low working temperature in combination with a grease not suitable for these
conditions. Replace the grease in the reservoir and bleed the system with a suitable
grease for the obtained working conditions.
5. The "pump motor current limit" setting not suitable for the extreme low working
temperature. Increase the "pump motor current limit" parameter setting but only after
checking whether the vehicle wiring and fuse can handle a higher setting.
E24 due to successive valve 1 open loads. Control unit detected a too low current draw to
first coil of the 5/2-way valve in combination with initial “system on pressure before cycle”
error.
Possible reason:
1. Interrupted wiring of the coil. Check wiring, repair or replace when necessary.
2. Defective coil. Check coil on wiring faulty, check the resistance of the coil. Repair or
replace when necessary.
129
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Display indications and error codes

Code + LED Explanation of error codes

E25 due to successive valve 1 over current. Control unit detected a too high current draw
to 5/2-way valve in combination with initial “system on pressure before cycle” error.
Possible reason:
1. Short circuit in wiring of the coil. Check wiring, repair or replace when necessary.
2. Defective coil. Check coil on wiring faulty, check the resistance of the coil. Repair or
replace when necessary.
E31 due to successive valve 2 open loads. Control unit detected a too low current draw to
second coil of the 5/2-way valve in combination with initial “system on pressure before
cycle” error.
Possible reason:
1. Interrupted wiring of the coil. Check wiring, repair or replace when necessary.
2. Defective coil. Check coil on wiring faulty, check the resistance of the coil. Repair or
replace when necessary.
E32 due to successive valve 2 over current. Control unit detected a too high current draw
to 5/2-way valve in combination with initial “system on pressure before cycle” error.
Possible reason:
1. Short circuit in wiring of the coil. Check wiring, repair or replace when necessary.
2. Defective coil. Check coil on wiring faulty, check the resistance of the coil. Repair or
replace when necessary.
E50 due to a communication error with the control unit.
Possible reason:
1. No communication between display and control unit. Check the purple
communication wire no. 6 between display and pump (pump connector pin no. 6).
Repair when necessary.
2. No supply voltage at the pump. Check the fuse and red power wire no.1 to pump
connector no. 1 and the black ground wire no. 2 to the pump connector no. 2. Replace
or repair when necessary.
3. Defective display. When no issues found as stated in solution A or B, replace display.
E51 due to a parameter checksum error.
Possible reason:
1. Control unit encountered corrupted parameters during power up and restored the
production default settings. Replace control unit.
E52 due to a low clock battery (RTC).
Possible reason:
1. Real time clock battery low (2,2 V) at the control unit. Replace the control unit.
130
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

Display indications and error codes

Code + LED Explanation of error codes

E53 due to RTC faulty. Control unit encountered a corrupted real time clock causing the
events and errors to be stored with in accurate time & dates.
Possible reason:
1. RTC battery empty. Replace the control unit.
E99 due to unknown cause. Control unit encountered an unknown cause.
Possible reason:
1. This error indication shows when pump motor is disconnected due to a number of
successive errors but no additional information available on the error cause. An error
cause that is not listed in the table. Replace the control unit.
The yellow low grease level indicator on the display will illuminate to alert when the system grease level
is low, refill the grease reservoir immediately.
131
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Quick Coupler (Optional)

Safety label instruction and location

Improper engagement of work attachment

could result in injury or death. Do not operate
this machine until you have positive
Make sure that the quick coupler switch is indication that the diverter valve is in Aux
locked before operating the machine. position and the quick coupler switch is in
LOCK position.
Raise the work attachment off the ground and
make sure the attachment is at max. bucket
tilting position before locking or unlocking
the quick coupler.
Make sure the attachment is at max. bucket
tilting position before locking the work
attachment.
Make sure the quick coupler is firmly locked
This safety label is located on the right side in the and extends before operating the machine.
cab. Failure to comply could result in death or
serious injury.

Check whether the oil lines of quicker

coupler cylinder have been cut off before
operation, that is turn the quick coupler
handle to "AUX" position, and check whether
the quick coupler is connected firmly.

1. Diverter valve
2. Handle
132
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

1. Install the Work Attachments

2
Before using the quick coupler, please check
the quick coupler carefully for a good 1
connection.
Improper engagement of work attachment
could result in injury or death. Do not operate 1. Diverter valve 2. Handle
this machine until you have positive
indication that the diverter valve is at Aux
position and the quick coupler switch is at
LOCK position.
Try to operate the auxiliary control lever
Do not raise the work attachment over repeatedly for several times, until the
100mm to the ground when installing and pressure in the pilot oil lines has been
removing the work attachment. released. If the pressure in the switch valve
Do not use the quick coupler when hydraulic has not been released, a turning failure or
line leaks or the structures are severely worn turning difficulty of the handle could be
down. Repair or replace it immediately. resulted.
3. Press the quick coupler switch to UNLOCK
The installation and removal procedures for z- position.
bar or eight-bar work implement, or fully
automatic or semi-automatic operating system
are the same. The following procedures are for UNLOCK
the z-bar work attachment and semi-automatic
operating system.
1. Park the machine on smooth ground. Lay the
work attachment flatly. LOCK
2. Shut down the engine. The diverter valve is
located on the right side of the quick coupler 4. If the machine is equipped with a pilot cut-off
frame. Then turn handle counterclockwise to lever, turn it to ON position. If the machine is
"COUPLER" position. equipped with a hydraulic lock switch, press it
to UNLOCK position.
Pilot cut-off lever is at ON position

OFF
133
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Hydraulic lock switch

UNLOCK

LOCK

5. Slightly turn the auxiliary control lever/ 7. Tilt the quick coupler frame backward until
auxiliary control knob forwards to let the the connecting pin aligns with pin hole of the
connecting pin of the quick coupler retracts work attachment.
inside.

3. Pin
6. Operate the machine to slightly tilt the quick
8. Turn the auxiliary control lever/ auxiliary
coupler frame forwards. Slowly drive the
control knob backward (to CLOSE position)
machine forwards. Raise the boom slightly to
to let the connecting pin of the quick coupler
let the quick coupler frame engage correctly
extends to connect with the work attachment.
in the hooks.
134
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

9. To ensure the coupler connecting pin is fully 2. The diverter valve is located on the right side
engaged into the work attachment, tilt the of coupler frame. Firstly turn the handle of the
work attachment downwards onto the ground quick coupler to "Coupler" position.
and apply slight force. Then raise the boom
(about 1.5 m) and tilt the bucket forwards. Do
not separate the bucket from the coupler
frame.

2
10. Press the quick coupler switch to LOCK
position.
1

UNLOCK

1. Diverter valve
2. Handle
LOCK
3. Press the quick coupler switch to UNLOCK
position.
11. Turn the handle to "Aux" position.

UNLOCK

2
LOCK
1

1. Diverter valve
2. Handle

2. Remove the Work Attachments

1. Park the machine on smooth ground. Lay the

work attachment flatly.
135
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

4. If the machine is equipped with a pilot cut-off 6. Slowly drive the machine backward and
lever, turn it to OFF position. If the machine is slightly tilt the quick coupler frame forwards
equipped with a hydraulic lock switch, press it to let the quick coupler frame disengage from
to LOCK position. the work attachment hook.
Pilot cut-off lever is at OFF position

OFF

Hydraulic lock switch

7. Press the quick coupler switch to LOCK
position.
UNLOCK

UNLOCK

LOCK

LOCK
5. Slightly turn the auxiliary control lever/
auxiliary control knob forwards to let the 8. Turn handle of the quick coupler to "Aux"
connecting pin of the quick coupler retract position.
inside.

3
2

3. Pin
1. Diverter valve
2. Handle
136
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

3. Bucket Transportation Pallet Forks (Optional)

The parameters of the quick coupler bucket are
as follows:
Quick coupler bucket
Bucket assembly The operator should be trained with
(4.2m3)
professional techniques and have
Bucket teeth only 1940kg
corresponding professional qualifications.
Movable blade only 2010kg
The loading capacity of the fork should not
Bucket teeth plus movable
2115kg exceed the specified value.
cushion

Follow the below procedures when a long - The loading capacity of the pallet forks varies
distance transportation of the bucket is required: with the goods’ center of gravity position on
1. Put the bucket gently on the trailer by using a them. When the goods’ center of gravity position
lifting device. Try to keep the bucket parallel is at the outside tips of the pallet forks, the
with the trailer body and move it to central maximum weight figures are reduced.
part of the trailer. The width of the bucket can 1820mm pallet fork is available for the machine:
not exceed that of the trailer in order to avoid
1820mm: The maximum weight of the goods can
collision during transportation.
not exceed 4352kg.
See following load diagram for more details.

Do not get close to the lifting device when

lifting the bucket to avoid injury or death.

2. After lifting the bucket onto trailer, fasten the

bucket with ropes of enough strength to
avoid injury caused by shaking or sliding
during transportation. As shown follows.

Vibration, noice or other dangers will occur

during bucket transportation, do not stay in
the bucket or get close to the bucket to avoid
injury.
137
September 4, 2020 Operation Manual
CLG877H Operator Controls and Instrument Panels

Load diagram for 1820mm pallet fork

Forward reach
0.0 200.0 400.0 600.0 800.0 1000.0 1200.0 1400.0 1600.0 1820.0
(mm)
Lift capacity (kg) 7473 7000 6583 6213 5883 5586 5317 5073 4851 4352

1. Lift the lock upward to release the fork, move 2. Level the forks, slowly load the material and
the fork evenly. Adjust the distance of forks to the forks should completely insert into the
meet the need of material with different width. material.

The forks should be evenly spaced in the

bracket and the lock should completely √
insert in the fork channel.
138
Operation Manual September 4, 2020
Operator Controls and Instrument Panels CLG877H

3. Slightly tilt the forks backward to get a better

stable position for the material.

4. Travel with the material as low as possible

while you still maintain ground clearance.
Travel forward with the material uphill on
upgrades and on downgrades. For better The level position of the forks top may
visibility, travel in reverse with bulky load. change during this operation. Therefore,
make sure that there is enough distance
from the forks top to the material surface.

When carrying the load, the height of the

work attachment can not exceed 300mm
and the travel speed can not exceed 6Km/h.

5. Slowly raise the boom. Then slowly drive the

machine forward. Lower the boom when the
material reaches the desired position and
level the forks when the material touches the
material surface. Drive the machine reversely
when the material is stable enough.
139
September 4, 2020 Operation Manual
CLG877H Engine Starting

Engine Starting 2. Mount and dismount the machine according

to the safety regulations.

Check Before Starting the Engine

Check the engine coolant level.

Check the engine oil level.
Check the hydraulic oil level.
Check each oil pipe, water pipe and fuel pipe for
airtight condition.
3. Close the left and right doors of the cab.
Make sure air pressure of the tires is normal. Check the seat belt for normal condition and
Check batteries for damaged wiring and loose fasten it.
connectors. 4. Adjust the rear view mirrors close to the
machine as much as possible in order to get
good rear view.
5. If the machine is equipped with a pilot cut-off
Before starting the engine, Clear personnel lever, turn it to OFF position. If the machine is
around the machine. Clear away any equipped with a hydraulic lock switch, press it
obstacles. Make sure the machine is under to LOCK position.
control by the operator.
Pilot cut-off lever is at OFF position

Engine Starting

1. Turn on the battery disconnect switch. After

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

O I Hydraulic lock switch

UNLOCK

LOCK
140
Operation Manual September 4, 2020
Engine Starting CLG877H

6. Make sure the shift control lever and work 10. Warm up the engine at idle speed of
implement control lever are at NEUTRAL 650~750 rpm after the engine is started.
position, if not, turn them to NEUTRAL Check the coolant temperature gauge. Run
position. the engine with full speed only after the
coolant temperature of the engine reaches
green zone.
11. The warning indicators on the central
The engine can start only when the shift instrument panel will turn off one by one after
control lever is at NEUTRAL position. This the engine is started. Disengage the parking
can avoid the accident that produced when brake, the parking brake low oil pressure
the machine is started suddenly. indicator will go out.

7. Insert the key to the start switch and turn

clockwise to turn on the power. Sound the
horn to warn that the machine is going to
start, keep away from it. After turning the start switch to ON position,
the parking brake low oil pressure indicator
and service brake low oil pressure indicator
will blink, and the buzzer will sound the
alarm. The service brake low oil pressure
indicator should go out after the engine is
started for half minute, the parking brake low
oil pressure indicator should go out after the
parking brake is disengaged. The buzzer
should stop alarm. Check the brake system
for fault if they are abnormal.

12. During low-speed operation, listen to whether

the engine is working properly and whether
8. Turn the fan speed switch and wind mode the transmission has abnormal noise.
switch of the air conditioner system (If
equipped) to OFF position.
9. Slightly depress the accelerator pedal, and
turn the start switch key clockwise to START Pay close attention to the engine oil
position to start the start motor of the engine. pressure, which should not lower than
In normal case, the engine will start within 10 0.1MPa at idle speed. If it is lower than
seconds. Release the start switch at once to 0.1MPa, stop the machine to check the
let it reset. engine for fault.

13. Check the readings of all the gauges to make

sure they are in the normal range. Check that
all the lights, indicators, horn, windshield
Start motor operation should not exceed 15
wiper and brake lights work normally.
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.
141
September 4, 2020 Operation Manual
CLG877H Operation Techniques

14. During severely cold weather, preheat the Conditions the clutch calibration (AEB)
hydraulic oil. Pull the control lever backward needs to meet:
and hold for about 4-5 minutes, depress the
accelerator pedal and let the bucket 1. The transmission oil temperature should be
positioner stop on the boom to make the in hot state. The normal oil temperature of
hydraulic oil flow out, which can increase the transmission oil is 60-90°C, and AEB will be
hydraulic oil temperature rapidly. suspended if the oil temperature is lower
than 60°C or higher than 90°C; under normal
15. Check the service brake and parking brake
conditions, the time required for AEB is 3-5
systems for normal condition.
minutes. In order to guarantee that the AEB
16. If there are no obstacles around the machine, is performed smoothly, the initial temperature
slowly turn the steering wheel and observe of AEB is preferably controlled between 70-
for left and right turning. 80°C.
2. The shift control lever must be in Neutral
Operation Techniques during calibration.
3. The parking brake must be engaged, the
machine must be kept in level position, and
Operation Information
the output speed must be zero. If necessary,
engage the parking brake and the service
Follow these basic instructions when you are brake at the same time to ensure that the
operating the machine. machine is still.
1. To prevent injury, make sure that no one 4. The engine is at idle. The default engine idle
works on the machine or near the machine. speed of TCU is 800-1000rpm, and the
Always keep control of the machine. engine speed shall be within this range
during calibration.
2. Raise the bucket or the implement high
enough to go over any obstacle.
3. Before disengaging the parking brake,
depress the service brake pedal in order to
prevent the machine from moving.
4. Drive the machine forward for best visibility
and the best stability.
5. Reduce the engine speed when turning and
go over a hill.

Falling objects can cause personal injury or

death. Remove any hanging objects and
watch out for rolling objects.

Never allow the bucket in the float position

to avoid bucket damage.
142
Operation Manual September 4, 2020
Operation Techniques CLG877H

Driving Operation of the Machine 2. Turn the pilot control lever to tilt the bucket
backward to limit position. Raise the boom to
the transportation position. Keep a clearance
of approximately H=500~600mm between
the lower articulation point of the boom and
the ground.
Before driving the machine on road, check
whether the machine meets the requirements
of the local road laws and regulations, and
obtain the road travel permission from the
related administration office. Observe the
local laws when driving.

1. If the machine is equipped with a pilot cut-off H

lever, turn it to the ON position. If the

machine is equipped with a hydraulic lock 3. Depress the service brake pedal and press
switch, press it to UNLOCK position. the parking brake button to disengage the
parking brake. Slowly release the service
brake pedal and observe the machine for
movement.

Depress brake pedal and pull up the parking

brake button if the machine moves. Then
check the shift control system for failure. If
Hydraulic lock switch the machine stops on slope, chock the wheel
to prevent movement before checking the
machine.

UNLOCK 4. Turn the shift control lever to get forward or

reverse gear, and depress the accelerator
pedal properly at the same time, the machine
will travel forward or backward.
LOCK
F

R 1

1. Shift control lever

F: Forward
N: Neutral
R: Reverse
143
September 4, 2020 Operation Manual
CLG877H Operation Techniques

FNR key has the same function as the shift Steering Operation of the Machine
control lever. For more information, refer to
section “Work Implement Control Lever”.
1. Release the accelerator pedal to slow down
the engine running speed.
2. Depress the service brake pedal to slow
The machine can start only when the F1, F2 down the driving speed.
or R1, R2 is selected. 3. Push the combination switch forward when
turning left; pull the combination switch
5. Drive the machine to open and flat ground;
backward when turning right. Then the turn
turn the steering wheel to check whether the
signal lights on both the front and rear of the
machine has spot right and left turn ability.
machine and the turn indicators on the
6. Check the brake performance of the central instrument panel will light to warn the
machine. Drive the machine at F1 or F2, neighboring vehicles and passerby that the
release the accelerator pedal, smoothly machine is going to turn.
depress the service brake pedal, the
machine should obviously reduce speed and
stop. A 1

After depressing the service brake pedal, if

you can not feel the machine obviously
reduce speed, to ensure safety, pull up the
parking brake button at once to engage the B
emergency brake to force the machine to
stop. 1. Combination switch
A. Turn left
7. Check engagement of all the gears. B. Turn right
4. Turn the steering wheel for turning. Turn the
steering wheel oppositely for straight driving
after steering operation is finished.
To protect the clutch, before shifting gear, 5. After the steering is finished, turn the
first release the accelerator pedal, then combination switch to NATURAL position.
operate the shift control lever. The turn signal lights and the turn indicators
will go out.
6. Depress the accelerator pedal to get a
desired running speed of the engine.

Never turn the machine on a slope. Drive the

machine to flat ground before turning.
144
Operation Manual September 4, 2020
Operation Techniques CLG877H

Brake Operation of the Machine

When performing brake, first release the

accelerator pedal, then smoothly depress the When the machine is traveling or working on
brake pedal to perform the service brake a slope, do not cut off the transmission
operation. power output when performing the service
The machine will cut off the oil line of the shift brake to ensure safety.
control valve automatically at the same time
when performing the service brake, therefore, it Downhill Operation
is unnecessary to turn the shift control lever to
NEUTRAL position before braking. After
releasing the bake, the machine will return to the Select a proper speed before going down a hill.
gear automatically used before braking. Do not change gears during the downhill
process. Most of time, the speed for downhill
operation is the same.
Maintain a proper speed that is slow enough for
When the machine runs at high speed, do not the conditions. Use the service brake to control
rapidly depress the brake pedal unless an the travel speed. Using service brake when the
emergency occurs, so as to avoid accidents machine runs at a high speed may result an
and damage to the machine. overheating of the brakes and driving axle oil.
These will bring serious abrasion or damage to
When performing the service brake, two the brakes.
operating modes are available. One mode is
disconnect of the transmission power output, and Drive the machine reversely when going down a
the other is connect of the transmission power hill with a load. Drive forward when going up the
output. Both modes are controlled by the clutch hill.
cut-off switch.
In normal operation, turn on the clutch cut-off Operation during Cold Weather
switch to cut off the transmission power output
when braking in order to protect the transmission
and drive system, and improve the power use of
the engine and work efficiency of the work
implements. If the ambient temperature is too low, the
However, when the machine is in manual shift engine can't be started easily, and the
mode and running at 3rd or 4th speed, no matter radiator will be frozen.
which position the clutch cut-off switch is in, the
machine will not cut off the transmission power
1. Use fuel, hydraulic oil and lubrication with low
output when performing the service brake to
viscosity. Refer to section “Oil Specifications”
ensure safety.
for particular oil brands.
2. Add anti-freeze in coolant.
CLUTCH CUT-OFF

CLUTCH CUT-ON Keep antifreeze away from an open fire. Do

not smoke when adding antifreeze.
145
September 4, 2020 Operation Manual
CLG877H Operation Techniques

3. In severe cold areas, use anti-cold batteries. 1. Drive the machine at F2 speed to approach
As the ambient temperature drops, the materials. Align the bucket middle with the
electrolyte may be frozen. In order to prevent materials, lower the boom to transportation
battery capacity loss, cover the battery or position (about 500mm above the ground).
move it to a warm place and install it the next
2. At the distance of about 3' (one meter) from
day, then the engine can be started easily at
the material, lower the boom, let the bucket
the next day.
contact the ground and keep the bucket
4. Thoroughly clear sludge, water or frozen bottom parallel with the ground. At the same
snow from the machine to avoid them time, press lightly the KD key on the end of
entering into the seams and damaging shift control lever (or the KD key beside or on
sealing performance. the work implement control lever). Operate
the machine to change the speed of the
5. Park the machine on dry and hard ground. If
machine from F2 speed to F1 speed.
impossible, park the machine on wooden
boards. The wooden boards can prevent the
machine from being frozen.
6. After the weather turns warm, change fuel,
hydraulic oil and lubricant with half viscosity.
Refer to section “Oil Specifications” for
particular oil brands.

Machine Operation
Pilot-hydraulic control lever
Preparation before Operation

Before operation, first level the work site with this

machine. Remove bulges, fill in the pits and
shovel away the operational barriers on the wet
and slippery ground. Clean up large, sharp rocks
on the work site to avoid damaging the
machine's tires.
If this machine is used to load or unload a truck
or hopper, adjust the limit height of the boom lift
kickout according to the height of the truck or the
hopper to allow the bucket to go in and out of the Electro-hydraulic control lever
truck or hopper safely.
For information about how to use the work
implement control lever, refer to section “Wok
Implement Control Lever”.

Shoveling

1. Common Shoveling

Common shoveling is suitable for loading loose

materials.
146
Operation Manual September 4, 2020
Operation Techniques CLG877H

3. Repeat cutting in material and tilting the

bucket until the bucket is completely filled.

When the bucket touches the ground, too

much pressure to the ground should be
avoided, so as to avoid the unnecessary
resistance to go forward. Moreover, the front
and rear frames of the machine should be
aligned, and no included angle between
them.
3. Depress the accelerator pedal to force the
bucket to cut into the material with full power. 3. Retreating from the material
When the machine can't advance any more,
tilt the bucket backward, then release the 1. After the bucket is filled fully, tilt the bucket
work implement control lever back to the backward until the bucket block contacts the
NEUTRAL position. The machine will boom.
advance and continuously cut in the material. 2. Raise the boom to a certain height to keep
Repeat cut in material and tilting the bucket the machine away from the material when
until the bucket is completely filled. reversing. Then operate the machine
backward.
3. After the machine retreats from the material,
lower the boom to the transportation position.

Excavating With Bucket

1. Lower the bucket to the ground and position

for a slight digging angle.
2. Combination Shoveling

Combination shoveling is mainly used for hard

and viscous materials.
1. The operation of the cutting in the material
pile is the same as the common shoveling.
2. When the bucket can't advance after cutting
in the material, tilt the bucket upward, then
the bucket cuts in forward for some
distances. Then tilt the bucket backward so
as the bucket can continue to cut in the
material.
147
September 4, 2020 Operation Manual
CLG877H Operation Techniques

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

Never raise the bucket to a higher position

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

Dumping Operation

1. Dumping materials into a truck or hopper

1. Release the accelerator pedal to let the

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

Transportation of Materials

The machine can be used for transporting

material under the following conditions:
● When the ground is too soft or the ground is
not leveled, a truck can not be used.
148
Operation Manual September 4, 2020
Operation Techniques CLG877H

To ensure shoving safety, operate the work

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

Do not lower the boom when the bucket is at

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

Shoving Operation

Place the bucket on the ground, push the shift

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

The machine can be towed by a 40T trailer.

Operate as follows:
1. Secure the trailer firmly to the traction pin of
the towed machine.
2. The trailer should be equipped with a brake
system of strong brake ability.
149
September 4, 2020 Operation Manual
CLG877H Operation Techniques

3. Set the bucket to transportation position. 5. Then operate the auxiliary control lever to tilt
the side dump bucket and dump the
4. Start and stop the towed machine slowly.
materials.
Engage brake before going down a hill.

When braking, engage the brake of the trailer

first, then the towed machine.

Side Dump Operation

1. The shoveling operation of the side dump

bucket is the same as the general purpose
bucket. Refer to section “Shoveling” for more
information.

2. Depress the accelerator pedal and operate 6. After dumping, tilt the side dump bucket until
the shift control lever to transport the it reaches the positioning position.
material. Release the accelerator pedal to let 7. Then push the shift control lever to the
the machine approach the truck or hopper at REVERSE position so that the machine can
a low speed when the machine is at a leave the truck or hopper reversely. After the
distance of 15 meters from the truck or machine leaves the truck or hopper, the
hopper with a full load. driver could drive the machine with lowering
3. Let the boom raise to its limit position, the the boom for next operation.
boom will not raise up any more once it
reaches its limitation.
4. Depress the brake pedal to stop the
machine.
150
Operation Manual September 4, 2020
Operation Techniques CLG877H

Snow Plowing Operation 2. Tilt the snow plow device forward to let the
ground bear the pressure of the snow plow
moldboard and the spring.

Side slip may occur due to side force during

fast operation. Pay attention to adjust the
travel direction.
Avoid moldboard tilting back and boom
lifting as possible as you can during
operation.
Turn the boom control lever to FLOAT
position during operaion.
This device is only used for plowing snow.
Do not use it for dozing or other operation. 3. Remove the pin and the bolt to release the
function of the mechanism. Readjust the
Seal rings are used for important pins to snow plow device to level state.
prevent dust. Grease them before and after
operation.

1. Operate the boom and the snow plow 2

moldboard slowly by the work implement
control lever to let the supporting plate of the
adjusting device contact the ground. Keep
the whole snow plow device in level state.
Avoid additional torque appplying to the
supporting plate which is caused by the
boom and the snow plow moldboard.

1
1. Adjusting device 2. Bolt
3. Pin
151
September 4, 2020 Operation Manual
CLG877H Operation Techniques

4. Raise or lower the snow plow device by 6. Turn the bucket control lever to NEUTRAL
rotating the adjusting rod of the adjusting position and the boom control lever to FLOAT
device. The snow plow blade should be position, then this device is in operation state.
10mm off the ground. Readjust the clearance
between the snow plow blade and the ground
according to the road and the snow condition
during operation. Tighten the bolt after
finishing adjusting.

7. After finishing operation, install the pin and

the bolt to protect the snow plow device,
which is convenient for transportation.

2
5

3
4. Adjusting rod
5. Bolt
5. Operate the hydraulic oil cylinder of the snow
plow device, choose suitable travel angle
according to snow thickness and
compactness degree. Adjust it as required
during operation.

2. Bolt
3. Pin
152
Operation Manual September 4, 2020
Operation Techniques CLG877H

8. Adjust the adjusting rod to ensure that the 2. Close the top clamp and tilt the fork back to
supporting plate contacts the ground. hold the load against the fork uprights.
Operate the snow plow moldboard off the
ground to avoid malfunction of the spring due
to strong tension.

3. For best operator vision and loader stability,

carry the load as low as possible.

4. Depress the brake pedal to stop the

machine, position the load over the stacking
area. Tilt the fork down and raise the clamp
to release the load.
4. Adjusting rod
5. Bolt

Log Fork with Top Clamp

1. Drive the machine at F2 speed to approach

materials. Position the fork in the center of
the load, with the top clamp open.
153
September 4, 2020 Operation Manual
CLG877H Operation Techniques

Operation Method 1. As shown below, after loading, the machine

returns to a distance of 2~3 times the truck
1. V Type operation method width. Then the truck runs to the front of the
machine from one side and stops. The
machine moves forwards and lifts the boom.
After dumping, the machine returns to the
original position.

1. As shown in the above figure, maintain 60° 2. If the truck is not completely filled with
angle between the machine and the truck. materials, drive the truck forward for one
Stop the machine at 12~15m away from the position. After the machine performs the
truck. second loading, it will return to the original
2. After the machine is loaded fully, drive the position. Then the truck returns to the front of
machine to 12~15m from the material, then the machine for dumping.
run the machine towards to the truck with 3. Repeat the operation until the truck is filled
bucket lifted while it is turning. After dumping, with material. The machine then goes on
return the machine to the original position for loading the next truck.
next loading.
4. This operation requires skillful cooperation
2. Shuttle operation method between the machine and the truck drivers.
They communicate with each other by using
The shuttle operation is mainly used for the the horn, lights, or hand signals.
combination operation of the machine with a
truck team.
154
Operation Manual September 4, 2020
Operation Techniques CLG877H

Parking Lowering the Work Implement with

Engine Stopped
Stopping the Machine Make sure that no pesonnel is around the
machine before lowering the implement.
1. Park the machine on flat ground. If it is
needed to park the machine on a slope, 1. Turn the engine start switch to ON position.
place a wedge under the wheels to stop it 2. Push the pilot cut-off lever to ON position (If
from moving. equipped). If the machine is equipped with a
hydraulic lock switch, press it to UNLOCK
position.
Pilot cut-off lever is at ON position

2. Use the service brake to stop the machine.

3. Turn the shift control lever to NEUTRAL Hydraulic lock switch
position.
4. Pull up the parking brake button (or parking
brake handle).
UNLOCK
5. Lowering all the implements to the ground
and press the bucket downwards slightly.

Turning off the Engine LOCK

3. Push the work implement control lever to

Do not turn off the engine when the machine LOWER position to lower the implement.
is working with a load. Otherwise, the This lever can return to HOLD position
engine parts will be worn quickly due to automatically after being released.
overheating. 4. Push the pilot cut-off lever to OFF position (If
equipped). If the machine is equipped with a
1. Let the engine run at idle speed for 5min to hydraulic lock switch, press it to LOCK
cool down the parts. position.
2. Turn the start switch of the engine to OFF 5. Turn the engine start switch to OFF position.
position and take out the key.
Leaving the Machine
3. Turn all the switches to NEUTRAL or OFF
position.
1. Close the left and right doors and lock them.
155
September 4, 2020 Operation Manual
CLG877H Operation Techniques

2. Use the ladder and the handrail when you get 5. If the air temperature is below 0°C, add anti-
off the machine. Face the machine and use freeze in cooling water of the engine until it
both hands. Make sure that the steps are reaches the engine body and evaporator of
clear of debris before you dismounting. the air conditioner. Drain out water in the
cooling system, also drain out water in the
3. Inspect the engine compartment for debris.
evaporator of the air conditioner.
Clean out any debris and paper in order to
avoid a fire.
During Storage
4. Remove all flammable debris in order to
reduce a fire hazard. Dispose all debris 1. Start the machine once every month and run
properly. every system, and lubricate every parts of the
5. Turn the battery disconnect switch to the “O” moving pins and shafts. Meanwhile, charge
position. the batteries.

6. If the machine is not filled with anti-freeze, 2. Before starting the machine, wipe off grease
after the machine parks in winter, open all from the hydraulic oil cylinder piston rod.
water drain valves of the engine in time to After operation, paint a layer of grease on it.
discharge coolant in the cooling system and 3. Paint antirust additive on rusted parts.
air conditioner system so as to prevent the
machine from being cracked by frost. If the
machine has been filled with anti-freeze at
ex-factory, refer to the instructions of the anti-
freeze labels. To avoid personal injury or death, when
working with anti-freeze inside the room,
7. Fix all covers, lock all equipment and remove open the windows for ventilation.
the key.
Before Reuse
Storage
1. Change lubricant of the engine, transmission,
axles lubrication and hydraulic oil, brake oil
Before Storage and anti-freeze of the engine.
1. Clean and dry every part of the machine and 2. Lubricate all moving pins and shafts.
store it in a dry warehouse. If the machine 3. Before starting the machine, wipe off grease
has to be stored in the open air, park the from the hydraulic oil cylinder piston rod.
machine on concrete ground and cover with
canvas.
2. Before storage, refill the oil tank, lubricate
every moving pin & shaft and change If the machine is not coated with antirust
hydraulic oil. additive per month during storage, consult
3. Paint a thin layer of grease on the exposed your LiuGong dealer.
parts of the hydraulic oil cylinder piston rod.
4. For the machine equipped with ZF wet-type
4. Remove batteries from the machine and axle (MT-L3105/3115/3125), in order to
store in a separate place. ensure the service performance of the
machine, when the machine is not used for a
long time (more than 4 months), the following
operations should be carried out:
156
Operation Manual September 4, 2020
Transportation Information CLG877H

a) Run the engine for 10 minutes in the first Perform loading according to the following
gear (less than 5km/h). steps:
b) Run the engine for two minutes in the
1. Chock the trailer wheels or the truck wheels
second gear.
before you load the machine.
c) Run the engine for two minutes in the
third gear.
d) Run the engine for two minutes in the 4th
gear.
If there is oil leakage at wheel edges during
the run-in stage, wipe the oil after one cycle
of run-in, and carry out the second run-in
after one day’s standing of the machine.

2. When the machine is loading on the trailer or

Transportation Information truck, it is forbidden to turn.
3. After the machine being parked, use the
steering frame lock to lock the front frame
Transportation of the Machine and the rear frame.

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.
4. Lower the bucket to the floor of the trailer.
Clean ice, snow, or other slippery material from Turn the shift control lever to the NEUTRAL
the loading dock and from the truck bed before position.
you load the machine onto the transport
machine. This will prevent the machine from
slipping in transit. This will also prevent the
machine from moving during transportation.
157
September 4, 2020 Operation Manual
CLG877H Transportation Information

5. Push the pilot cut-off lever to the OFF 11. Cover the exhaust outlet to prevent the
position (if equipped). If the machine is turbocharger from rotating during
equipped with a hydraulic lock switch, press it transportation. Damage to the turbocharger
to LOCK position. can result.
Pilot cut-off lever is at OFF position
Driving the Machine

1. Before operating the machine, consult your

tire dealer for recommended tire pressure
and speed limitations.
2. Stop for 30 minutes after every 40km or after
every hour when driving the machine for a
long distance in order to cool down the tires.
Hydraulic lock switch
3. Inflate the tires to the correct pressure. Refer
to the maintenance section for tire inflation
information.
UNLOCK
4. Travel at a moderate speed. Observe all
speed limitations when you drive the
machine.

LOCK
Lifting the Machine

6. Engage the parking brake.

7. Stop the engine, turn every switch to
NEUTRAL or OFF position and remove the
Use suitable lifting device and shackles when
key.
lifting a machine to avoid damage or falling of
8. Lock the door and remove the key. the machine. Improper lifting or securing
could cause the machine to move
9. Turn the battery disconnect switch to the
accidentally and cause machine damage,
OFF position.
personnel injury or death. Install the steering
10. Chock the wheels of the machine and fasten frame lock before lifting.
it with steel wires or chains to avoid
movement during transportation.
1. Lift the machine by professional personnel.
2. Calculate the maximum lift weight of the
crane and loading capacity of the lifting
device to ensure the lift safety.
158
Operation Manual September 4, 2020
Transportation Information CLG877H

3. Lift the machine by the lifting device with 7. Before lifting, secure the front and rear frame
frame to avoid damaging the machine. The with the steering frame lock so that the
length and width of the frame are 4m and machine can not move.
2.2m. The 8t D type or bow shackle will be
preferred (reference standard: JB8112-
1999).

8. The lifting device should be fixed on the lift

eyes with lift decals on the machine.

4. The length of the four ropes on the lifting Towing Information

device must be the same to ensure the four
lifting eyes share the same pressure.
Towing the Machine
5. Turn the battery disconnect switch to OFF
position.
6. The lifting decal can be seen on the front and
rear frame of the machine.
Personal injury or death could result when
towing a disabled machine incorrectly. Chock
the wheels before disengage the brake to
prevent the machine from moving.

Do not tow the machine unless the loader has a

severe trouble. The machine can only be towed
for a short distance for repair. Never tow the
machine for a long distance. The towing distance
should not exceed 10Km and towing speed
should not exceed 10km/h; otherwise, the gear
box will be damaged due to insufficient
lubrication. If the machine needs to be
transported for a long distance, a truck and trailer
should be used.
159
September 4, 2020 Operation Manual
CLG877H Transportation Information

Do the following steps: 5. Do not use a chain for pulling. A chain link
may break. This can cause personal injury.
1. Spring brake and hydraulic release are used Use a wire rope that has cable loops or end
for machine parking brake. If the machine rings. Position an observer at a safe location.
doesn’t move due to machine brakes caused The observer should stop the pulling
by an engine fault or a brake system fault. procedure if the cable starts to break or the
Remove the connecting shaft between the cable starts to loose. If the towing machine
parking brake cylinder and the parking brake moves without the pulled machine, stop the
rod to disengage the parking brake by force. pulling procedure.
6. The minimum angle between the towing
ropes and straight direction should not
exceed 30°.
7. Quick machine movement could cause the
towing ropes or the towing bar overload. This
could cause the towing ropes or the towing
bar to break. A smooth machine movement
helps towing operation easier.
8. Normally, the towing machine should be as
large as the disabled machine. The towing
machine must have enough brake capacity,
weight, and power for the grade and distance
that is involved.
Before releasing the parking brake, chock the 9. During towing, all personnel should keep
wheel to prevent movement. Remove the away from the both sides of the towing ropes
wedge before starting the machine. so as to avoid injury caused by break.

2. The towing machine should be equipped with 10. It may be necessary to connect a large
protective guard to protect the towing machine or additional machine to the
operator once the towing ropes or towing bar disabled machine in order to provide
cracks accidentally. sufficient control and brake ability. This will
prevent the disabled machine from rolling
3. Do not allow riders on the machine that is away on a downgrade.
being towed unless the operator can control
the steering wheel or the brake. 11. When towing the disabled machine downhill,
to get enough control and brake ability, it is
4. Before you towing the machine, make sure necessary to connect a larger truck or
that the towing ropes or the towing bar are additional machine on the back to avoid a
strong enough for towing the machine. The rolling accident.
towing ropes or towing bar must have a
strength that is 1.5 times of the gross weight It is impossible to list all the requirements for all
of the machine that is being towed. different situations. Refer to LiuGong dealer for
more information of towing the disabled
machine.
160
Operation Manual September 4, 2020
Transportation Information CLG877H

Towing with a Running Engine Engine Fault Diagnosis

If the engine is running, the machine can be
towed for a short distance under certain The engine fault code can show by two ways:
conditions. The power train and the steering Through the LCD screen or the stop indicator.
system must be operable. Tow the machine for a
short distance only. For example, pull the 1. LCD screen
machine out of mud or to the side of the road.
When SERV. CODE illuminates, the engine fault
The operator on the towed machine must turn code will be shown through the LCD screen.
the machine in the direction of the towing ropes. E.g:1308.
Turn the shift control lever to NEUTRAL position,
lift all implements and strictly observe all the
instructions that are outlined in this topic.

2. Stop indicator

The flash mode of diagnostic codes is available

through the diagnostic ON/OFF switch or
accelerator pedal:
1. Enter the flash mode of diagnostic code
through the diagnostic ON/OFF switch.
Turn the start switch to I position and stop the
engine. The stop indicator will flash the first fault
code automatically after turning the diagnostic
ON/OFF switch to ON position.

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

Engine Variable
Geometry VGT Actuator Driver Circuit -
1894 641 9 Amber X X X
Turbocharger Abnormal update rate
Actuator #1
Engine Exhaust
Gas Recirculation 1 EGR Valve Controller - Out of
1896 2791 13 Amber X X X
(EGR1) Valve Calibration
Control
Engine Variable
Geometry VGT Actuator Controller - Out
1898 641 13 Amber X X X
Turbocharger of Calibration
Actuator #1
Aftertreatment Diesel
Aftertreatment 1 X X
Particulate Filter Differential
Diesel Particulate DOC/ DOC/
1921 3251 16 Amber Pressure - Data Valid But X
Filter Differential DPF+ DPF+
Above Normal Operating
Pressure SCR SCR
Range
Aftertreatment 1 Aftertreatment Diesel X X
Diesel Particulate Particulate Filter Differential DOC/ DOC/
1922 3251 0 Red X
Filter Differential Pressure - Data valid but above DPF+ DPF+
Pressure normal Operating Range SCR SCR
Aftertreatment Fuel Shutoff
Aftertreatment 1
Valve Circuit - Voltage above
1923 3482 3 Amber Fuel Enable X
normal, or shorted to high
Actuator
source
Aftertreatment Fuel Shutoff
Aftertreatment 1
Valve Circuit - Voltage below
1924 3482 4 Amber Fuel Enable X
normal, or shorted to low
Actuator
source
Aftertreatment 1 Aftertreatment Fuel Shutoff
1925 3482 2 Amber Fuel Enable Valve - Data erratic, intermittent X
Actuator or incorrect
Aftertreatment Fuel Pressure
Aftertreatment Fuel
1926 3480 2 Amber Sensor - Data erratic, X
Pressure
intermittent or incorrect
Aftertreatment Fuel Pressure
Aftertreatment Fuel Sensor Circuit - Voltage above
1927 3480 3 Amber X
Pressure normal, or shorted to high
source
Aftertreatment Fuel Pressure
Aftertreatment Fuel Sensor Circuit - Voltage below
1928 3480 4 Amber X
Pressure normal, or shorted to low
source
Aftertreatment Aftertreatment Doser - Data
1932 3556 2 Amber X
Hydrocarbon Doser erratic, intermittent or incorrect
180
Operation Manual September 4, 2020
Transportation Information CLG877H

FAULT CODE INDEX FOR ENGINE

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

ECU Power Output Supply

ECU Power Output Voltage 1 - Data Valid But
1938 3597 18 Amber X X X X
Supply Voltage #1 Below Normal Operating Range
- Moderately Severe Level
ECU Power Output Supply
ECU Power Output Voltage 1 - Voltage above
1939 3597 3 Amber X
Supply Voltage #1 normal, or shorted to high
source
ECU Power Output Supply
ECU Power Output Voltage 1 - Voltage below
1941 3597 4 Amber
Supply Voltage #1 normal, or shorted to low
source
Engine Crankcase Crankcase Pressure - Data
1942 101 2 Amber X X X X
Pressure erratic, intermittent or incorrect
Ambient Air Density - Data
Valid But Below Normal
1943 3555 17 None Ambient Air Density X
Operating Range - Least
Severe Level
Engine Exhaust EGR Valve Control Circuit Over
Gas Recirculation 1 Temperature - Data Valid But
1961 2791 15 Amber X X X
(EGR1) Valve Above Normal Operating
Control Range - Least Severe Level
VGT Actuator Driver Over
Engine Variable
Temperature (Calculated) -
Geometry
1962 641 15 Amber Data Valid But Above Normal X X X
Turbocharger
Operating Range - Least
Actuator #1
Severe Level
Aftertreatment 1 Aftertreatment Fuel Shutoff
1963 3482 7 Amber Fuel Enable Valve - Mechanical system not X
Actuator responding or out of adjustment
Aftertreatment Doser -
Aftertreatment
1964 3556 7 Amber Mechanical system not X
Hydrocarbon Doser
responding or out of adjustment
Crankcase Pressure - Data
Amber
Engine Crankcase Valid But Above Normal
1974 101 15 (Blinki X X X X
Pressure Operating Range - Least
ng)
Severe Level
VGT Actuator Driver Over
Engine Variable
Temperature (Calculated) -
Geometry
1976 641 15 None Data Valid But Above Normal X X X X
Turbocharger
Operating Range - Least
Actuator #1
Severe Level
Aftertreatment Doser Circuit -
Aftertreatment
1977 3556 5 Amber Current below normal or open X
Hydrocarbon Doser
circuit.
181
September 4, 2020 Operation Manual
CLG877H Transportation Information

FAULT CODE INDEX FOR ENGINE

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

Aftertreatment 1 Diesel X X
Aftertreatment
Particulate Filter System - Data DOC/ DOC/
1981 3936 15 Amber Diesel Particulate X
Valid But Above Normal DPF+ DPF+
Filter System
Operating Range - Level SCR SCR
Engine Crankshaft Speed/
Position - Data Valid But Above
1992 190 16 Red Engine Speed
Normal Operating Range -
Moderately Severe Level
X X
Aftertreatment 1 Aftertreatment 1 Diesel
DOC/ DOC/
1993 4795 31 Amber Diesel Particulate Particulate Filter Missing - X
DPF+ DPF+
Filter Missing Condition Exists
SCR SCR
Engine Engine Brake Actuator Driver 1
2182 1072 3 Amber (Compression) Circuit - Voltage above normal, X X
Brake Output #1 or shorted to high source
Engine Engine Brake Actuator Driver 1
2183 1072 4 Amber (Compression) Circuit - Voltage below normal, X X
Brake Output #1 or shorted to low source
Sensor Supply 4 Circuit -
Sensor supply
2185 3512 3 Amber Voltage above normal, or X X X X
voltage 4
shorted to high source
Sensor Supply 4 Circuit -
Sensor supply
2186 3512 4 Amber Voltage below normal, or X X X X
voltage 4
shorted to low source
Engine Variable
Geometry VGT Actuator Driver Circuit -
2198 641 11 Amber X X X
Turbocharger Root Cause Not Known
Actuator #1
Fuel Pump Delivery Pressure -
Engine Fuel Data Valid But Below Normal
2215 94 18 Amber
Delivery Pressure Operating Range - Moderately
Severe Level
Injector Metering Rail 1
Engine Injector
Pressure - Data valid but below
2249 157 1 Amber Metering Rail 1
normal operational range - Most
Pressure
Severe Level
Fuel Pump Delivery Pressure -
Amber
Engine Fuel Data Valid But Above Normal
2261 94 15 (Blinki
Delivery Pressure Operating Range - Least
ng)
Severe Level
Fuel Pump Delivery Pressure -
Amber
Engine Fuel Data Valid But Below Normal
2262 94 17 (Blinki
Delivery Pressure Operating Range - Least
ng)
Severe Level
182
Operation Manual September 4, 2020
Transportation Information CLG877H

FAULT CODE INDEX FOR ENGINE

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

Battery Temperature - Data

Battery 1 Valid But Above Normal
2263 1800 16 Amber
Temperature Operating Range - Moderately
Severe Level
Battery Temperature - Data
Battery 1 Valid But Below Normal
2264 1800 18 Amber
Temperature Operating Range - Moderately
Severe Level
Electric Lift Pump for Engine
Engine Electric Lift
Fuel Supply Circuit - Voltage
2265 1075 3 Amber Pump for Engine X X
above normal, or shorted to
Fuel Supply
high source
Electric Lift Pump for Engine
Engine Electric Lift
Fuel Supply Circuit - Voltage
2266 1075 4 Amber Pump for Engine X X
below normal, or shorted to low
Fuel Supply
source
Engine Exhaust EGR Valve Position Circuit -
2272 27 4 Amber Gas Recirculation 1 Voltage below normal, or X X X
Valve Position shorted to low source
Engine Exhaust Exhaust Gas Recirculation
Gas Recirculation 1 Differential Pressure Sensor
2273 411 3 Amber X X X
Differential Circuit - Voltage above normal,
Pressure or shorted to high source
Engine Exhaust Exhaust Gas Recirculation
Gas Recirculation 1 Differential Pressure Sensor
2274 411 4 Amber X X X
Differential Circuit - Voltage below normal,
Pressure or shorted to low source
Turbocharger 1 Speed - Data
Engine
Valid But Above Normal
2288 103 15 None Turbocharger 1 X X X
Operating Range - Least
Speed
Severe Level
Engine Fuel Electronic Fuel Injection
2311 633 31 Amber Actuator 1 Control Control Valve Circuit - X X X X
Command Condition Exists
Engine Crankshaft Speed/
2321 190 2 None Engine Speed Position - Data erratic, X X X X
intermittent or incorrect
Engine Camshaft Speed /
2322 723 2 None Engine Speed 2 Position Sensor - Data erratic, X X X X
intermittent or incorrect
Engine Turbocharger Turbine Intake
Turbocharger 1 Temperature - Data Valid But
2346 2789 15 None X X X X
Calculated Turbine Above Normal Operating
Intake Temperature Range - Least Severe
183
September 4, 2020 Operation Manual
CLG877H Transportation Information

FAULT CODE INDEX FOR ENGINE

FAULT CODE INDEX FOR ENGINE

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

Aftertreatment 1 Diesel
Aftertreatment 1 X X
Particulate Filter Intake
Diesel Particulate DOC/ DOC/
3317 3242 3 Amber Temperature Sensor Circuit - X
Filter Intake Gas DPF+ DPF+
Voltage above normal, or
Temperature SCR SCR
shorted to high source
Aftertreatment 1 Aftertreatment 1 Diesel X X
Diesel Particulate Particulate Filter Intake DOC/ DOC/
3318 3242 2 Amber X
Filter Intake Gas Temperature - Data erratic, DPF+ DPF+
Temperature intermittent or incorrect SCR SCR
Aftertreatment 1 Diesel
Aftertreatment 1 X X
Particulate Filter Outlet
Diesel Particulate DOC/ DOC/
3319 3246 3 Amber Temperature Sensor Circuit - X
Filter Outlet Gas DPF+ DPF+
Voltage above normal, or
Temperature SCR SCR
shorted to high source
Aftertreatment 1 Diesel
Aftertreatment 1 X X
Particulate Filter Outlet
Diesel Particulate DOC/ DOC/
3321 3246 4 Amber Temperature Sensor Circuit - X
Filter Outlet Gas DPF+ DPF+
Voltage below normal, or
Temperature SCR SCR
shorted to low source
X X
Aftertreatment 1 Aftertreatment 1 Diesel
DOC/ DOC/
Diesel Particulate Particulate Filter Outlet
3322 3246 2 Amber DPF DPF X
Filter Outlet Gas Temperature - Data erratic,
+ +
Temperature intermittent or incorrect
SCR SCR
Aftertreatment Aftertreatment 1 Diesel
Diesel Oxidation Oxidation Catalyst Intake
3325 4765 13 Amber
Catalyst Intake Temperature Swapped - Out of
Temperature Calibration
SAE J1939 Multiplexed
Accelerator Pedal Accelerator Pedal or Lever
3326 91 9 Red X X X X
Position 1 Sensor System - Abnormal
update rate
Transmission Transmission Output Shaft
3328 191 9 Amber X X X
Output Shaft Speed Speed - Abnormal update rate
J1939 Network #2 - Data
3329 1231 2 None J1939 Network #2 X X X X
erratic, intermittent or incorrect
J1939 Network #3 - Data
3331 1235 2 None J1939 Network #3 X X X X
erratic, intermittent or incorrect
Engine Idle Fuel Quantity -
Engine Idle Fuel Data Valid But Above Normal
3337 5395 16 Amber
Quantity Operating Range - Moderately
Severe Level
Engine Idle Fuel Quantity -
Engine Idle Fuel Data Valid But Below Normal
3338 5395 18 Amber
Quantity Operating Range - Moderately
Severe Level
195
September 4, 2020 Operation Manual
CLG877H Transportation Information

FAULT CODE INDEX FOR ENGINE

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

Engine Air Filter Differential

Pressure - Data Valid But
Engine Air Filter 1
3341 107 16 Amber Above Normal Operating X X X X
Differential Pressure
Range - Moderately Severe
Level
Engine Turbocharger 1 Compressor
Turbocharger 1 Intake Pressure - Data valid but
3348 1176 1 Red
Compressor Intake below normal operational range
Pressure - Most Severe Level
Engine Intake
Intake Manifold 1 Pressure -
3361 102 10 Amber Manifold #1
Abnormal rate of change
Pressure
Coolant Level - Data Valid But
Engine Coolant
3366 111 18 None Below Normal Operating Range
Level
- Moderately Severe Level
Specific Humidity Sensor -
3367 4490 9 Amber Specific Humidity
Abnormal update rate
Specific Humidity Sensor -
3368 4490 19 Amber Specific Humidity X
Received Network Data In Error
Engine
Turbocharger 1 Compressor
Turbocharger 1
3369 1172 9 Amber Intake Temperature Sensor -
Compressor Intake
Abnormal update rate
Temperature
Engine
Turbocharger 1 Compressor
Turbocharger 1
3371 1172 19 Amber Intake Temperature Sensor -
Compressor Intake
Received Network Data In Error
Temperature
Engine
Turbocharger 1 Compressor
Turbocharger 1
3372 1176 9 Amber Intake Pressure - Abnormal
Compressor Intake
update rate
Pressure
Engine
Turbocharger 1 Compressor
Turbocharger 1
3373 1176 19 Amber Intake Pressure - Received
Compressor Intake
Network Data In Error
Pressure
Roll Over Protection Brake
ROP Brake Control
3374 1818 31 None Control Active - Condition
active
Exists
X X
Aftertreatment 1
Aftertreatment Diesel DOC/ DOC/
Diesel Particulate
3375 5397 31 Amber Particulate Filter Regeneration DPF DPF X
Filter Regeneration
too Frequent - Condition Exists + +
too Frequent
SCR SCR
196
Operation Manual September 4, 2020
Transportation Information CLG877H

FAULT CODE INDEX FOR ENGINE

FAULT CODE INDEX FOR ENGINE

QSB6.7

QSB4.5

QSG12
Fault J1939 J1939 J1939_SPN

QSL9
Lamp Cummins_Description
Code _SPN _FMI Description

Aftertreatment 1
Fluid Quality - Data Valid But
6752 3364 18 None Diesel Exhaust X X X X
Below Normal Operating Range
Fluid Tank 1 Quality
- Moderately Severe Level
Reserved for temporary use -
9491 524286 31 Amber X
Condition Exists
Reserved for temporary use -
9999 524286 31 Amber X
Condition Exists
224
Maintenance Manual September 4, 2020
Maintenance Guidance CLG877H

Maintenance Manual Maintenance Suggestions

1. Use only recommended fuels and lubricants.

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

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

Learn how to maintain your machine correctly. Clean Engine Oil

Follow the instructions of this manual, if your
machine has troubles, you must maintain or Use clean engine oil and keep the engine oil
contact your dealer before operating. clean. Ensure no foreign matter mixes with the
engine oil.
Daily Checks
Check Discharged Oil or Used Filter Element
1. Check the gauges.
After replacing the oil or filter element, check the
2. Check the coolant, fuel and oil level.
discharged oil or filter element for iron particles
3. Check hoses and tubes for leakage, wear and foreign matter. If any iron particles or foreign
conditions and damage. matter is found, report this immediately and take
preventive measures.
4. Perform a walk-around inspection of the
machine.
Welding Cautions
5. Check for loose or missing parts.
1. Turn off the engine.
Check Service Hour Meter
2. Do not keep using voltage above 200V.
1. The service hour meter determines when 3. Keep the welding area and earth cables
your machine needs to be maintained. The within 1m. If the earth cable is close to
time in the maintenance table is basically gauges or connectors, failure could result.
given for normal operation. If the machine is
4. Protect the seals and bearings located
operated in severe conditions, you must
between the welding area and earth cables.
maintain the machine more frequently.
5. Never use the surrounding area of the work
Maintain Machine on Schedule implement pin or cylinder as an earthing
point.
Follow the maintenance methods listed in this
maintenance manual.
225
September 4, 2020 Maintenance Manual
CLG877H Maintenance Guidance

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

Dusty Environment

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

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

Install Hydraulic Hoses

1. If components equipped with O-rings or Before starting the engine, make sure
gaskests need to be removed, clean the nobody is on or near the machine. Keep the
mounting surfaces. Do not forget to install machine controlled by the operator.
new O-rings and gaskets.
226
Maintenance Manual September 4, 2020
Run-in CLG877H

Preparation before Maintenance Run-in

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

5. It is better to load with loose material during

AR
W

er not
!

run-in period. Do not operate rushly and

e
at
do

exceed its rating load capacity and travel

speed by 70%.
r:
te
ra
pe
O

:
ate
D

6. Check the lubricant periodically. Replace or

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

The following must be done after the first 8

hours of operation during the run-in period.

1. Check the tightness of all the bolts and nuts

especially the bolts of the engine cylinder
cover, exhaust pipe, front and rear axles,
drive shaft, diesel engine, transmission, front
and rear frames joint, and wheel rim nuts etc.
227
September 4, 2020 Maintenance Manual
CLG877H Maintenance Interval Schedule

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

belt and air conditioner compressor belt.
Schedule
3. Check the oil level of the transmission, drive
axle and diesel engine.
4. Check the hydraulic system and brake
system for oil leakage.
5. Check the connections of all control levers, Read and understand all the safety
throttle linkage (if equipped) and flexible instructions, warnings and indications before
shaft. any operations or maintenance.
6. Check temperatures and connections of the
electrical system, power supply of the The maintenance intervals stated in this manual
alternator, lights and the turn signal lights. are determined according to the service hour
meter or calendar intervals shown (daily, weekly,
monthly, etc). Liugong recommends that
maintenance should be performed according to
Check oil level according to the relevant whichever of the above-mentioned intervals
operation regulations. occurs first.
Under extremely severe, dusty or wet operating
Work should be done after the finish of run-in conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart
1. Check the tightness of all the bolts and nuts may be necessary.
especially the bolts of the cylinder head, Perform service on items at multiples of the
exhaust pipe, front and rear axles, drive original requirement. For example, at every 500
shaft, diesel engine, transmission, front and service hours or 3 months, also service those
rear frames joint, and wheel rim nuts etc.. items listed under every 250 service hours or
2. Check the tightness of the fan belt, engine monthly, every 50 service hours or weekly and
belt and air conditioner compressor belt. every 10 service hours or daily.
3. Check the hydraulic system and brake Every 10 Service Hours or Every Day
system for oil leakage.
4. Replace the transmission oil and axle 1. Check engine oil level.
lubricant. 2. Check coolant level.
5. Replace the secondary filter and clean the 3. Check hydraulic oil level.
primary filter of the transmission.
4. Check fuel level.
6. Clean the return oil filter element of the
hydraulic oil tank. 5. Drain any water and impurity from the fuel
pre-filter and filter of the engine.
6. Daily inspection.
7. Check the engine fan and belt.
Replace transmission oil, axle lubricant and
secondary filter of the transmission 8. Check working condition of lights and
according to operation instructions. gauges.
9. Check the appearance and damage of the
tires.
228
Maintenance Manual September 4, 2020
Maintenance Interval Schedule CLG877H

10. Check the working condition of the backup 4. Replace gear oil of the axles after the first
alarm. 100 service hours, replace once every 1000
service hours later on. If the operating hours
Every 50 Service Hours or Every Week are less than 1000 hours a year, replace the
gear oil of the axles at least once every year.
In addition to all previous service checks:
5. Clean the radiator groups (suitable for Tier 4
1. Check the transmission oil level. machines).
2. At the first 50 service hours, check the 6. Clean the filter strainer of the fuel tank.
clearance between the parking brake shoe
7. Check nitrogen precharge pressure of the
and brake drum, adjust it if necessary; check
accumulators at the first 100 service hours.
the wear condition of the friction disc, replace
it if it has been worn away. Check once every
Every 250 Service Hours or Every Month
250 service hours later on.
3. For the machine equipped with air In addition to all previous service checks:
conditioner, clean the dust and sundries from
1. Check battery voltage.
the cab recirculating air strainer and fresh air
strainer. Wash them if it is necessary. Check 2. Check the tightening torque of the
the compressor belt for tightness and check transmission and engine mounting bolts.
the condenser for grease, dirt and sundries.
3. Check the work implement, and each stress
4. Check the lubrication condition of the weld and mounting bolt of the front & rear
lubricating points and lubricate every frames for cracks and looseness.
lubricating point according to lubrication
4. Check the engine air intake system, air filter
diagram on the machine. If the machine is
service indicator or air filter alert indicator (if
equipped with central lubrication system, for
equipped). If the yellow piston of the service
those manual lubricating points, pump
indicator rises to red area or the alert
grease by hand according to the lubrication
indicator blinks, clean or replace the air filter
diagram on the machine.
element.
5. Check nitrogen precharge pressure of the
5. Replace the coolant filter.
accumulators at the first 50 service hours.
6. Check tension and wear conditions of the
Every 100 Service Hours or Two Weeks engine belt and air conditioner compressor
belts.
In addition to all previous service checks: 7. Check the service brake ability and parking
1. Lubricate every drive shaft according to brake ability.
lubrication diagram on the machine. 8. Check the clearance between the parking
2. Tighten all connecting bolts on drive shafts at brake shoe and brake drum, adjust it if
the first 100 service hours, tighten them necessary; check the wear condition of the
every 2000 service hours later on. friction disc, replace it if it has been worn
away.
3. Replace transmission oil, the filter element
and seal ring of transmission oil filter, and 9. Check nitrogen precharge pressure of the
clean the primary filter in the transmission oil accumulators at the first 250 service hours.
sump at the first 100 service hours, and 10. Check the oil level of the front and rear axles.
doing once every 1000 service hours later
on. If the operating hours are less than 1000
hours a year, replace the transmission oil at
least once every year.
229
September 4, 2020 Maintenance Manual
CLG877H Maintenance Interval Schedule

Every 500 Service Hours or Three Months 5. Tighten all mounting bolts of the battery and
clean the battery surface.
In addition to all previous service checks:
6. Check nitrogen precharge pressure of the
1. Check the density of anti-freeze and coolant accumulators at the first 1000 service hours.
additives.
7. For the machine equipped with air
2. Tighten connecting bolts of the front & rear conditioner, replace the fresh air strainer of
axles and front & rear frames. the cab.
3. Check bolts on the articulation joint of the 8. Clean the AdBlue tank.
frame for loose condition.
9. Clean the radiator groups (suitable for Stage
4. Check nitrogen precharge pressure of the V machines).
accumulators at the first 500 service hours.
Every 1500 Service Hours or Nine Months
5. Replce the breather filter element of
hydraulic oil tank.
In addition to all previous service checks:
6. Replace the return oil filter element of the
1. Replace the return oil filter element of the
hydraulic system at the first 500 service
hydraulic system.
hours. Replace the return oil filter element of
the hydraulic system once every 1500 2. Replace the pilot oil filter element of the
service hours later on. hydraulic system.
7. Replace the pilot oil filter element of the
Every 2000 Service Hours or Every Year
hydraulic system at the first 500 service
hours. Replace the pilot oil filter element of
In addition to all previous service checks:
the hydraulic system once every 1500
service hours later on. 1. Replace coolant, coolant filter and clean the
cooling system. If the operating hours are
8. Replace the fuel pre-filter (the fuel /water
less than specified, replace the coolant at
separator) and fuel filter on the engine.
least every two years.
9. Replace the engine oil and engine oil filter.
2. Replace hydraulic oil, clean the hydraulic oil
Use higher grade engine oil can prolong the
tank and check the oil suction hose.
service hour of engine oil, contact LiuGong or
engine manufacturer for details. 3. Check the service brake system and parking
brake system. Remove and check the friction
Every 1000 Service Hours or Six Months disc for wear condition and replace if
necessary.
In addition to all previous service checks:
4. Check airtight condition of the control valve
1. Adjust the engine valve lash. and work cylinder by measuring natural
sediment of the cylinder.
2. Replace transmission oil, transmission oil
filter and its seal ring, and clean the primary 5. For the machine equipped with air
filter at the bottom of the transmission conditioner, check the refrigerant pipe and
housing (AEB calibration must be carried out water hose of the air conditioner for cracks,
after changing the transmission oil. Refer to wear or foaming by oil. Check the connectors
"Operation Procedure of Clutch Calibration and clamps for loose condition.
(AEB)" for the operation method).
6. For the machine equipped with air
3. Change gear oil of the drive axles. conditioner, replace the recirculating air
strainer of the cab.
4. Clean the fuel tank.
230
Maintenance Manual September 4, 2020
Maintenance Interval Schedule CLG877H

7. For the machine equipped with air

conditioner, check the refrigerant level in the
refrigerant receiver.
8. Check flexibility of the steering system.
9. Tighten all connecting bolts on drive shafts.
10. Check the tightening torque of the
transmission mounting bolts.
11. Check nitrogen precharge pressure of the
accumulators at the first 2000 service hours,
check the pressure every 2000 hours later
on.

Every 4000 Service Hours

In addition to all previous service checks:

1. Clean the AdBlue pump.

Every 4500 Service Hours or Every Three

Years

In addition to all previous service checks:

1. Replace the filter element of the AdBlue
pump.
231
September 4, 2020 Maintenance Manual
CLG877H General Torque Specifications

General Torque Specifications

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

Standard Torque lb.ft (N·m)

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

British System

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

1/4 9±3 (12±4)
5/16 18±5 (25±7)
3/8 33±5 (45±7)
7/16 52±11 (70±15)
1/2 74±11 (100±15)
9/16 110±15 (150±20)
5/8 148±18 (200±25)
3/4 266±37 (360±50)
7/8 420±59 (570±80)
1 645±74 (875±100)
232
Maintenance Manual September 4, 2020
Tire Inflation Information CLG877H

Tire Inflation Information Ply rating Front wheel Rear wheel

Tire size or strength inflation inflation
index pressure (kPa) pressure (kPa)
Liugong recommends the use of dry nitrogen for 23.5R25 PR12 225~245 205~225
tire inflation and tire pressure adjustments. It 23.5-25 PR16 300~320 280~300
includes all machines with rubber tires. Nitrogen 23.5-25 PR20 375~395 355~375
is an inert gas that will not aid combustion inside
23.5-25 PR24 475~495 455~475
the tire.
23.5-25 PR28 550~575 530~550
The use of nitrogen for tire inflation can not only 23.5R25 ★ 475~495 455~475
reduce the risk of explosion, but also help to 23.5R25 ★★ 600~620 580~600
prevent oxidation, aging of the rubber, and 26.5-25 PR20 350~375 330~350
corrosion of the wheel rim parts. 26.5-25 PR24 400~420 380~400
26.5-25 PR28 475~495 455~475
26.5-25 PR32 550~570 530~550
26.5R25 ★ 475~495 455~475
Training for using the equipment is 26.5R25 ★★ 600~620 580~600
necessary to avoid over inflation. A tire 29.5-25 PR22 325~345 305~325
blowout or a rim failure can cause personal 29.5-25 PR28 425~445 405~425
injury. Do not set the tire inflation equipment 29.5-25 PR34 525~545 505~525
regulator higher than 140 kPa (20 psi) over 29.5R25 ★ 475~495 455~475
the recommended tire pressure. 29.5R25 ★★ 600~620 580~600
35/65-33 PR24 350~370 330~350
Check and adjust the tire inflation pressure after 35/65-33 PR30 425~445 405~425
the tire cools down completely. Ask all other 35/65-33 PR36 525~545 505~525
persons to leave the danger area (around the
35/65R33 ★ 550~570 530~550
rim).
35/65R33 ★★ 650~670 630~650
The inflation pressure for nitrogen and air are the 750/65R25 ★★ 625~645 605~625
same when charging the tires. Consult your tire 850/65R25 ★★ 625~645 605~625
dealer for operating pressures. “ ★ ”: the star represents the bearing capacity of tires, for
radial tires of the same size, the more the stars, the
See the following table for the tire inflation greater the bearing capacity.
pressure under normal temperatures.
The tire pressure will significantly change when
Ply rating Front wheel Rear wheel you drive the machine into freezing temperature
Tire size or strength inflation inflation from a normal environment with a temperature of
index pressure (kPa) pressure (kPa) 18°C to 21°C (65 °F to 70 °F). If you inflate the
17.5-25 PR8 225~275 205~225 tire to the correct pressure under normal
17.5-25 PR12 350~370 330~350 temperature, the tire will be under inflated in
17.5-25 PR16 475~495 455~475 freezing temperature. Low pressure will shorten
17.5-25 PR20 575~595 555~575 the service life of the tires. Consult your Liugong
17.5R25 ★ 475~495 455~475 dealer when you are not sure about the tire
17.5R25 ★★ 600~620 580~600 inflation pressure.
20.5-25 PR12 250~270 230~250
20.5-25 PR16 350~370 330~350
20.5-25 PR20 470~490 450~470
20.5-25 PR24 525~545 505~525 If the machine travels for a long distance at
20.5-25 PR28 625~645 605~625 high speed, stop the machine for 30 minutes
20.5R25 ★ 475~495 455~475 each time when it has travelled for 45km so
20.5R25 ★★ 600~620 580~600 as to let the tires cool down.
233
September 4, 2020 Maintenance Manual
CLG877H Lubrication Specifications

Lubrication Specifications

Oil Change Interval and Refill Capacities

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

Approximative quantity (L)

Interval
Item
(service hours)
877H T4F 877H Stage V
Engine oil 500 33 33
Torque converter oil,
1000 50 50
Transmission oil
Hydraulic oil 2000 220 300
Front axle oil 1000 60 60
Rear axle oil 1000 60 60
Fuel tank Every day 372 417
Cooling system 2000 36 36
AdBlue 18 49.2
234
Maintenance Manual September 4, 2020
Lubrication Specifications CLG877H

Oil Specifications

Please use specified oil according to the following table when adding and replacing various oil for the
machines to ensure the normal use of the machines.

Application
Item Ambient temperature Type of oil Remarks
parts
-35°C~10°C -31°F~50°F SAE 0W-20/CJ-4
-35°C~30°C -31°F~86°F SAE 0W-30/CJ-4
-35°C~40°C -31°F~104°F SAE 0W-40/CJ-4
-30°C~30°C -22°F~86°F SAE 5W-30/CJ-4
Engine oil Diesel engine
-30°C~50°C -22°F~122°F SAE 5W-40/CJ-4
-20°C~40°C -4°F~104°F SAE 10W-30/CJ-4
-20°C~50°C -4°F~122°F SAE 10W-40/CJ-4
-10°C~50°C 14°F~122°F ★ SAE 15W-40/CJ-4
≥8°C ≥46.4°F 5
≥4°C ≥39.2°F ★0
≥-5°C ≥23°F -10 Ultra low sulfur diesel
Diesel fuel
Fuel with sulfur content ≤
≥-14°C ≥6.8°F -20 system
15ppm must be used
≥-29°C ≥-20.2°F -35
≥-44°C ≥-47.2°F -50
Meets ISO22241-1or DIN
Adblue Adblue tank
70070
HM46 Anti-wear hydraulic oil
Work hydraulic
-10°C~45°C 14°F~113°F ★ MOBIL DTE25 Anti-wear system,
hydraulic oil steering
Hydraulic
HV32 Low-temperature hydraulic
oil -20°C~35°C -4°F~95°F
hydraulic oil system and
brake hydraulic
HS32 Ultra-low temperature
-24°C~35°C -11.2°F~95°F system
hydraulic oil
≥-10°C ≥14°F SAE 30 Transmission oil must
meet the requirements of
≥-20°C ≥-4°F SAE 20W-20, 20W-40
ZF oil table TEML03
SAE 15W-30,15W-40 (The oil table can be
≥-25°C ≥-13°F
★ Mobil Delvac 1400 inquired to www.zf.com/
lubricants, and subject to
Torque SAE 10W,10W-30,10W-40
≥-30°C ≥-22°F the latest version).
converter Gearbox
UTTO Generally, diesel engine
oil
oil is used. Dilute ATF oil
≥-35°C ≥-31°F SAE 5W-30, 5W-40
is recommended for use
SAE 0W-30, 0W-40 at extremely low ambient
temperatures (ie,
≥-40°C ≥-40°F
ATF automatic transmission
oil for cars).
235
September 4, 2020 Maintenance Manual
CLG877H Lubrication Specifications

Application
Item Ambient temperature Type of oil Remarks
parts
The drive axle must use
oil 05F/ 05G in the ZF oil
SAE 80W-90 table TE-ML05 (The oil
Gear oil ≥-20°C ≥-4°F ZF-Powerfluid Plus Drive axle table can be inquired to
★ MOBILFLUID 424 www.zf.com/lubricants,
and subject to the latest
version).
Work
≥-15°C ≥5°F
★ 2# complex lithium-based implement pin Centralized lubrication
grease shaft, cylinder requires that the grease
pin shaft, frame should not contain
pin shaft, rear graphite or PFTE
Grease
axle swing (polytetrafluoroeth
0#,1# complex lithium-based frame, drive ylene); it is not allowed to
≤-15°C ≤5°F shaft spline, use grease containing
grease
universal joint, molybdenum disulfide.
etc.
≥-10°C ≥14°F -15°C
≥-25°C ≥-13°F ★ -30°C Diesel engine
Coolant
≥-30°C ≥-22°F -35°C cooling system

≥-40°C ≥-40°F -45°C

Air conditioner
Refrigerant ★ R134a system
Hydraulic
Engine hood
oil for
engine ★ 10# aviation hydraulic oil hydraulic lifting
electric pump
hood lifting

Do not mix oils of different brands even if they have the same specifications. Clean the system
before refilling with different oil.
If the machine is used at low temperature in severe cold areas for a long time, 46# low
temperature anti-wear hydraulic oil should be used, and ATF220 or DEXRON-III or Donax TC
transmission oil should be used.
Replace the lubricant periodically even though the lubricant is very clean because the lubricant
might break down after long use.
Choose the oil according to the lowest air temperature in the local area where the machine is
used.
Only the engine oil that meets the requirement of engine oil grade and engine oil viscidity grade
at the same time can be used on the engine.
236
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Important Maintenance Check all the lighting equipment and replace

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

Check the engine compartment and clean the

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

It is a normal phenomenon if there is a little

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

Check the hydraulic oil tank, all of the tubes and

hoses, plugs, seals, connectors and grease
fittings for leakage. Repair the leakage and
replace the hose if necessary.
Check all of the implements and linkage for
cracks and damage.
Ensure that all doors, covers and shields are
securely attached. Check them for damage.
Check the ladder, walkway and handrail. Clear
away all the trash and repair or replace any
damaged part.
Check the air inlet and outlet of the evaporator in
the air conditioner. Clear away the cotton, paper,
plastic and film that can block the air inlet.
Check the ROPS for visible damage. Consult
your Liugong dealer for repair information if there
is damage.
237
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Engine System

Maintenance Table

Interval (Hours)
Item As
10hr or 50hr or 100hr 250hr or 500hr or 1000hr 2000hr
every every or 2 every three or half a or one
required
day week weeks month months year year
Coolant level--Check
Coolant--Add
Coolant--Replace
Air filter main element--Clean/
Replace
Air filter safety element--
Replace
Fuel level--Check
Fuel--Add
Fuel tank--Clean
Fuel tank strainer--Clean
Water and impurity--Remove
Fuel pre-filter--Replace
Fuel filter--Replace
Engine oil level--Check
Engine oil--Replace
Enigne oil filter--Replace
Radiator group--Clean
Engine valve lash--Adjust
Air intake system--Check
Tensioner bearing and fan
hub--Check
Engine belt--Check
Belt tension--Check/Adjust
Note: ★ ★ ★ indicates the first service interval.
238
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Coolant Level--Check

Check the cooling system of the engine for

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

Anti-freeze has been added into the machine

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

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

When adding anti-freeze, use the anti-freeze

of the same brand.
239
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Coolant must contain additive (DCA4 for GCIC Water used in coolant must be soft water or
engine, SCA for other engines) to prevent the distilled water, because ordinary fresh water and
engine parts which contact with coolant from tap water contains a lot of calcium and
rusting, scaling, pitting, and corrosion. Additive magnesium materials, which will cause scaling of
(DCA4 for GCIC engine, SCA for other engines) the cooling system radiator, engine and piping,
of low density doesn’t have effect, additive while excessive chlorine compounds and sulfate
(DCA4 for GCIC engine, SCA for other engines) will corrode the cooling system and engine
of high density will have a negative impact on waterways. If there isn’t soft water or distilled
engine, it may result in water pump leakage and water, the quality of water used in coolant must
corrosion of cooling system solder and aluminum meet all of the requirements listed in the
parts. following table, and the density level of each
element shall not exceed the permitted
The density of coolant additive should be
maximum value in the following table.
maintained at about 3% (0.49-0.58 units/L for
GCIC engine). Anti-freeze already contains Min. water quality requirement
additive, but the additive will be consumed up
Permitted max. content
during running the engine. Therefore, check the Item
value
coolant density every 500 work hours or six
months. Add additive by changing the coolant Calcium and
Max. content in (CaCO3 + MgCO3)
filter periodically. magnesium
is 170ppm
content (hardness)
Refer to the Operation and Maintenance Manual
Chlorine Max. content in (Cl) is 40ppm
of Diesel Engine provided with the machine for
Sulfur Max. content in (SO4) is 100ppm
the additive density inspection method and
detailed instructions. If the temperature is forecasted to drop below
0°C (32° F), add anti-freeze suited to local
Coolant--Add climatic conditions into coolant. If only anti-freeze
concentrate is available, it is needed to mix it
with soft water in a certain proportion. Refer to
the proportioning instruction for the mixing
proportion of anti-freeze concentrate.
Hot coolant can cause serious burn. To open
cap, stop engine until radiator cools down. Since the heat absorption capacity of anti-freeze
Then loosen cap slowly to release the to the engine isn’t as good as water, add anti-
pressure. freeze into the engine before thoroughly mixed
with water will cause overheat of the engine.
Before adding anti-freeze, use refractometer to
measure the freezing point of the well mixed anti-
Anti-freeze is flammable. Never expose anti- freeze accurately to ensure that the anti-freeze
freeze to an open fire. Never use water as the adapt to the local lowest temperature. The anti-
coolant otherwise it will cause corrosion freeze concentration mixed by experience is just
damage to the cooling system. a general range, the anti-freeze value measured
by refractometer is accurate, which can
effectively avoid damage to the radiator and
engine caused by frost cracking.
240
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

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

O I

When adding coolant, exhaust air from the

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

Close the radiator filler cap before stopping

the engine, or coolant will spray out from the
filler.

9. Check the radiator filler cap for good

condition, replace it if damaged.

Do not add coolant when the engine

temperature is high, otherwise this could
cause damage to the engine. Add coolant
only after the coolant temperature is below
50°C.
241
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Coolant--Replace
Water filter (coolant filter)

Hot coolant can cause serious burn. To open

cap, stop engine until radiator cools down.
Then loosen cap slowly to release the
pressure.
Anti-freeze might hurt the skin, when
replacing it, wear goggles and protective
clothing to avoid personal injury.

When coolant is polluted, engine overheated or

bubbles appeared in radiator, test the freezing
Care must be taken in order to ensure that point of the additive and anti-freeze in the cooling
fluids are contained during performance of system to determine whether the coolant must
inspection, maintenance, testing, adjusting be replaced, replace the coolant if it exceeds any
and repair of the equipment. Prepare to permitted limit value in the coolant replacement
collect the fluid with suitable containers limit table.
before disassembling any hydraulic oil lines.
Coolant replacement limit table
Obey all local regulation for the disposal of
liquids. Pollutants Permitted limit value
If the cooling system failed to be cleaned Sulfate (SO4) Max. 1500ppm
thoroughly, the new coolant may be polluted Chloride (Cl) fluoride,
during adding, and result in the cooling Max. 200ppm
bromide
system and engine failure.
Engine oil or fuel Coolant shall not contain
Do not mixed use multiple brands of coolant, pollution engine oil or fuel
otherwise the consequent cooling system pH value Min. 6.5 (see Note ★ )
and engine failures are not covered by Grease, solder,
warranty. Coolant shall not contain these
silicone, corrosion or
pollutants.
scaling
Completely replace the coolant every 2000
Note ★ : The replacement limit of the min. pH value may
service hours or one year (which ever comes change with the product changes. Consult the
first) and clean the cooling system. Clean the product manufacturer for the pH value limit. The
cooling system before that interval if the coolant pH value less than 6.5 is unacceptable generally.
is polluted, the engine is running excessively hot
Steps for cleaning the cooling system
or bubbles appear in the radiator.
1. Turn on the disconnect switch.

O I
242
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

2. Insert the start switch key and turn clockwise 7. The water drain plug is located at the left side
to the ON position to turn on the power of the of the rear frame, near the rear left wheel.
machine. Loosen it to drain out coolant of the engine
and collect with a container.
3. Turn the selector switch of the air conditioner
to WARM AIR position.
4. Turn the manual valve on the water inlet hose
of the engine to ON position (The valve is at
ON as shown).

5. Start and run the engine at idle speed for

5~10 minutes, then stop the engine. Turn the
start switch to the first position to turn on
power of the machine. Open the water
solenoid valve of the air conditioner.
8. After draining out coolant, close the water
6. Slowly screw out the water radiator filler cap
drain plug.
to release pressure after the coolant
temperature is below 50°C. 9. Check all water lines and clamps of the
cooling system for damage, replace if
necessary. Check water radiator for leakage,
damage and piled-up trash, clean and repair
if necessary.
243
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

10. Add cleanser mixed with water and sodium 15. Replace with a new coolant filter, close all
carbonate into the cooling system of the drain plugs, then add new coolant according
engine, its proportion is 0.5 kilograms of to the operation rules previously described in
sodium carbonate against 23 liters of water. section “Coolant--Add”.
The level should reach normal level of the
engine and keep stable within 10~15
minutes.
The coolant of the engine is poisonous and
impotable. Dispose of it according to the
local laws and regulations.
When adding cleanser into the cooling
system, exhaust air from cooling system
lines of the engine. During cleaning of the
cooling system, never cover the water
radiator filler cap of the recovery tank while
running the engine.

11. Keep the water radiator filler cap open, start

the engine, when the coolant temperature
reaches over 80°C, run the engine for 5~10
minutes again.

If the coolant temperature can not reach

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

12. Stop the engine, drain out cleanser.

13. Add clean water into cooling system of the
engine until it reaches normal level and
keeps stable within 10 minutes. keep the
water radiator filler cap open, start the
engine, when the coolant temperature
reaches over 80°C, run the engine for 5~10
minutes again.
14. Stop the engine, drain out water in the
cooling system. If the drained water is still
dirty, clean the system again until the drained
water gets clean.
244
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Filter Elements of the Air Filter--Replace

(for 877H T4F)
B

Maintain the air filter when the air filter

service indicator illuminates. Shut down the A
engine before maintaining the air filter to
avoid damaging the engine.
Air filter elements cleaning and reusing is not
recommended as it’s easy to produce A: Main filter element
invisible damage to the air filter elements, B: Safety filter element
even results risk to the machine. It is 3. Take out the main filter element along with
suggested to replace the air filter element the housing direction. Push the main filter
directly. element downward by handles to loosen the
gasket from it and tilt it for about 5°, and then
pull the main filter element out.

1. Stop the engine and open the engine hood.

1. Handle
4. Take out the safety filter element. Use the
handles on the safety filter element to pull it
towards the filter housing center, and then
take it out.

2. Unlock the four metal latches, and remove

the cover of the air filter.

2. Handle
245
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

9. Check the connection of the air inlet and air

outlet. If the air filter is equipped with a dust
exhaust valve, check the valve, and replace it
if it is damaged.
The safety air filter element only needs to be 10. Close the engine hood.
replaced every time the main air filter element
is replaced to the third time.
Filter Element of the Air Filter--Replace
5. Check the new filter elements before (for 877H T4F with Dedusting A/C)
installation to see if there is any cutting,
tearing or indentation on the seal surface. Do
not install it if damaged.
6. If replace with a new safety filter element,
use the handles on the safety filter element to Air filter elements cleaning and reusing is not
tilt it a little bit and slide it into the filter recommended as it’s easy to produce
housing, and then push the safety filter invisible damage to the air filter elements,
element in position firmly and evenly in the even results risk to the machine. It is
filter housing. suggested to replace the air filter element
directly.

1. Park the machine on level ground, stop the

engine and open the engine hood.
Before the safety filter element is pushed to
correctly position, insert the fins of it into the 2. Unscrew the nut of the air filter cover.
locating slot.

7. Insert the main filter element. Tilt the main

filter element for about 5° and slide it into the
end of the filter housing.
8. Install the cover of the air filter, lock the metal
latches.

3. Remove the cover of the air filter.

If the air filter cover can’t be installed, remove

it and check the location of the filter element
again. It is difficult to install the air filter cover
if the filter element is not installed properly.
246
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

4. Remove the lock nut of the main filter 7. Check the new filter element before
element with a wrench of 17. installation. Visually inspect the seal surface
for cuts, tears or indentations before
installation. Do not install if there is any
visible damage.
8. Install the safety filter element into the central
fixing screw, adjust its position so that the
filter element is basically coaxial with the
central fixing screw, and tighten the lock nut.

5. Rotate it left and right to loosen the main filter

element, and then take it out.

9. Push the main filter element into the air filter

to the end and tighten the lock nut.
10. Install the cover of the air filter, adjust the
dust exhaust valve vertically downwards, and
tighten the nut.

The safety air filter element only needs to be If the air filter cover can’t be installed, remove
replaced every time the main air filter element it and check the location of the filter element
is replaced to the third time. again. It is difficult to install the air filter cover
if the filter element is not installed properly.
6. If the safety filter element needs to be
replaced, remove the safety filter element 11. Check the connection of the air inlet and air
lock nut with a wrench of 17 to remove the outlet. If the air filter is equipped with a dust
safety filter element. exhaust valve, check the valve, and replace it
if there is any visible damage.
247
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Air Filter Service Indicator--Check (for 2. Remove outer cover of the air filter.
877H Stage V)

The service indicator is located on the air filter.

Service indicator

3. Take out the main filter element along with

the housing direction.

Service the air filter element if the yellow piston

of the service indicator rises to the red zone.

Main Filter Element of the Air Filter--

Clean/ Replace (for 877H Stage V)

If the engine air filter alert indicator on the 4. Check the main filter element.
instrument panel is on, then maintain the (a) Replace the main filter element if any
engine air filter. damage is found to pleats and gaskets.
(b) Clean the main filter element if it is not
1. Stop the engine, the air filter is located on the
damaged.
right rear fender.
5. Clean the inner wall of the air filter housing.
248
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

6. Clean the main filter element with 9. Clean and install the cap of the air filter, make
compressed air (below 300kPa/ 3.1kgf/cm3) sure that the inner cap gasket in the air filter
from inside to outside. contacts evenly with the air filter housing.

It is not allowed to clean the main element The main element should be replaced after
from outside to inside with compressed air. being cleaned for 4-5 times. It is forbidden to
Do not use oil or water to clean the main remove the safety element when servicing
element. the main element.

Air Filter Safety Element--Replace (for

877H Stage V)
Do not hit the main element when cleaning it.
Otherwise the engine could be damaged.

Replace the main element and safety

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

1. Stop the engine, the air filter is located on the

right rear fender.

7. After cleaning the main filter element, check

with a bulb, if small holes and particles as
well as damage of the washer and seal are
found, replace with a new main filter element.

2. Remove the outer cap of the air filter.

8. Install a clean main filter element into the air

filter and ensure an even contact with the
housing.
249
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

3. Remove the main filter element along with There is a sight glass in the lower part of the fuel
the housing direction. tank, which is located on the rear left side of the
machine. User also can check the fuel level of
the fuel tank through this sight glass. When the
fuel level decreased to the level of the sight
glass, refill the fuel tank timely.

4. Remove the safety filter element.

5. Cover the air inlet. Clean the inside wall of
the air filter.
Fuel--Add

No smoking and keep away from the flames

or spark area when adding fuel.

6. Check the gasket between the air inlet tube The fuel tank of the machine is located below the
and the air filter housing. Replace with a new rear of the engine.
one if it is damaged.
7. Open the air inlet. Install a new safety filter
element, make sure the seal ring on the top
of the safety filter element contacts evenly.
8. Install a new main filter element and install
the outer cap of the air filter. Tighten the clip
to secure the cap of the air filter housing.

Fuel Level--Check
1. Stop the engine.
The fuel level gauge is on the cab instrument
panel. It has two zones. “1” indicates the high
fuel level. “0” indicates the low fuel level. Add fuel
in time when the fuel level is lower than “0.2”.
If the fuel level is lower than 0.2, ensure enough
time for the operator to add fuel.
250
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

2. Open the rear door of the engine hood to 4. Add fuel.

access the fuel filler of the fuel tank.

3. Pull up the lock plate of the fuel filler cap, turn

the cap counterclockwise to the next position
and move it outwards, and then remove the Don't take out the strainer of the fuel filler
cap. when adding fuel.
877H T4F fuel filler
Fuel Tank--Clean

Care must be taken to ensure that fluids are

contained during performance of
inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
collect the fluid with suitable containers
before disassembling any component
containing fluids. Dispose of all fluids
877H Stage V fuel filler according to local regulations.
No smoking and keep away from the flames
or spark area when cleaning the fuel tank.

1. Stop the engine.

251
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

2. Remove the flange cover in front of the fuel 2. Before filling, screw out the drain plug at the
tank. Wash the inner surface of the tank with bottom of the fuel tank to drain out water and
clean fuel. impurity deposited in the tank once every
week.
3. After completing daily work, add fuel and
remove the humid air in the fuel tank.
4. After replenishing the fuel tank every time,
wait for 5-10 minutes before starting the
engine so that water and impurity have sunk
to the bottom of the tank.
5. After completing daily work, loosen the water
1 drain plugs of fuel water separator, fuel filters
2
to drain out water and impurity.
1. Flange cover
2. Drain plug
3. Remove the drain plug to drain out the
residual fuel.
4. Repeat washing until the drained fuel is
clean.

Fuel Strainer--Clean

1. Stop the engine.

1 2
2. Remove the fuel filler cap of the fuel tank.
Check the gaskets for damage. Replace the 1. Fuel pre-filter (fuel water separator)
gaskets if damaged. 2. Fuel filters

3. Take out and check the fuel strainer. Replace

if damaged.
4. Wash the fuel filler and fuel strainer with
clean and nonflammable detergent. Dry them Add the fuel in time. Any residual fuel at the
in the air or by compressed air. bottom of the fuel tank that contains water
and impurity will affect the normal running of
5. Install the fuel filler cap and strainer. the engine. Drain and clean fuel tank before
adding.
Water and Impurity--Remove

The fuel pump and fuel injection nozzle are

precision devices, if fuel is mixed with water or
impurity, the fuel pump and fuel injection nozzle
can't work properly and quickly worn. Measures
should be taken to remove water and impurity in
fuel.
1. If the condition is permitted, fuel should be
deposited for 24 hours before it is filled to the
tank.
252
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Fuel Pre-filter--Replace 4. Check the gasket, replace if damaged.

5. Install a new fuel pre-filter to the support.
The fuel pre-filter is located on the right side of
the machine.
Fuel pre-filter
Do not fill with fuel before the fuel pre-filter is
installed. Fuel contamination will quicken
damage of the fuel system parts.

Fuel Filter--Replace

The fuel filters are located on the right side of the

machine.
Fuel filters

1. First clean the fuel pre-filter surroundings and

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

1. First clean the fuel filter surroundings and the

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

3. Remove the gasket on the thread connector

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

3. Clean the fuel filter surroundings and the

support. Make sure that all old gaskets are
removed.

1. Gasket
253
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

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

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

Too much or too little engine oil can result in

damage to the engine.

1. Drive the machine to flat ground, stop the

engine and engage the parking brake.
2. After stopping the engine, wait for 10 minutes
to let the engine oil in the crankcase return to
the engine oil pan.
3. Open the engine hood, the engine oil filler
and the engine oil dipstick are located on the
5. Install the filter to the support by hand. After right side of the machine.
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 2
to avoid damaging the filter.

1. Engine oil dipstick

2. Engine oil filler
4. Take out the dipstick. Wipe it with a clean
cloth and completely reinsert the dipstick into
the end of the oil level of the engine. Take the
dipstick out again and check the oil level. The
oil level on the dipstick should be between
the low (L) and high (H) graduation marks.
Do not fill with fuel before the fuel filter is
installed. Fuel contamination will quicken
damage of the fuel system parts.
254
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

5. If the oil level is below L, add oil. If the oil 3. The engine oil drain plug is located at the left
level is above the H, screw out the oil drain side of the rear frame, near the rear left
plug at the bottom of the engine oil pan to wheel. Loosen it to drain the oil and collect
release some oil. with a container. Replace the engine oil filter.
Oil level range

6. Reinsert the oil dipstick and close the engine

hood.

Engine Oil--Replace

Care must be taken to ensure that fluids are 4. Tighten the oil drain plug.
contained during performance of inspection, 5. Add clean engine oil to the oil filler of the
maintenance, testing, adjusting and repair of engine until the engine oil is at H on the oil
the product. Be prepared to collect the fluid dipstick. Run the engine at idle speed to
with suitable containers before check the engine oil filter and oil drain plug
disassembling any component containing for leakage.
fluids or dismounting any hydraulic line.
Dispose of all fluids according to local 6. Stop the engine and wait for about 10
regulations. minutes, let the engine oil fully return to the
oil pan, check the engine oil level again, if
insufficient, add engine oil to the H on the
dipstick.
High-temperature lubricant can cause
personal injury. Replace the lubricant only
when the lubricant is warm and the impurity
is floating.

1. Park the machine on flat ground, start the

engine and run until the water temperature
reaches 60°C.
2. Stop the engine and engage the parking
brake.
255
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

5. Install a new O-ring, replenish the oil filter

with clean engine oil, and apply a coat of
clean engine oil on the gasket surface.
Within 15 seconds after the engine has been
started, check the reading of engine oil
pressure gauge. If no reading is found, shut
down the engine immediately to protect the
engine. Check to see if the engine oil level is
correct.

Engine Oil Filter--Replace

The engine oil filter is located on the left side of

the machine.
Engine oil filter

Fill the filter with clean engine oil before the

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

6. Secure the engine oil filter on the support and

tighten the gasket of the engine oil filter until
it contacts with the support. Tighten engine
oil filter according to the specified
requirements with the spanner.
7. Close the engine hood.
1. Open the engine hood.
2. Clean the area around the support of the
engine oil filter.
3. Remove the engine oil filter with a belt
spanner and check it.
4. Clean the surface of the gasket of the
support with a clean cloth. If old O-ring
adheres to the support, remove it.
256
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Engine Aftertreatment System

877H Stage V
877H T4F

The aftertreatment system of the T4F engine 1

mainly includes the aftertreatment assembly,
AdBlue tank, AdBlue pump and AdBlue pipeline
integrated system, AdBlue heating solenoid
valve and corresponding pipelines. The
aftertreatment assembly includes DOC, DRT and
SCR. Except that the SCR system requires
regular maintenance, the other assemblies of the
aftertreatment system are maintenance-free
assemblies.
877H T4F 2
3

1. Aftertreatment assembly
1 2. AdBlue pump
3. AdBlue tank

3
2

The aftertreatment system is a maintenance

free assembly.
5 Pay attention to AdBlue level indicator light.
The AdBlue tank must be filled with specified
4 AdBlue. The water or other solutions are not
allowed, or the AdBlue pump and
aftertreatment system will be damaged.
1. DRT
2. SCR Normal injection of AdBlue in the
3. DOC aftertreatment system must be ensured
4. AdBlue pump
5. AdBlue tank
during operation of the engine.

877H Stage V

The aftertreatment system of the stage V engine

mainly includes the aftertreatment assembly,
AdBlue tank, AdBlue pump and AdBlue pipeline
integrated system, AdBlue heating solenoid
valve and corresponding pipelines. The
aftertreatment assembly includes DOC, DPF and
SCR. Except that the SCR system requires
regular maintenance, the other assemblies of the
aftertreatment system are maintenance-free
assemblies.
257
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

SCR System--Maintain

AdBlue supply pipes refers to AdBlue feed

pipe, AdBlue return pipe and AdBlue AdBlue and pipeline should be isolated from
injection pipe, which have a inside diameter outside pollution sources.
of Φ6; AdBlue supply pipes are quick plug
Do not disconnect each connecting joint at
structures, so it shall be ensured that each
random, otherwise foreign matter will bypass
joint is sealed and that fracture does not
the filter device and directly damage the
occur along the pipelines; Pipelines shall be
system. If it is necessary to disconnect the
kept away from high temperature heat
joint, clean the interface and its adjacent
source. Heat insulation measures shall be
parts before disconnecting, and protect the
taken for the AdBlue injection pipe near the
joint, such as installing a dust cover to
exhaust pipe.
prevent foreign matter from entering the
The aftertreatment system shall be as closer pipeline or metering pump.
as possible to the engine supercharger.
Flexible connection structures such as metal 1. AdBlue--Add
hose must be provided in the exhaust line in
front of the aftertreatment system; The inlet/ There are AdBlue gauge and DEF low indicator
outlet direction shall not be opposite. on the central instrument panel. When the
Installation shall be conducted according to pointer of the AdBlue gauge points to the red
direction of arrow marked on the surface. It zone or when the DEF low indicator lights or
must be fixed firmly and reliably. blinks, immediately add AdBlue in order to avoid
Exhaust pipes and accessories 200mm in the decrease in engine power because of long-
front of and at rear of AdBlue nozzle must be term insufficient AdBlue. AdBlue filler is located
made of steel of OCr18Ni9 or above level. at the rear of the machine.
Each joint shall be sealed. 877H T4F AdBlue filler
Harness of inlet/ outlet temperature sensor
on the aftertreatment assembly shall be
bundled and fixed reasonably. The harness is
not allowed to contact the aftertreatment
assembly surface.
It is forbidden to cut off power supply of the
whole vehicle within 60 seconds after the
engine is switched off to ensure evacuation
of the AdBlue pump.
258
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

877H Stage V AdBlue filler 2. Open the engine hood of machine, remove
the mounting clamp from the AdBlue tank,
and remove the pipelines connected with
AdBlue tank. Take out the AdBlue tank.

2 1

1. Unscrew the cap of the AdBlue filler, add

AdBlue.
2. Plug the AdBlue filler with a rubber plug after
filling to avoid AdBlue spilling. 1. Mounting clamp
2. Connecting pipelines
3. There is a drain plug at the bottom of the
3. Use T25 screwdriver to unscrew the fixed
AdBlue tank, drain the sediment periodically.
bolt of the head assembly of the AdBlue
4. Install the seal cap of the AdBlue filler well. pump, remove the entire assembly. The filter
is at the bottom of the assembly. Clear
2. AdBlue Tank--Clean (for 877H T4F) impurities from the filter surface. It is
necessary to replace the filter if there are
Clean the AdBlue tank once every 4000 service cracks or big holes on the filter.
hours.

5
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting the product.
Be prepared to collect the fluid with suitable 3
containers before disassembling any
hydraulic lines or component containing
fluids. And dispose all fluids according to 6
local regulations. 4

1. Park the machine on flat ground, turn off the

engine, and turn the battery disconnect 3. T25 screwdriver
4. Fixed bolt
switch to OFF position after the AdBlue pump 5. Head
stops working. 6. Filter element
259
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

4. Unscrew the drain plug at the bottom of the 2. Remove the access door of the box under
AdBlue tank to drain the impurities deposited the right ladder.
in the bottom of the AdBlue tank, wash the
interior of the AdBlue tank with clean water.
Drain plug

P28P01182

5. Wash the interior of the tank with AdBlue 3. Loosen the clamp of the water pipe and pull
again after draining impurities. Fix the the pipe out of the DEF tank. Seal each end
AdBlue tank inside the counterweight box with a plastic sealing film as required.
after cleaning, and then tighten it clockwise.
6. Install the pipelines after the installation of
the AdBlue tank, and then fill the tank with
AdBlue.

3. AdBlue Tank--Clean (for 877H Stage V)

Clean the AdBlue tank once every 4000 service

hours.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting the product.
P28P01183
Be prepared to collect the fluid with suitable
containers before disassembling any
hydraulic lines or component containing
fluids. And dispose all fluids according to
local regulations.

1. Park the machine on flat ground, turn off the

engine, and turn the battery disconnect
switch to OFF position after the AdBlue pump
stops working.
260
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

4. Loosen the clamps of the DEF tank. .

6
4

3. T25 screwdriver
4. Fixed bolt
5. Head
6. Filter element
7. Unscrew the drain plug at the bottom of the
AdBlue tank to drain the impurities deposited
P28P01184
in the bottom of the AdBlue tank, wash the
5. Take the DEF tank out of the box under the interior of the AdBlue tank with clean water.
right ladder, unscrew the DEF tank mounting Drain plug
clamp bolts with a wrench, and remove the
cover to take out the DEF tank.

P28P01185 8. Wash the interior of the tank with AdBlue

again after draining impurities. Fix the
6. Use T25 screwdriver to unscrew the fixed AdBlue tank inside the counterweight box
bolt of the head assembly of the AdBlue after cleaning, and then tighten it clockwise.
pump, remove the entire assembly. The filter
is at the bottom of the assembly. Clear 9. Install the pipelines after the installation of
impurities from the filter surface. It is the AdBlue tank, and then fill the tank with
necessary to replace the filter if there are AdBlue.
cracks or big holes on the filter
261
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

4. AdBlue Pump Filter--Replace 3. Unscrew the filter cap with a wrench of

27mm. Remove the balance filter and main
filter.

Care must be taken to ensure that fluids are

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

If there isn’t leak, maintain the AdBlue pump filter 1. Filter cap
once every 4500h or three years. 2. Balance filter
3. Main filter
1. Park the machine on flat ground, turn off the
engine and wait for about 5 minutes, and 4. Check the filter cap for cracks or holes.
then turn the battery disconnect switch to These cracks or holes could cause leakage
OFF position after the pumping sound of the of AdBlue. Check the threads of the filter cap
AdBlue pump stopped. for damage, replace the filter cap if it has
been damaged. Check the threads of the
2. Check for leaks around the filter cap. White AdBlue pump, replace the entire AdBlue
marks will occur if there is AdBlue leak. Deal pump if its threads have been damaged.
with the AdBlue leak according to step 4 if
there are white marks.

5. Clean the filter cap with warm water and a

soft cloth.
262
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

6. Install the balance filter into the main filter, Radiator Group--Clean
and then insert the entire assembly into the
AdBlue pump. Screw the filter cap onto the 1. Open the engine hood to get access to the
AdBlue pump and tighten it with a wrench of radiator group.
27mm.

2. Remove the dust and debris on the radiator

group by compressed air.
1. Filter cap
2. Balance filter
3. Main filter

Do not let the AdBlue into the eyes. If AdBlue

got into the eyes, immediately flush eyes with
plenty of water for 15 minutes. Do not
swallow AdBlue. If accidentally swallowed
AdBlue, contact a doctor immediately.
Do not remove the AdBlue pipes (if
necessary) immediately after stopped the
machine, as the AdBlue pump is still working
at this time. It is necessary to wait until the Reduce the compressed air pressure when
AdBlue pump stopped working, and then cleaning. Keep any bystander away and use
remove the AdBlue pipe so as to avoid protective devices to avoid being hurt.
AdBlue splashing.
Do not remove the filter cap when the Engine Valve Lash--Adjust
machine is working.

Adjustment of the engine valve lash must be

performed by trained personnel with special
tools.

For more information about the adjusting

procedure of the engine valve lash, refer to the
Operation and Maintenance Manual of the
Engine.
263
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Engine Air Intake System--Check

Check the air intake system for cracked hoses,

loose clamps or holes. Tighten or replace the
parts to ensure the sealability of the air intake
system.

Engine Belt--Check

Check the belt of the engine by sight for cracked

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

Fan Belt Tension--Check/Adjust

For more information on fan belt adjustment

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

Loose fan belt could cause improper battery

charging, engine heating and rapid
abnormal belt wear problems. But an over
tightened fan belt will cause damage to both
bearings and the belt .
264
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Power Train System

Maintenance Table

Interval (Hours)

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

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

Transmission primary filter--

Clean ★★★

Drive axle gear oil level--Check

Drive axle gear oil--Replace ★★★
Transmission mounting thread
torque--Check
Drive shaft hitch bolt--Check ★★★
Note: ★ ★ ★ indicates the first service interval.

Transmission Oil Level--Check

Stop the machine on flat ground when

checking the oil level. Turn the shift control
lever to NEUTRAL position, engage the
parking brake and install the steering frame
lock to avoid movement of the machine.

Check the transmission oil level every 50 service 2

hours or once a week to ensure enough oil.
The transmission oil filler is located on left side of
the articulation joint. The transmission oil sight 1
glass is near the oil filling pipe.

1. Sight glass
2. Oil filler
265
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Check the transmission oil level for

transmissions with thermostat on the
transmission cooling pipe as follows:

When checking the transmission oil level, 1. During the first refueling and oil change of
always separately check cold oil level and hot the machine:
oil level. Too high or too low oil level of the
transmission could result in damage to the 1. Park the machine on level ground.
transmission, make sure the oil level of the 2. Select "manual" mode for shift control mode
transmission is at proper level. (for models with shift mode selection),
depress the service brake pedal completely.
Check the transmission oil level for
transmissions with a sight glass as follows: 3. Turn the shift control lever to the forward top
gear of the transmission gear, increase the
1. Park the machine on level ground. engine throttle opening to 60% and keep it.
(at this time, the torque converter is in stall
2. Turn the shift control lever to NEUTRAL condition, and the transmission oil
position. Engage the parking brake and temperature will rise rapidly).
install the steering frame lock to avoid
movement of the machine. 4. Observe the indicator of torque converter oil
temperature on the instrument. When the
3. The transmission oil temperature is 20-40°C. pointer reaches the middle position of the
4. The engine idling speed is 1000rpm. green area of the torque converter oil
temperature gauge, release the engine
5. Observe the transmission oil level sight throttle and turn the shift control lever to
glass. The oil level should be in the "MIN" NEUTRAL position.
and "MAX" areas.
5. Check the transmission oil level according to
the oil level check procedure for
transmissions with a sight glass.

2. Normal oil level inspection of the

machine:

1. Check the transmission oil level according to

the oil level check procedure for
transmissions with a sight glass.

Pay close attention to cleanliness when

checking the transmission oil level and
replacing transmission oil and filter. Do not
let impurity enter the transmission system to
avoid damage to the transmission.
266
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Transmission Oil--Replace

Because the transmission oil temperature is

still high when draining, wear protective
Care must be taken to ensure that fluids are clothing and be careful to prevent injury.
contained during performance of inspection,
maintenance, testing, adjusting the product. 4. The oil drain plug of the torque converter oil
Be prepared to collect the fluid with suitable radiator is located at the left side of the rear
containers before disassembling any frame, near the rear left wheel. Loosen it to
hydraulic lines or component containing drain oil and collect with a container. Loosen
fluids. And dispose all fluids according to the air release plug of the torque converter oil
local regulations. radiator to quicken oil release speed.

Replace the transmission oil at the first 100

hours. Replace the transmission oil every 1000
service hours or at least once a year later on
(The AEB calibration must be carried out after
changing the transmission oil. Refer to
"Operation Procedure of Clutch Calibration
(AEB)" on page 315 for operation method).
1. Park the machine on flat ground and turn the
shift control lever to NEUTRAL. Engage the
parking brake and attach the steering frame
lock to the front and rear frames to avoid
movement of the machine.
2. Start the engine and run at idle speed. When
the transmission oil temperature reaches
80~100°C, stop the engine.
3. Loosen the oil drain plug at the bottom of the
transmission to drain oil. Collect oil with an
appropriate container.
Oil drain plug

Drain out the oil in transmission, torque

converter and radiator simultaneously.
267
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

5. Replace the transmission oil filter and seal 7. Unscrew the transmission oil filler cap
ring. Refer to section “Transmission Oil Filter- counterclockwise. Add clean transmission oil
-Replace”. until the oil level is above the mark "MAX".
877H T4F transmission oil filter

877H Stage V transmission oil filter 8. Start the engine and let it run at idle speed
(800-1000rpm). Check the transmission oil
level again and add the transmission oil until
the oil level is above the mark "MIN". The
transmission could produce a slightly
abnormal noise due to transmission oil
insufficiency. The abnormal noise will
disappear after the transmission oil reaches
the specified level.

6. Loosen the oil filling plug above the torque

converter oil radiator. Add clean transmission
oil from the oil filler of the torque converter oil
radiator. After the radiator is fully filled with
transmission oil, tighten the air drain plug and
oil drain plug.
268
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

9. When the transmission oil temperature Transmission Oil Filter--Replace

reaches 20~40°C, check the oil level again.
The oil level should be in the "MIN" and
"MAX" areas. If the oil is insufficient, add oil.
If the oil is excessive, drain some excessive
oil. Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting the product.
Be prepared to collect the fluid with suitable
containers before disassembling any
hydraulic lines or component containing
fluids. And dispose all fluids according to
local regulations.

Replace the primary filter as follows:

1. Remove the oil suction pipe on the rear right

side of the transmission. Take the primary
filter out. Clean it with compressed air or fuel.
10. Tighten the transmission oil filler cap Install the primary filter after it is dried in the
clockwise. sun.

Before replacing transmission oil, cover the

parking brake by cloth to prevent the friction
disc from touching with oil to protect the 3
parking brake performance. 1
2

1. Oil drain plug

2. Transmission primary filter
3. Oil suction pipe
2. Clean any iron filings attached on the drain
plug by the magnet. Insert the magnet into
the transmission oil pan from the primary
filter mounting port. Clean the iron filings on
the inner wall of the primary filter.
3. Secure the primary filter, oil suction pipe,
drain plug and oil drain plug of the torque
converter oil radiator and seals.
269
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Replace the secondary filter as follows:

The transmission secondary filter of 877H T4F is

located behind the left ladder. The transmission
secondary filter of 877H stage V is located Dispose of the transmission oil that drained
behind the right ladder. See the following from the transmission oil sump properly to
pictures. avoid polluting the environment.
877H T4F transmission oil filter

877H Stage V transmission oil filter

1. Clean the surface around the transmission

secondary filter.
2. Remove the secondary filter from the support
with a wrench.
3. Clean the seal surface of the support with a
clean cloth.
4. Coat the gasket of the new secondary filter
with transmission oil.
5. Install the secondary filter on the support until
the gasket contacts with the seal surface of
the support and then manually further tighten
it by 1/3 or 1/2 turn.
270
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Axle Oil Level--Check a) Remove the oil filler plug on the side of
the rear axle to check the oil level. The
inner axle oil level should be at the lower
edge of the oil filler. If the oil level is lower
than the lower edge of the oil filler, refill
Be careful of the splashing hot oil when with clean axle oil. Observe for about 10
adding, draining, or loosening the plug. minutes after adding until the oil keeps
stable.
1. Park the machine on level ground, clean the Rear axle
surface around the oil filler before checking
the axle oil level.
2. Turn the shift control lever to NEUTRAL
position, engage the parking brake to prevent
movement of the machine and stop the
engine.
3. Check the front axle oil level:
a) Remove the oil filler plug in the middle of
the front axle to check the oil level. The 1 2 3
inner axle oil level should be at the lower
edge of the oil filler. If the oil level is lower 1. Oil drain plug
than the lower edge of the oil filler, refill 2. Oil filler
3. Oil drain plug
with clean axle oil. Observe for about 10
minutes after adding until the oil keeps b) Tighten the oil filler plug.
stable.
Front axle

1 2 3

1. Oil drain plug

2. Oil filler
3. Oil drain plug
b) Tighten the oil filler plug.
4. Check the rear axle oil level:
271
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Axle Oil--Replace
Rear axle

Care must be taken to ensure that fluids are

contained during the performance of
inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
collect the fluid with suitable containers
before disassembling any hydraulic line or
component containing fluids. Dispose of all 1 2 3
fluids according to local regulations. Drain
oil after the machine runs for a period of 1. Oil drain plug
2. Oil filler
time to let the impurities deposited in the oil
3. Oil drain plug
suspend.

1. Drive the machine for a while to let the

settling impurities in the axle suspend fully.
Park the machine on level ground. Because the axle oil temperature is still hot
when draining, wear protective clothing and
2. Turn the shift control lever to NEUTRAL
be careful to prevent injury.
position, engage the parking brake and stop
the engine, and install the steering frame lock 4. Tighten the oil drain plugs in the middle of the
to prevent movement of the machine. front axle and rear axle and the oil drain
3. Loosen the oil drain plugs in the middle of the plugs on the wheel end of the axles.
front axle and rear axle and the oil drain 5. Loosen the oil filler plugs of the front axle and
plugs on the wheel end of the axles to drain rear axle separately, add clean axle oil until
oil, and collect with a container. the oil flows over the oil filler.
Front axle 6. Observe for about 10 minutes after oiling,
and then tighten the oil filler plug if the oil
level keeps stable.
7. Remove the steering frame lock after
replacing axle oil.

1 2 3

1. Oil drain plug

2. Oil filler
3. Oil drain plug
272
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Hydraulic System

Maintenance Table

Interval (Hours)
Item As 10hr or 50hr or 500hr or 1000hr or 1500hr or 2000hr or
required every day every week three months half a year nine months one year
Hydraulic oil level--Check
Hydraulic oil--Add
Hydraulic oil--Replace
Serious polluted hydraulic oil--
Replace
Hydraulic oil tank breather
filter--Clean
Return oil filter element--
Replace ★★★

Hydraulic oil tank--Clean

Pilot filter element--Replace
Pre-charge pressure of pilot
oil supply valve accumulator-- ★★★ ★★★ ★★★
Check
Accumulator of pilot oil supply
valve--Charge
Ride control accumulator pre-
charge pressure--Check ★★★ ★★★ ★★★

Ride control accumulator--

Charge
Steering Cushion
Accumulator Pre-charge ★★★ ★★★ ★★★
Pressure--Check
Steering Cushion
Accumulator--Charge
Note: ★ ★ ★ indicates the first service interval.
273
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

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

2
1

5. Check the sight glass of the hydraulic oil tank

when there aren’t bubbles. The hydraulic oil
level should be within green range of MAX
line and MIN line of the sight glass.
Sight glass 1. Access plate
2. Cover plate
2. Loosen the breather filter cap of the hydraulic
oil tank to release the pressure.
274
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

3. Unscrew the mounting bolts from the oil filler 1. Park the machine on flat ground, push the
flange, and remove the flange. Add hydraulic shift control lever to NEUTRAL position, pull
oil and check the oil level according to the up the parking brake button and install the
section “Hydraulic Oil Level--Check”. steering frame lock.

4. Install the oil filler flange and tighten the

2. Start and run the engine at idle speed for 10
breather filter cap.
minutes. Operate the boom and tilt the
5. Install the access plate on the top of the bucket repeatedly to raise the hydraulic oil
hydraulic oil tank. temperature.
3. Raise the boom to the highest position, tilt
Hydraulic Oil--Replace the bucket backward to the limit position, and
stop the engine.
4. Push the work implement control lever
rightward to let the bucket tilt forward by its
Care must be taken to ensure that fluids are deadweight, and discharge the hydraulic oil
contained during performance of inspection, in the tilting cylinder. After the bucket tilts to
maintenance, testing, adjusting and repair of the limit position, push the work implement
the product. Be prepared to collect the fluid control lever forward to let the boom lower by
with suitable containers before its deadweight, and discharge the hydraulic
disassembling any component containing oil in the boom cylinder.
fluids or dismounting any hydraulic line. 5. Turn the pilot cut-off lever (if equipped) to
Dispose of all fluids according to local OFF position.
regulations.
Pay close attention to the cleanliness when
replacing the hydraulic oil, do not allow dirt
enter the hydraulic system.
275
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

6. The oil drain plug of the hydraulic oil tank is 8. Remove the end cap of the return oil filter
located on the right side of the machine, near from the hydraulic oil tank, take out the return
the articulation point of the front frame. oil filter element and replace with a new one.
Loosen it to drain oil and collect with a Open the oil filler flange, take out the oil filler
container. strainer and clean it.
Hydraulic oil drain plug Return oil filters

9. Remove the cleaning flange beside the oil

filler, wash the bottom and inner walls of the
hydraulic oil tank with clean fuel, and dry it
Because the hydraulic oil temperature is still
with clean cloth.
high when draining, wear protective clothing
and be careful to prevent injury. Cleaning flange

7. The oil drain plug of the hydraulic oil cooler is

located at the left side of the rear frame, near
the rear left wheel. Loosen it to drain oil and
collect with a container.

10. Install the oil drain plug, return oil filter,

strainer, cleaning flange, and oil inlet pipe of
the hydraulic oil cooler.
11. Refill the hydraulic oil tank from the hydraulic
oil filler until the oil level reaches the upper
graduation of the sight glass. Tighten the oil
filler flange after finishing.
276
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

12. Remove the steering frame lock and start the 3. Remove the return oil flanges, take out the oil
engine. Turn the pilot cut-off lever (if filter elements and O-rings, dispose of them
equipped) to ON position. Operate the work properly.
implement control lever to raise and lower the
boom for 2~3 times. Tilt the bucket forward
and backward and turn from left to right to the
maximum angle to fill cylinders with hydraulic 1
oil. Then run the engine at idle speed for five
minutes to drain air in the system. 3
13. Stop the engine. Open the hydraulic oil filler
flange. Refill the hydraulic oil tank.

Hydraulic Oil Tank--Clean 2

Care must be taken to ensure that fluids are

contained during performance of inspection, 1. Return oil flanges
maintenance, testing, adjusting and repair of 2. Return oil filter elements
3. Cleaning flange
the product. Be prepared to collect the fluid
with suitable containers before 4. Remove the cleaning flange.
disassembling any component containing 5. Wash the bottom and four walls of the
fluids or dismounting any hydraulic line. hydraulic oil tank with fuel through the return
Dispose of all fluids according to local oil flange openings and cleaning flange
regulations. opening, and then dry with a clean cloth.
6. Wash the bottom and four walls of the
1. Shut down the engine.
hydraulic oil tank with hydraulic oil again.
2. The oil drain plug of the hydraulic oil tank is
7. Install new oil filter elements, new O-rings
located on the right side of the machine, near
and return oil flanges.
the articulation point of the front frame.
Loosen it to drain oil and collect with a 8. Install the oil drain plug and the cleaning
container. flange.
Hydraulic oil drain plug
277
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

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

The breather filter is located on the top of the Replace the return oil filter element at first 500
hydraulic oil tank. service hours, replace it every 1500 service
hours later on. Replace the return oil filter
element in advance if the working condition is
very bad.
1. Remove the return oil filter flanges, take out
the elements and O-rings.

1. Pull up the lock plate (if equipped) of the

breather filter cap. Rotate the cap
counterclockwise to next position and move
the cap outward to take off the cap. Unscrew 2
the mounting bolt then take out the filter
element.
2. Wash the breather filter with clean and
nonflammable detergent. Dry it in the air or
with compressed air.
1. Return oil filter flanges
3. Install the breather filter element and the cap. 2. Return oil filter elements

There are compression springs under the

return oil filter flanges, press the flange when
removing the last two bolts on it.
2. Install new return oil filter elements, O-rings
and flanges.
278
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Pilot Filter Element--Replace 5. Clean the mounting support of the pilot filter.
Remove the old O-ring if it sticks to the
The pilot filter is located on the right side of the mounting support.
machine, inside the box behind the ladder. 6. Install the hexagonal plug and its
combination gaskets at the bottom of the pilot
filter.
7. Replace with a new filter element and fill the
pilot filter with clean hydraulic oil.
8. Screw the pilot filter on the mounting support
with hand. Tighten 1/2 ~ 3/4 turn when the O-
ring of the pilot filter contacts the mounting
support. Do not over tighten it to avoid
damage to the pilot filter.

1. Park the machine on flat ground and lower

the bucket to the ground. Engage the parking
brake and stop the engine.
2. Install the steering frame lock.

Keep the element clean during replacement

to protect the pilot filter from being
3. Remove the hexagonal plug at the bottom of contaminated.
the pilot filter and collect hydraulic oil with a
suitable container.

4. Remove the pilot filter from the mounting

support with a spanner and take out the
element from the pilot filter body. Dispose of
the pilot filter element properly.
279
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Pre-charge Pressure of Pilot Oil Supply 2. Move the pilot control lever to any directions
Valve Accumulator--Check continuously to discharge the high pressure
oil inside the accumulator.
Check the accumulator pre-charge pressure at
the first 50, 100, 250, 500, 1000 service hours of
operation. Check once every 2000 services
hours later on. Do not let the residual pressure oil in the
The charging tool of pilot oil supply valve accumulator spray any one as this can cause
accumulator is Heidek FPU-1-350 / 250F4G11K, injury or death.
LiuGong part number is:13C1215.
3. Remove the protection cap of the charging
The accumulator for pilot oil supply valve is valve from the accumulator.
located on the right side of the rear frame, inside
4. Tighten the mandrel handle and relief valve
the box under the ladder.
of the accumulator charging tool, and fasten
the charging tool to the charging valve of the
accumulator with slotted nut D.

1
5
2

4
3

Check accumulator nitrogen precharge 1. Mandrel handle

pressure according to the intervals specified 2. Check valve
in maintenance interval schedule section to 3. Charging valve body
4. Pressure gauge
ensure the proper working of the service 5. Relief valve
brake system and parking brake system.
5. Slowly turn the mandrel handle of the
Checking of the precharge pressure should
charging tool leftward to turn on the charging
only be done by trained personnel with
tool, the reading available on the pressure
special tools only.
gauge is the pre-pressure of the accumulator.
1. Park the machine on flat and open ground, The reading should be 1.0± 0.05 MPa.
and lower the bucket on the ground. Turn the 6. Add nitrogen if the pressure is low; if the
shift control lever to NEUTRAL, stop the pressure is higher than expected, adjust the
engine. Turn the engine start switch relief valve to get the desired pressure
clockwise to the I position to turn on the reading.
power.
7. Turn the mandrel handle of the charging tool
rightwards to finish charging, and then
remove the charging tool from the
accumulator. Install the protection cap of the
charging valve.
280
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Accumulator of Pilot Oil Supply Valve-- 4. Tighten the mandrel handle and relief valve
Charge of the accumulator charging tool, and fasten
the charging tool to the charging valve of the
accumulator with slotted nut D.

If nitrogen pre-pressure of the accumulators

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

4
Charge the accumulator by trained personnel
with special tools only.
8
Operation steps are as follows:
1. Park the machine on flat ground and lay the
bucket flatly on the ground. Place the shift
control lever to NEUTRAL position and shut
down the engine. Turn the engine start switch
clockwise to the I position to turn on the
power.
2. Move the work implement lever to any
direction continuously to discharge the high
pressure oil inside the accumulator. 3 2

1
7

Do not let the residual pressure oil in the

accumulator spray any one as this can cause
5
injury or death.

3. Remove the protection cap of the charging

valve from the accumulator.

1. Mandrel handle 5. Gasket

2. Charging valve body 6. Charging hose
3. Pressure gauge 7. Relief valve
4. Check valve 8. Charging joint
281
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

10. Install the protection cap of the charging

valve on the accumulator.

Charging joint 8 only suitable for Chinese

nitrogen bottle. If the charging tool is used to
Do not turn the steering wheel when
nitrogen bottles of other countries, consult
removing the protection cap of the charging
the supplier to purchase the charging joints
valve, and ensure that the engine has been
of the relative countries.
stopped to avoid personal injury.
5. Connect the port M of the charging hose to Charge the accumulator with nitrogen only.
the check valve of the charging tool, install Do not charge it with oxygen, compressed air
the charging joint on the port G1 of the or other flammable gas to avoid explosion.
charging hose, and connect the G5 / 8 thread
connector of the charging joint to the
charging valve of the nitrogen bottle. Ride Control Accumulator Pre-Charge
Pressure--Check
6. Open the nitrogen bottle valve. Slowly turn
the mandrel handle leftward to charge the Check the ride control accumulator pre-charge
accumulator after the pointer of the pressure pressure at the first 50, 100, 250, 500, 1000
gauge is stable. service hours of operation. Check once every
7. The inflated pressure may be obtained in a 2000 services hours later on.
short period. Turn off the nitrogen bottle valve The charging tool of ride control accumulator is
to check whether the pressure on the gauge Parker 201381-121, LiuGong part number is:
have reached 1.0 ± 0.05MPa. Recharge if the 44C2684.
pressure is not sufficient and adjust relief
valve on the charging tool to lower the
pressure to appropriate value if the pressure
is too high.
Check accumulator nitrogen precharge
8. If the desired pressure is available, turn off pressure according to the intervals specified
the nitrogen bottle valve then turn the in Maintenance Interval Schedule section to
mandrel handle rightwards to turn off the ensure the proper working of the service
charging tool. Remove the charging tool. brake system and parking brake system.
9. Apply a coat of engine oil to the top of the Checking of the pre-charge pressure should
charging valve to check if any leakage only be done by trained personnel with
occurs. There is a leak if air bubbles are special tools only.
found. Consult your LiuGong dealer to
eliminate the fault.
282
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

The ride control accumulator of this machine is 4. Tighten the valve A (turn rightwards) on the
attached inside the front frame. accumulator charging tool, turn off the valve
B then tighten the cap of valve C. Install the
charging tool to the charging valve of the ride
1 control accumulator with slotted nut D.

B A C
2

1. Ride control accumulator

2. Protection cap of the charging valve
1. Park the machine on flat and open ground,
A. Valve
and lower the bucket on the ground. Turn the B. Exhaust valve
shift control lever to NEUTRAL position and C. Anti-return valve
set the engine to idle speed. Turn the engine D. Slotted nut
start switch clockwise to the I position to turn 5. Slowly open the valve A (turn leftward) on the
on the power. charging tool, then the reading on the
2. Turn on the ride control switch, and then pressure gauge is the nitrogen pre-charge
operate the work implement control lever to pressure of the accumulator. Its valve should
set the boom to FLOAT state for about 3~4 be: 2.5±0.05MPa.
minutes to drain out the high-pressure oil in 6. Add nitrogen if the pressure is low; if the
the accumulator. pressure is higher than expected, adjust the
Ride control switch exhaust valve B to get the desired pressure
reading.
7. Close the valve A (turn rightwards) on the
charging tool, and then remove the charging
tool from the accumulator. Install the
protection cap of the charging valve.

3. Stop the engine and remove the protection

cap of the charging valve from the top of
accumulator.
283
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Ride Control Accumulator--Charge 5. Take off the cap of the anti-return valve C.
Connect a hose with one end to the anti-
return valve C and the other end to the
nitrogen bottle.
6. Open the nitrogen bottle valve. After the
If nitrogen pre-pressure of the accumulator is pointer of the pressure gauge is stable,
insufficient, refill in time, otherwise the slowly open the valve A (turn leftward) to
normal use of the ride control system could charge the accumulator.
be affected. Charge the accumulator by
trained personnel with special tools only. 7. The charge pressure may be obtained in a
short time. Close the nitrogen bottle valve to
check whether the pressure on the gauge
1. Park the machine on flat and open ground,
has reached 5.5±0.05MPa. Recharge if the
and lower the bucket on the ground. Turn the
pressure is insufficient and adjust exhaust
shift control lever to NEUTRAL position and
valve B on the charging tool to lower the
set the engine to idle speed. Turn the engine
pressure to the appropriate value if the
start switch clockwise to the I position to turn
pressure is too high.
on the power.
8. If the pressure reaches the required value,
2. Turn on the ride control switch, and then
close the nitrogen bottle valve first, and then
operate the work implement control lever to
close the valve A on the charging tool.
set the boom to FLOAT state for about 3~4
Remove the charging tool.
minutes to drain out the high-pressure oil in
the accumulator. 9. Apply a coat of engine oil to the top of the
charging valve to check if any leakage
3. Stop the engine and remove the protection
occurs. There should be a leak if air bubbles
cap of the charging valve from the top of
are found. Contact your LiuGong dealer for
accumulator.
repair information.
4. Tighten the valve A (turn rightwards) on the
10. Install the protection cap of the charging
accumulator charging tool, turn off the valve
valve on the accumulator.
B. Install the charging tool to the charging
valve of the accumulator with slotted nut D.

B A C
Do not turn the steering wheel when
removing the protection cap of the charging
valve, and ensure that the engine has been
stopped to avoid personal injury.

D Charge the accumulator with nitrogen only.

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

A. Valve
B. Exhaust valve
C. Anti-return valve
D. Slotted nut
284
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Steering Cushion Accumulator Pre- 3. Move the pilot control lever to any directions
charge Pressure--Check continuously to discharge the high pressure
oil inside the accumulator.
Check the accumulator pre-charge pressure at
the first 50, 100, 250, 500, 1000 service hours of
operation. Check once every 2000 services
hours later on. Do not let the residual pressure oil in the
The accumulators for the steering system are accumulator spray any one as this can
located on the front frame, one on the left and cause injury or death.
one on the right.
4. Remove the protection cap of the charge
valve from the accumulator.
5. Tighten the valve A (rightwards) on the
accumulator charge tool, turn off the valve B
then tighten the cap of valve C. Install the
charge tool to the charge valve of the
accumulator with slotted nut D.

B A C

D
Check accumulator nitrogen precharge
pressure according to the intervals specified
in Maintenance Interval Schedule section to
ensure the proper working of the service A. Valve
brake system and parking brake system. B. Exhaust valve
Checking of the precharge pressure should C. Anti-return valve
only be done by trained personnel with D. Slotted nut
special tools only. 6. Slowly open the valve A on the charge tool
(leftwards), the reading available on the
1. Park the machine on flat and open ground,
pressure gauge is the pre-pressure of the
and lower the bucket on the ground. Turn the
accumulation. The reading should be 3 ±
shift control lever to NEUTRAL, stop the
0.05MPa.
engine.
7. Add nitrogen if the pressure is low; if the
2. Turn the steering wheel left and right 5 times.
pressure is higher than expected, adjust the
exhaust valve B to get the desired pressure
reading.
8. Turn off the valve A on the charge tool
(rightwards), and then remove the charge
tool from the accumulator. Install the
protection cap of the charge valve.
285
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Steering Cushion Accumulator--Charge 6. Take off the cap of anti-return valve C.

Connect a hose with one end of it and the
another end to the nitrogen bottle.
7. Open the nitrogen bottle valve. Slowly open
the valve A (leftward) to charge the
If nitrogen pre-pressure of the accumulator is
accumulator after the pointer of the pressure
insufficient, refill in time, otherwise the
gauge is stable.
normal use of the ride control system could
be affected. Charge the accumulator by 8. The inflated pressure may be obtained in a
trained personnel with special tools only. short period. Turn off the nitrogen bottle valve
to check whether the pressure on the gauge
1. Park the machine on flat and open ground, have reached 3 ± 0.05MPa. Recharge if the
and lower the bucket on the ground. Turn the pressure is not sufficient and adjust exhaust
shift control lever to NEUTRAL, stop the valve B on the charge tool to lower the
engine. pressure to appropriate value if the pressure
is too high.
2. Turn the steering wheel left and right 5 times.
9. If the desired pressure is available, turn off
3. Move the pilot control lever to any directions
the nitrogen bottle valve then take off the
continuously to discharge the high pressure
valve A on the charge tool. Remove the
oil inside the accumulator.
charge tool.
4. Remove the protection cap of the charge
10. Apply a coat of engine oil to the top of the
valve from the bottom of the accumulator.
charge valve to check if any leakage occurs.
There is a leak if air bubbles are found.
Consult your LiuGong dealer to eliminate the
fault.
11. Install the protection cap of the charge valve
on the accumulator.

When removing the protection cap of the

charging valve, do not rotate the steering
5. Tighten the valve A (rightward) on the wheel and ensure the engine has been
accumulator charge tool, turn off the valve B stopped to avoid personnel injury.
then tighten the cap of valve C. Install the
Charge the accumulator with nitrogen only.
charge tool to the charge valve of the
Do not charge it with oxygen, compressed air
accumulator with slotted nut D.
or other flammable gas to avoid explosion.
B A C

D
286
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Brake System

Maintenance Table

Interval (Hours)

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

As
every every or 2 or every or three or half or one
required
day week weeks month months a year year
Service brake performance--
Inspect
Parking brake performance--
Inspect
Parking brake clearance--
Check/ Adjust ★★★

Parking brake and service

brake accumulator pre-charge ★★★ ★★★ ★★★ ★★★ ★★★
pressure--Check
Parking brake and service
brake accumulators--Charge
Note: ★ ★ ★ indicates the first service interval.

Service Brake Performance--Inspect If the brake distance exceeds 15m, consult your
Liugong dealer for brake system checking.
Eliminate the problems before going on working.

Before checking the service brake ability,

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

Check the service brake performance of the

machine on hard, dry and flat road surface. Make
sure no personnel or obstacles are around when
checking. Fasten the seat belt before checking.
1. Start and drive the machine at 32km/h.
Depress the service brake pedal to fully
brake the machine. After the machine stops,
turn the shift control lever to NEUTRAL,
engage the parking brake then release the
service brake pedal. The brake distance
should not exceed 15m.
2. Start and drive the machine at 32km/h.
Perform spot braking, the machine should
stop immediately without deflection.
287
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Parking Brake Performance--Inspect Parking Brake Clearance--Check/Adjust

Check the parking brake performance Check and adjust the parking brake
frequently to ensure the machine can safely clearance after the brake cools down.
stop and ensure its emergency braking
capability. Check the parking brake clearance at the first 50
hours, then check it every 250 hours later on to
1. Adjust the air pressure of the machine tires to ensure good braking ability.
the specified value, lay the bucket flatly with
The parking brake is located at the front side of
a distance about 300mm above the ground.
the output shaft of the transmission.
Make sure the service brake is performing
normally.
2. Start the engine and drive the machine to a
slope with a gradient of 18% (the angle is
about 10°12'). The slope surface should be
smooth and dry.

1. Park the machine on flat ground, stop the

engine and install the steering frame lock.
10°12’

3. Depress the service brake pedal to stop the

machine. Turn the shift control lever to
NEUTRAL position, and do not stop the
engine.
4. Engage the parking brake and slowly release
the service brake pedal. Check to see if the
machine has moved from its original location.
If the machine moves while checking, consult
your Liugong dealer for brake system checking.
2. Press the parking brake button to disengage
Eliminate the problems before going on working.
the parking brake.

Personal injury can result if the machine

moves while checking.
288
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

3. Use a clearance gauge to measure the c) After adjusting in position, hold the
clearance between the brake shoe friction adjusting rod, and screw the locknut.
plates and brake disc. The clearance should
d) After finishing adjustment, use the
be within the range of 1mm~3mm.
clearance gauge to measure the
clearance between the brake shoe
friction plates and brake disc again. If the
1mm~3mm
clearance still can not meet the
requirement, replace the friction plates of
the brake shoe.
e) Install the brake screw cap.
f) Operate the parking brake button
repeatedly to check the parking brake
1
ability by stopping the machine on a
slope.
1. Brake disc
Parking Brake and Service Brake
4. If the clearance is beyond 1mm~3mm, adjust
Accumulator Pre-charge Pressure
the clearance according to the following
method:
--Check

a) Remove the brake screw cap, loosen the Check the accumulator pre-charge pressure at
locknut, and adjust the adjusting rod to the first 50, 100, 250, 500, 1000 service hours of
press the brake shoe friction plates operation. Check once every 2000 services
against the brake disc tightly. At this time, hours later on.
the clearance between the brake shoe
friction plates and brake disc should be 0. Three accumulators are used for the brake
system. They are located in the box near the
right ladder.

2
7
6
5
The charging tool of brake accumulators is
2. Brake shoe friction plates Heidek FPU-1-350 / 250F4G11K, LiuGong part
3. Open end wrench number is: 13C1215.
4. Brake screw cap
5. Socket wrench
6. Locknut
7. Adjusting rod
b) Loosen the adjusting rod in reverse for 4/
5 turns, at this time, the clearance
between the brake shoe friction plates
and brake disc should be 2.0mm.
289
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Accumulator 1 is used for the parking brake 4. Tighten the mandrel handle and relief valve
circuit and accumulator 2 and 3 are used for the of the accumulator charging tool, and fasten
service brake circuit. the charging tool to the charging valve of the
accumulator with slotted nut D.

1
5
1 2

2
4
3

1. Parking brake accumulator 1

2. Service brake accumulator 2 1. Mandrel handle
3. Service brake accumulator 3 2. Check valve
3. Charging valve body
4. Pressure gauge
5. Relief valve

Check accumulator nitrogen precharge 5. Slowly turn the mandrel handle of the
pressure according to the intervals specified charging tool leftward to turn on the charging
in Maintenance Interval Schedule section to tool, the reading available on the pressure
ensure the proper working of the service gauge is the precharge pressure of the
brake system and parking brake system. accumulator after the pointer of the pressure
Checking of the pre-charge pressure should gauge is stable. The reading should reach
only be done by trained personnel with the standard value in the following table.
special tools only. Nitrogen precharge
Name
1. Park the machine on flat and open ground, pressure
and lower the bucket on the ground. Turn the Parking brake
shift control lever to NEUTRAL, stop the 9.2 ± 0.3MPa
accumulator 1
engine. Then turn the engine start switch Service brake
clockwise to the I position to turn on power. 5.5 ± 0.3MPa
accumulators 2 & 3
2. Continuously depress the brake for about 20 6. Add nitrogen if the pressure is low; if the
times, then press down and pull up the pressure is higher than expected, adjust the
parking brake button for about 20 times, relief valve to get the desired pressure
release high pressure oil from the reading.
accumulators.
7. Turn the mandrel handle of the charging tool
3. Remove the protection cap of the charging rightwards to finish charging, and then
valve from the accumulators. remove the charging tool from the
accumulator. Install the protection cap of the
charging valve.
290
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Parking Brake and Service Brake 8

Accumulators--Charge

If nitrogen pre-pressure of the accumulators

is insufficient, refill in time, otherwise the
normal use of the brake system could be
affected. Charge the accumulator by trained
personnel with special tools only.
3 2
1. Park the machine on flat ground and lay the 1
bucket flatly on the ground. Place the shift
control lever to NEUTRAL position and shut 7
down the engine. Then turn the start switch
clockwise to I position to turn on the power.
5
2. Depress the brake pedal repeatedly for 20
times, then pull up and push down the
parking brake button for about 20 times to
discharge the high pressure oil inside the
accumulator. 6
3. Remove the protection cap of the charging
valve from the accumulator.
4. Tighten the mandrel handle and relief valve
of the accumulator charging tool, and fasten
the charging tool to the charging valve of the
accumulator with slotted nut D.
1. Mandrel handle 5. Gasket
2. Charging valve body 6. Charging hose
3. Pressure gauge 7. Relief valve
4. Check valve 8. Charging joint

5. Connect the port M of the charging hose to

the check valve of the charging tool, install
the charging joint on the port G1 of the
charging hose, and connect the G5 / 8 thread
connector of the charging joint to the
4 charging valve of the nitrogen bottle.
6. Open the nitrogen bottle valve. After the
pressure reading on the pressure gauge is
stable, slowly turn the mandrel handle
leftward to charge the accumulator.
291
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

7. The charge pressure may be obtained in a Lubrication System

short time. Close the nitrogen bottle valve to
check whether the pressure on the gauge
has met the standard. Recharge if the Grease--Add
pressure is insufficient and adjust relief valve
on the charging tool to lower the pressure to The yellow indicator on the display will light to
the appropriate value if the pressure is too alarm when the grease level of lubrication
high. See the following table for the standard system is too low, the grease in the reservoir has
nitrogen precharge pressure. dropped to the lowest level, add grease at once.

Nitrogen precharge
Name
pressure
Parking brake
9.2 ± 0.3MPa
accumulator 1
Service brake
5.5 ± 0.3MPa
accumulators 2 & 3

8. If the pressure reaches the required value,

close the nitrogen bottle valve first, and turn
the mandrel handle of the charging tool
rightwards to finish charging, and then 1
remove the charging tool from the
accumulator. 1. Dust cap

9. Apply a coat of engine oil to the top of the Add grease according to the following steps:
charging valve to check if any leakage 1. Remove the dust cap from the filler coupling;
occurs. There should be a leak if an air
bubble is found. Contact LiuGong service 2. Carefully clean the filler coupling and
personnel for maintenance. coupling on the filler hose used;

10. Install the protection cap of the charging 3. Fix the filler hose on the filler coupling;
valve on the accumulator. 4. Fill the reservoir up to maximum level
indicated on the reservoir;
5. The bottom of follower plate should line up
with max. level mark;
Do not turn the steering wheel when
removing the protection cap of the charging 6. Remove the filler hose and fit the dust cap.
valve, and ensure that the engine has been
stopped to avoid personal injury.
Charge the accumulator with nitrogen only.
Do not charge it with oxygen, compressed air Do not fill the reservoir until the low level
or other flammable gas to avoid explosion. warning comes on at the display.
If there is filler hose on the filler coupling of
the grease pump, add grease through this
filler hose.
292
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Lubrication Diagram and Intervals

If centralized lubrication system is not provided on this machine, add lubricant according to the
lubrication diagram and intervals.

Lubrication chart
293
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Intervals in work hours

No. Service points As
Oil Capacity
10 50 100 250 500 1000 1500 2000 4000 4500
needed
1 Coolant ◆ ▲ ■ COO 36L
2 Air filter (primary) ● ■
3 Air filter (main) ■
4 Fuel tank ◆ ▲ FO 420L
5 Fuel tank filter ● ■ ▲
6 Fuel pre-filter ★ ■
7 Fuel filter ■
8 Engine oil ▲ ■ EO 35L
9 Engine oil filter ■
10 DEF tank ◆ ▲ ● DEF 50L
11 DEF supply module ●
12 DEF supply module filter ■
13 Transmission ◎■ ■ TO 50L
14 Transmission oil filter ◎■ ■
15 Front axle oil ◆ ◎■ ■ AO 60L
16 Rear axle oil ◆ ◎■ ■ AO 60L
17 Hydraulic tank return filter ◎■ ■
18 Hydraulic oil tank ◆ ▲ ● HO 300L
19 Pilot oil filter ◎■ ■
Pilot oil supply valve
20 ▲◆
accumulators
21 Ride control accumulator ▲◆
(Service & parking) brake
22 ◆ ▲
accumulators
Air condition freezing
23 ◆ ▲ ACF 0.9kg
medium
24 Air condition outer filter ● ■
25 Air condition inner filter ● ■
26 Steering accumulator ▲◆
A A type lubricating point ◆ GRE
B B type lubricating point ◆ GRE
294
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Service symbol Oil symbol Work hours Corresponding period

▲ Check Engine oil EO 10 Every day

● Clean Hydraulic oil HO 50 Every week
Add, lubricate, nitrogen
◆ Coolant COO 100 Two weeks
charge
■ Change, replace Fuel FO 250 Every month
★ Drain Axle oil AO 500 Three month
For first time Transmission oil TO 1000 Six months
(use in conjunction with Grease GRE 1500 Nine months
◎ other symbols, for example: Air condition freezing
ACF 2000 Every year
◎■ means the first change, medium
◎▲ means the first check) Diesel exhaust fluid DEF 4500 Three years
Use the specify element to maintenance to avoid any damage to the machine.
Shorten the intervals of maintenance when working in a rough condition.
295
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Electrical System 3. Check the battery hydrometer color. Green

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

1. Open the battery box cover to get access to The battery clamp plate, battery terminals
the battery. and cable leads 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 clamp plate. Tighten it if it is loose.

Battery--Install

Before installing the battery to the machine,

make sure that the battery hydrometer is green.

2. Check whether the clamp nut, battery

terminal and cable lead are loose. Tighten The battery should not be inclined over 40°.
them if they are loose. Do not place the battery reversely or by any
side of it.
Make sure the hydrometer is green before
installing the battery. It is not allowed to
5 install the battery with a black hydrometer
onto the machine.
1 3
Do not install a leaked battery onto the
machine.
4 2 1. Turn the start switch (also called ignition
switch) to OFF position then remove the key.
Turn disconnect switch to OFF position.
1. Battery terminal 2. Clean the battery terminals and surface with
2. Nut a clean cloth. Do not use harsh chemicals or
3. Battery terminal(without jacket)
4. Clamp plate cleansers for cleaning.
5. Hydrometer
3. When connecting:
a) Connect the positive post of one battery
to the negative terminal of the other
battery with the cable.
296
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

b) Connect one end of the battery positive Battery--Charge

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

4 Charge the battery to let it work normally if

the above-mentioned phenomenon
happens.

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

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

A wrong installation of the negative and

positive terminal will result in a serious
damage to the battery. Distinguish the
positive (+) and negative terminal (-)
correctly.
297
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Battery charging ● Table of charge time and battery voltage for

reference(lower current means a longer
charging time).

Battery Voltage Charge Time

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

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

keep any kindling away. 12.05-11.95VDC 6h

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

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

5. Connect the positive clamp of the charger to

the positive terminal of the battery, the
negative clamp to the negative terminal
under room temperature.
6. It is recommended to use a charger with a
constant voltage of 16VDC (the maximum
voltage cannot exceed 16 ± 0.1 V, maximum
current can not exceed 25A) to charge the
battery. Green hydrometer indicates the
battery charging is finished.
7. Charge the battery according to the following
specification if the above-mentioned
requirement can not meet:
● 1/10 of rated current to charge.
298
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

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

12. It is recommended applying vaseline on the 4. As for the machine which has not
battery terminals to avoid electric corrosion disconnected the battery terminals, check the
after charge is completed. battery voltage state every month. If the
voltage is under12.4V, recharge it according
Charge the battery according to the following to special procedures.
method when the battery voltage is low, but the
machine still can be started and alternator works 5. As for the machine which is stored over 1
normally. year, replace with a new battery and dispose
the old one if the above- mentioned
requirements can not be followed.
299
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Battery--Recycle 8. Connect the battery cable with the battery

disconnect switch.
When discarding a battery, its inner material 9. Install the switch key and turn the battery
such as lead, acid and plastic shell can pollute disconnect switch to ON position.
the environment due to its outer frayed structure
or other reasons. Therefore, do not throw away
Alternator--Maintain
the old battery randomly, deal with it by collecting
for a battery disposal station or put it into a
recycle can set by the manufacturer (if there is
any) in a local place.
It is forbidden to check the alternator by
Battery, Cable, Battery Disconnect short-circuiting the negative and positive
Switch--Replace terminals of the alternator, otherwise the
diode will be burnt and the voltage regulator
1. Turm the engine start switch key to OFF could be affected.
position. Turn all of the switches to OFF
position. Take out the switch key. Keep any metallic conductor away from
positive terminals of the alternator.
2. Turn the battery disconnect switch to OFF
position.
The alternator is a supporting component of the
3. Disconnect the negative battery cable from diesel engine, refer to specification section or the
the battery disconnect switch. alternator’s nameplate for the working voltage
and current value of the alternator. It has a built-
4. Sequences for disconnecting the battery
in electronic voltage regulator. Check the
cables:
connections of the alternator terminals
● Disconnect the negative battery cable from frequently. Connection looseness at either
the battery. positive terminal or negative terminal will result in
● Disconnect the positive battery cable from trouble of the electrical system, even cause
the battery. serious failure.
Turn off the start switch before checking the two
terminals for good connection.

Do not let the disconnected negative battery

cable contact with the battery disconnect
switch. The cable of the terminals can not be
incorrectly connected, otherwise the diode
5. Inspect the battery terminals for corrosion. could be burnt and result in serious failure.
Inspect the battery cables for wear or
damage. Method of judging whether the alternator
6. Make any necessary repairs. If necessary, works normally and the handling measures:
replace the battery cables or the battery. 1. Turn on the start switch and observe the
7. Sequences for connecting the battery cables: reading of the voltmeter, and then start the
diesel engine and observe reading of the
● Connect the positive battery cable to the voltmeter again. The latter reading should be
battery. higher than the former one.
● Connect the negative battery cable to the
battery.
300
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

2. You can also use the 200V DC voltage Fuse--Check/ Replace

position of a multimeter to check. Turn on the
start switch, measure terminal voltage of the The fuses protect the electrical system from
alternator (red meter pen connects positive being damaged due to circuit overload. If the
terminal of the alternator while black meter fuse is broken, replace with a new one. Check
pen connects the ground), and then write the circuit if the new fuse is broken again. Repair
down the reading of the multimeter. the circuit, if necessary.
3. Start the engine and increase the engine
speed to rated speed. Check the voltage of
the alternator again and write down the
reading of the multimeter. The latter reading Replacing fuses with the same type and size
should be higher than the former one. from different brands is allowed. Do not use
4. In case the alternator does not work: copper wire, otherwise the circuit could be
damaged.
a) Check the drive belt of the alternator for
looseness. It is recommended to use fuse supplied by
LiuGong if it needs to replace the fuse when
b) Turn off the start switch, and then use a repairing. Do not buy the fuse randomly in
wrench to check the connections of the the market as fuse of poor quality will bring
alternator terminals. bad effect to the machine, even could cause a
c) Check to see whether the alternator fire.
connects correctly to the ground.

Starter Motor--Maintain
If it is necessary to replace fuses frequently,
The starter motor is a supporting component of an electrical problem may occur. Contact
the diesel engine. It mainly consists of a your LiuGong dealer.
solenoid, DC motor, shifting fork and driving
gear. The starter motor converts electrical energy The fuse box is located in the cab on the rear left
of the battery into mechanical energy through the side of the driver’s seat, open the cover to
DC motor. Then the driving gear will drive the maintain the fuses, as show below:
flywheel of the engine to start the engine.
After the engine starts, the starter motor should
immediately stop. Otherwise, the driving gear
may be damaged, the DC motor may be burnt,
the chock electromagnet may be damaged, and
capacity and service life of the battery may also
be greatly affected.
It is prohibited to allow any metallic conductor to
approach any naked terminal freely. Especially
ensure that the other metallic articles around the See the picture inside the fuse box for the fuse
starter motor will not contact or rub the naked distribution.
terminal after a long and severe shock or
operation of the machine. Otherwise, fire may
occur to the machine.
301
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Definition table for function of plug-in fuse is as follows:

16
15
14 17
13 18
12
11
10
9 19
8 20
7 21
6 22
5 23
24
4
25
3
26
2 27
1 28

49C6609

No. Definition Specification No. Definition Specification

Radio and tape player/ cigar
1 10A 15 DEF sensor 10A
lighter
2 Auxiliary function 4 7.5A 16 Fuel heating 10A
3 Secondary steering system 7.5A 17 Right position lights 5A
4 ECM power supply 2 10A 18 Left position lights 5A
5 Instrument 7.5A 19 DEF heating 3 10A
6 Auxiliary function 2 10A 20 DEF heating 2 10A
302
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

No. Definition Specification No. Definition Specification

7 Auxiliary function 3 7.5A 21 Horn/ backup alarm 10A

8 Floodlights 10A 22 Brake lights 7.5A
9 Rear work lights 10A 23 Auxiliary function 1 10A
10 Defroster 20A 24 DEF heating 10A
11 DC-DC 10A 25 DEF supply module 10A
12 Seat 15A 26 Flasher/ position lights 7.5A
13 Wiper 20A 27 ECM power supply 1 7.5A
14 Front work lights 15A 28 Engine start switch 7.5A

Other fuses are in the battery box. Check and replace the fuse as follows:

1. Turn the start switch to OFF position.

2. Open the fuse box cover. Take off the broken
fuse with a clamp.
3. Replace the broken fuse with a new one with
same specification.
4. Install the fuse box cover.
The slice type fuse and flat type fuse that used in
this machine should meet the regulation in
standard of QC/T420 Fuse-Links for Motor
Vehicles.
See the following table for the fuse color:

Model Color
1 2 3 4 5 6 7 8 BK/ATC-5A Orange

No. Definition Specification BK/ATC-7.5A Brown

1 Start relay 150A BK/ATCC-10A Red

2 Engine hood lifting 30A BK/ATC-15A Blue

3 ECM 30A BK/ATC-20A Yellow

4 Air conditioner 30A BK/ATC-30A Green

5 Centralized control box 50A

6 Alternator fuse 80A
7 Grid heating 150A
8 Main power fuse 80A
303
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Air Conditioning System

Maintenance Table

Interval (Hours)

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

As
every every or 2 or every or three or half or one
required
day week weeks month months a year year
Air conditioner refrigerant
level--Check
Compressor belt tension--
Check
Evaporator--Check
Condenser--Clean
Compressor--Maintain
Cab recirculating air strainer--
Clean
Cab recirculating air strainer--
Replace
Cab fresh air strainer--Clean
Cab fresh air strainer--Replace

Refrigerant Level--Check See the following picture for the refrigerant level:

Personnel injury or death could result due

to the inhaled refrigerant gas or frog 3
through lighting the cigarette or other
smoking ways. Never smoke when
maintaining the air conditioner or in the
4
place where refrigerant gas may exist.

After turning on the air conditioner, check the

refrigerant in the refrigerant receiver for bubbles 5
through the sight glass to judge if the refrigerant
is sufficient or not. Many bubbles indicate 2
refrigerant is insufficient while few bubbles or no 1. Sight glass
bubbles indicate the refrigerant is sufficient. 2. Refrigerant receiver
3. Few refrigerant
4. Insufficient refrigerant
5. Enough refrigerant
304
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

3. Replace the belt if the belt has cracks or

splits.
4. Check the air conditioner belt tension with a
gauge.
R134a refrigerant is used in this air
conditioning system. Do not use other a) The used air conditioner belt tension
refrigerant or refrigerant with low quality to should be 400 ± 44N when it has run for
avoid damaging the compressor. more than 30 minutes at the rated speed.
Do not add excess refrigerant when adding b) The new air conditioner belt tension
refrigerant to avoid compressor liquid should be 534 ± 22N when it has run in
impact damage caused by insufficient space 30 minutes at the rated speed.
for refrigerant vaporization in the air
conditioning system. Adjusting the air conditioner belt tension as
follows:
If refrigerant leakage is found, check all the
joints that connect to the hoses for loose 1. Unscrew the mounting bolt of the compressor
conditions. bracket and adjust it.

Compressor Belt Tension--Check/ 2. Insert a pawl with a square bar into the
Adjust/ Replace mounting bracket hole. Rotate the
compressor outwards with this mechanism
being the lever. Rotate the compressor until
The compressor belt tension: apply(W=15N)
obtain a proper belt tension.
force in the center span of the pulleys
(compressor pulley and engine pulley). The 3. Tighten the mounting bolt of the compressor
deflection of the belt center distance should be 4 bracket and adjust it.
± 1mm. See the following picture:
4. Recheck the belt tension. Repeat the above
adjusting procedure if the belt tension is
W improper.
2

1. Engine pulley
2. Compressor pulley
1. Shut down the engine, open the engine hood
to access the air conditioner compressor.
2. Check the air conditoner belt. Replace with a
new belt if the belt is not tense. That is, the
deflection of the belt center distance is more
than 4±1mm when applying (W=15N) force in
the center span of the pulleys (compressor
pulley and engine pulley).
305
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Evaporator--Check Condenser--Clean

The evaporator is located at the ladder on the left Condenser is located near the radiator under the
side of the cab. engine hood.
The fresh air strainer (fresh air vent) and
recirculating air vent of the evaporator should be
regularly checked and cleaned to avoid being
blocked by accumulated dirt. If not, the fresh air
will be reduced due to clogging of the fresh air
vent or recirculating air vent, which could affect
the comfort in the cab.
Evaporator (recirculating air vents)
Clean the condenser regularly. Mainly need to
clean the radiator fin of the condenser, too much
dirt on the radiator fin will affect the condenser
cooling and reduce its performance, and finally
affect the cooling of the air conditioning system.

Evaporator (fresh air strainer)

306
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

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

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

5. Air conditioner system only can be used after

the engine is started. After stopping the
engine, turn off the power / fan speed switch.
(it’s better not to start the air conditioner
suddenly during high engine speed).
6. Normally, turn the temperature control switch
to the High position to decrease the
temperature, and turn it to Medium or Low
position to keep the temperature.
7. Do not turn the temperature control switch to
High position with fan speed switch at low
position, otherwise the evaporator could be
frosted.
8. In moist weather, air is wet due to humidity.
Turn the temperature control switch to
Medium cooling position and fan speed
switch to Low position to dehumidify.
9. R12 and R134a refrigerant can not
interchanged in the air conditioning system.
The reparing tools and spare parts for them
are also non-interchangable.
307
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Cab Air Strainer--Clean and Replace

The cab air strainers consist of the fresh air

strainer and recirculating air strainer. The
blockage condition of the strainers is entirely If the fresh air strainer is still blocked or
depending on the working environment of the damaged after being cleaned by compressed
machine. air or water, replace it with a new one.
3. Install the fresh air strainer to the original
position, and then install the cover plate.

The cab strainers are only intended to Clean /replace the recirculating air strainer
separate particles (dust and sundries) from
the air. Do not use it to filter toxic gas! 1. Open the blinds on the rear left interior trim.
The air flow rate will reduce if the
recirculating air strainer is blocked, and the
effect of cooling and heating will be
weakened. The fresh air will reduce if the
fresh air strainer is be blocked.
It may be dangerous when using compressed
air or high-pressured water to clean dust or
dirty materials. Wear protective glasses,
shields or other protective devices.

Clean /replace the fresh air strainer

1. Remove the four mounting bolts on the right

door cover plate of the cab, then remove the 2. Remove the recirculating air strainer.
cover plate. Remove the fresh air strainer
from the air conditioner evaporator.

2. Clean the strainer with compressed air. If the

strainer is too dirty or too oily, wash it with
neutral detergent. Dry the strainer completely
before reuse.
308
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

3. Clean the recirculating air strainer with

compressed air. Blow off the dust from the air
outlet side to the air inlet side.

If the recirculating air strainer is still blocked

or damaged after being cleaned by
compressed air or water, replace it with a new
one.

4. Install the clean recirculating air strainer to

the original position.
309
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Other Maintenance

Maintenance Table

Interval (Hours)
Item As
10hr or 50hr or 100hr 250hr or 500hr or 1000hr 2000hr
every every or 2 every three or half a or one
required
day week weeks month months year year
Tire air pressure and wear
condition--Check
Mounting bolt torque of hub--
Check
Hitch bolts of front and rear
axles--Tighten
Bucket positioner--Adjust
Boom lift kickout--Adjust
Bucket cutting edges--Check/
Replace
Bucket teeth--Replace
Backup alarm--Test
Seat belt--Inspect
Windows--Clean
Window wiper--Inspect/
Replace
Window washer reservoir--Fill

Bucket Positioner--Adjust 3. Push the pilot shutoff valve to OFF position if

equipped. If the machine is equipped with a
hydraulic lock switch, press it to LOCK
1. Park the machine on flat ground, push the position.
shift control lever to NEUTRAL position.
Pilot cut-off lever is at OFF position
2. Lower the bucket onto ground, engage the
parking brake, shut down the engine.
310
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Hydraulic lock switch Boom Lift Kickout--Adjust

UNLOCK
Pay close attention to safety when adjusting
the boom lift kickout. Keep any unauthorized
persons away from the machine. Do not allow
LOCK any person to stand under the boom.

1. Park the machine on flat ground and turn the

4. Install the steering frame lock. shift control lever to NEUTRAL position.
2. Turn the work implement control lever to
lower the bucket onto ground, and then
engage the parking brake. Stop the engine.
3. Turn the pilot shutoff lever (If equipped) to
OFF position. If the machine is equipped with
a hydraulic lock switch, press it to LOCK
position.

5. Loosen the bolts in following picture, adjust

the bucket positioner switch in back and forth
direction until it reaches proper position.
Tighten the bolts.

Hydraulic lock switch

UNLOCK

LOCK
1. Bolt
2. Bracket
6. Remove the steering frame lock and start the
engine. Check whether the above adjustment
is suitable or not.
311
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

4. Install the steering frame lock. Bucket Cutting Edges--Check/Replace

Personal injury or death can result from

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

5. Turn the start switch clockwise to ON position

to turn on power. Pull the work implement
control lever to the most backwards position,
then the lift kickout will be attracted by
electromagnetic force.
6. Loosen the bolt and adjust the kickout to
make the kickout switch align with the
magnet, then the electromagnetic force will
disappear and the work implement control
lever will reset to NEUTRAL position Check the cutting edges and the end bits for
automatically. Tighten bolt. wear and for damage. Use the following
procedure to service the cutting edges and the
3 2 end bits:
1. Raise the bucket and chock the bucket.
2. Lower the bucket onto the wedge. Stop the
engine.
1
3. Remove bolts, cutting edge and the end bits.
4. Clean all contact surfaces.
5. lf the opposite side of the cutting edge is not
worn, use the opposite side of the cutting
edge. The end bits are not overturned. If both
1. Magnet sides are worn, replace a new cutting edge.
2. Kickout switch
3. Bolt 6. Screw the bolts to the specified torque.
7. Keep a distance of 4~6mm between the 7. Start the engine. Raise the bucket and
kickout switch and magnet. Adjust the kickout remove the wedge. Lower the bucket to the
switch clockwise to reduce the lift height and ground.
counterclockwise to increase.
8. After a few hours of operation, check the
8. After adjustment, remove the steering frame bolts for proper torque.
lock and start the engine. Check whether the
above adjustment is suitable or not.
312
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Bucket Teeth--Replace 5. Install new tip on the tooth. Drive the pin into
the snap ring, tooth, and tip from the side of
Check the bucket teeth for wear and for damage. the snap ring.
Use the following procedure to service the
bucket teeth:

Personal injury or death can result from

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

1. Raise the bucket and chock the bucket.

2. Lay the bucket flatly on the block. Do not
place the bucket higher than required height
when replace the bucket teeth. Stop the
engine.
3. Remove the pin from the retainer of the teeth
then take off the tooth sleeve and the
retainer.

6. Start the engine.

7. Raise the bucket, take out the wedge, and
lower the bucket to the ground.

Backup Alarm--Test
4. Clean the tooth, pin and retainer. Install the Turn the engine start switch to I or ON position to
retainer on the lateral slot of the teeth. turn on the power of the machine.
Pull the parking brake button (parking brake
handle) up to engage the parking brake.
Turn the engine start switch to II or START
position to start the diesel engine.
Turn the shift control lever to REVERSE position,
the backup alarm should sound immediately.
The backup alarm will sound continuously until
the shift control lever is turned to NEUTRAL or
FORWARD position.
313
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Seat Belt--Inspect Window Washer Reservoir--Fill

The driver should check the seat belt for its Add washer through the water filler of the washer
condition and security before use. Replace it, if reservoir.
necessary. Washer reservoir location
Adjust the length of the seat belt to ensure its
restraint and comfort ability before use. Adjust it
by moving its buckle position on the belt.
Replace the seat belt every 3 years even though
it is in good condition. A valid date is provided on
every seat belt, confirm the use deadline of the
seat belt according to it.
For further information of the seat belt
replacement, refer to your Liugong dealer.

Windows--Clean

Use commercially available window cleaning

solutions in order to clean the windows. Clean
the outside windows from ground unless Check the washer reservoir frequently to
handholds are available. ensure enough water is in it, otherwise a
dirty windshield may impact the visibility of
Window Wiper--Inspect / Replace the operator.
Do not use wiper to wipe windshield when
the washer reservoir is out of water,
otherwise the wiper motor may be burnt out.
The washer reservoir should be emptied or
filled with antifreeze when the ambient
temperature is below 0 °C, otherwise the
washer will not work or even be damaged by
being frozen.

Inspect wiper blades. Replace the wiper blade if As the washer with additive may be harmful
it is worn or damaged or if streaking occurs. to human body, dispose of it according to
local laws and regulations.
314
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Welding Operation ● Electronic parts

● Other possible parts on the machine
To avoid possible damage to the machine, read
and understand the following cautions before 10. Keep any inflammable and explosive
welding and always observe the welding materials away from the welding site, protect
operation procedures as follows: any cable, do not allow sparks and solders
produced in welding to splash onto the
1. Park the machine on flat ground. cables, thus cause a fire and resulting in loss
2. Engage the parking brake. and injury.
3. Turn the pilot shutoff lever to OFF position (if 11. Use proper safety welding operation
equipped) or turn the hydraulic lock switch to procedures for welding.
LOCK position (if equipped).
Cautions for Welding Operation
4. Turn off the start switch to stop the engine.
5. Turn off the battery disconnect switch to ● Never use the earth position of the electrical
disconnect the battery and frame. parts on the machine as that of the welder.
6. If the machine is equipped with ZF control ●When performing welding near the earth
unit, to avoid damage of it, always remove all position of an electrical part, always
connectors of the instruments connected to disconnect the earth position of this electrical
the machine harness and ZF transmission part, and perform welding operation after
control unit before welding. ensuring that the welding circuit of the welder
doesn't get across this electrical part.
7. If your machine is equipped with other
Otherwise it will result in damage to this
electronic components such as
electrical part or even result in a fire.
loudspeakers, remove all connectors of the
electronic components connected to the ● Do not keep using voltage above 200V. Keep
machine harness before welding to avoid the welding area and earth cables within 1m.
possible loss. ● Avoid seals and bearings located between
8. Clear away paint from those parts to be the welding area and earth cables.
welded to prevent harmful air from ● Never weld any pipe or container with fuel,
production. engine oil or hydraulic oil.
9. Clamp the earth cables of the welder with the ● Never weld any sealed container or container
parts to be welded, keep the earth position which is poorly ventilated.
close to the welded place. Check and confirm
the circuits from the earth cables to the ● Do not allow sparks and solders produced in
welded parts don't get across any of the welding to splash onto the cables, rubber
following parts: hoses and other inflammable materials, thus
cause a fire and resulting in loss and injury.
● Bearings
● Hydraulic cylinders
● Controllers
● Internal circuit of other electronic parts
Any damage to the following parts could be
avoided by doing so:
● Bearings
● Hydraulic parts
315
September 4, 2020 Maintenance Manual
CLG877H Important Maintenance Procedures

Operation Procedure of Clutch Calibration (AEB)

If AEB has not been performed, a fault code "F6" will appear on the display.

Steps Information on display Remarks

The transmission oil temperature
1 General operating information
should be in hot state
2 Turn off the engine No display
3 Access AEB - Starter
1. The shift control lever must be
in Neutral.
4
2. The parking brake must be
engaged.
The button can be pressed to perform
AEB operation only when the TCU
5 Start the engine "PL"
detected the "PL" for more than 2
seconds
"PL" is displayed under normal
6 Engine is idling at about 800rpm
start
The start button can be released when
"ST" will be displayed if it is the AEB begins to operate or the fault
7 Press the AEB - Starter switch
normal codes appear (see description in
section 4)
TCU begins to perform AEB operation
Press the button until the AEB “K1”... (running state information
8 in the order K1, K2,..., KR (button can
begins of AEB)
be released)
9 AEB completed “OK” (successful AEB)
Turn off the engine and
10 No display
disconnect AEB - Starter
316
Maintenance Manual September 4, 2020
Important Maintenance Procedures CLG877H

Display Information Description

Display symbols Description Remarks

PL AEB - Starter access diagnostic interface
ST Press AEB - Starter button switch
K1..K4,KV,KR Calibrate clutch K1..K4,KV,KR
- and Kx Start calibration, initialize clutch Kx
≡ and Kx Kx fast oil filling stage
= and Kx Kx compensation oil filling stage
The transmission is in Neutral, disconnect
All clutch calibrations were successfully
OK AEB-Starter
completed
Restart TCU (power off/ on)
The transmission is in Neutral
STOP AEB was interrupted
TCU must be restarted (power off/ on)
AEB stopped The transmission is in Neutral
STOP and Kx
Kx cannot be calibrated TCU must be restarted (power off/ on)
AEB completed The transmission is in Neutral
Spanner and Kx
But Kx calibration failed TCU must be restarted (power off/ on)
The engine speed is too low ->
↑E
Increase engine speed
The engine speed is too high ->
↓E
Reduce engine speed
Transmission oil temperature is too low ->
↑T
Increase transmission oil temperature
Transmission oil temperature is too high
↓T
-> Reduce transmission oil temperature
The transmission is in Neutral, disconnect
The transmission oil temperature is within
FT AEB-Starter
the specified range during calibration.
Restart TCU (power off/ on)
Not in normal working mode;
The transmission is in Neutral, disconnect
Or the transmission oil temperature
FB AEB-Starter
sensor fails;
Restart TCU (power off/ on)
Or the memory EEPROM fails.
The transmission is in Neutral, disconnect
The machine did not stop completely
FO AEB-Starter
(output speed is not zero)
Restart TCU (power off/ on)
The transmission is in Neutral, disconnect
FN The shift control lever isn’t in Neutral AEB-Starter
Restart TCU (power off/ on)
The transmission is in Neutral, disconnect
The parking brake/ handbrake was not
FP AEB-Starter
engaged
Restart TCU (power off/ on)
The transmission is in Neutral, disconnect
AEB - Starter is not properly used or has
STOP AEB-Starter
failed
Restart TCU (power off/ on)

Note: AEB means clutch calibration; TCU means transmission control unit.
317
September 4, 2020 INDEX
CLG877H

INDEX

A C

A/C Panel ........................................................77 Cab Air Strainer--Clean and Replace ........... 307
Accelerator Pedal ............................................94 Cautions about Machine Maintenance ........... 37
Accumulator of Pilot Oil Supply Valve--Charge Cautions about Machine Operations .............. 30
.......................................................................280 CE Marking, EMC Directive .............................. 5
Air Conditioning System ................................303 Central Instrument Panel ................................ 55
Air Filter Safety Element--Replace ................248 Centralized Lubrication System .................... 124
Air Filter Service Indicator--Check ................247 Check Before Starting the Engine ................ 139
Alternator--maintain ......................................299 Combination Switch ........................................ 89
Applications .....................................................42 Compressor Belt Tension--Check/Adjust/
Applications and Specifications ......................42 Replace ........................................................ 304
Auxiliary Control Knob ..................................100 Compressor--Maintain .................................. 306
Auxiliary Control Lever ..................................102 Condenser--Clean ........................................ 305
Axle Oil Level--Check ...................................270 Control Devices .............................................. 83
Axle Oil--Replace ..........................................271 Coolant Level--Check ................................... 238
Coolant--Add ................................................ 239
Coolant--Replace .......................................... 241
B Crushing and Cutting Prevention .................... 25

Backup Alarm System (Optional) ..................123

Backup Alarm--Test ......................................312
D
Battery Disconnect Switch ..............................50
Battery, Cable, Battery Disconnect Switch-- Daily Inspection ............................................ 236
Replace .........................................................299 Display Information Description .................... 316
Battery--Charge ............................................296 Door Lock ..................................................... 118
Battery--Check ..............................................295 Door Positioner ............................................. 118
Battery--Install ...............................................295 Downhill Operation ....................................... 144
Battery--Recycle ...........................................299 Driving Operation of the Machine ................. 142
Battery--Store/ Service ..................................298 Driving the Machine ...................................... 157
Before Operation .............................................49 Dumping Operation ...................................... 147
Before Reuse ................................................155 During Storage ............................................. 155
Before Storage ..............................................155
Boom Lift Kickout--Adjust ..............................310
Brake Operation of the Machine ...................144
E
Brake System ................................................286
Breather Filter of Hydraulic Oil Tank--Clean .277 EC DECLARATION OF CONFORMITY ........... 6
Bucket Cutting Edges--Check/Replace .........311 Electrical Storm Injury Prevention .................. 28
Bucket Positioner--Adjust ..............................309 Electrical System .......................................... 295
Bucket Teeth--Replace .................................312 Engine Aftertreatment System ...................... 256
Burn Prevention ..............................................25 Engine Air Intake System--Check ................. 263
Engine Belt--Check ....................................... 263
Engine Fault Diagnosis ................................. 160
Engine Hood Lift Device ............................... 121
Engine Oil Filter--Replace ............................ 255
318
INDEX September 4, 2020
CLG877H

Engine Oil Level--Check ...............................253 I

Engine Oil--Replace ......................................254
Engine Start Switch .........................................51
Engine Starting .............................................139 Important Maintenance Procedures ............. 236
Engine System ..............................................237 Important Safety Information ............................ 1
Engine Valve Lash--Adjust ............................262 Information on Attachments ............................ 29
Evaporator--Check ........................................305 Instrument Panels ........................................... 52
Excavating With Bucket ................................146
K
F
Key Spare Parts to be Periodically Changed .. 40
Fan Belt Tension--Check/Adjust ...................263
Filter Element of the Air Filter--Replace (for L
Machine with Dedusting A/C) ........................245
Filter Elements of the Air Filter--Replace ......244
Fire &Explosion Prevention .............................26 Latch ............................................................. 119
Fire Extinguishers and First-aid Kit .................27 Leaving the Machine .................................... 154
Front Left Switch Panel ...................................64 Lifting the Machine ....................................... 157
Front Right Switch Panel ................................64 Lights ............................................................ 116
Fuel Filter--Replace ......................................252 Log Fork with Top Clamp ............................. 152
Fuel Level--Check .........................................249 Lowering the Work Implement with Engine
Fuel Pre-filter--Replace .................................252 Stopped ........................................................ 154
Fuel Strainer--Clean ......................................251 Lubrication Diagram and Intervals ................ 292
Fuel Tank--Clean ..........................................250 Lubrication Specifications ............................. 233
Fuel--Add ......................................................249 Lubrication System ....................................... 291
Fuse--Check/ Replace ..................................300
M
G
Machine Operation ....................................... 145
General Hazard Information ............................21 Main Components ............................................ 3
General Torque Specifications ......................231 Main Filter Element of the Air Filter--Clean/
Grease--Add .................................................291 Replace ........................................................ 247
Main Specifications ......................................... 43
Maintenance Guidance ................................. 224
H Maintenance Interval Schedule .................... 227
Maintenance Manual .................................... 224
Hand Pad ......................................................113 Mechanical Suspension Seat ....................... 110
Horn Switches .................................................88
Hydraulic Oil Level--Check ...........................273 O
Hydraulic Oil Tank--Clean .............................276
Hydraulic Oil--Add .........................................273
Hydraulic Oil--Replace ..................................274 Oil Change Interval and Refill Capacities ..... 233
Hydraulic System ..........................................272 Oil Specifications .......................................... 234
Operation during Cold Weather .................... 144
Operation Information ................................... 141
Operation Manual ........................................... 49
Operation Method ......................................... 153
319
September 4, 2020 INDEX
CLG877H

Operation Procedure of Clutch Calibration (AEB) ROPS/FOPS ................................................... 29

.......................................................................315 Run-in ........................................................... 226
Operation Techniques ...................................141
Operator Controls and Instrument Panels ......50
Operator Station ..............................................29
S
Other Devices ...............................................106
Other Maintenance .......................................309 Safety Decals and Decal Locations .................. 7
Safety Information ............................................ 7
Safety Warning Labels ..................................... 7
P Safety Warning Symbol .................................... 7
SCR System--Maintain ................................. 257
Pallet Forks ...................................................136 Scraping Operation ....................................... 148
Parking ..........................................................154 Seat Belt ....................................................... 112
Parking Brake and Service Brake Accumulator Seat Belt--Inspect ......................................... 313
Pre-charge Pressure --Check .......................288 Service Brake Pedal ....................................... 94
Parking Brake and Service Brake Accumulators-- Service Brake Performance--Inspect ............ 286
Charge ..........................................................290 Shift Control Lever .......................................... 90
Parking Brake Button ......................................94 Shoveling ...................................................... 145
Parking Brake Clearance--Check/Adjust ......287 Shoving Operation ........................................ 148
Parking Brake Performance--Inspect ............287 Side Dump Operation ................................... 149
Parking Brake Switch (for 877H Stage V) .......95 Small Tool Kit ............................................... 116
Pilot Filter Element--Replace ........................278 Snow Plowing Operation .............................. 150
Pilot Shutoff Lever .........................................107 Sound and Vibration ....................................... 39
Pneumatic Suspension Seat .........................108 Sound System .............................................. 113
Power Train System ......................................264 Starter Motor--Maintain ................................. 300
Pre-charge Pressure of Pilot Oil Supply Valve Steering Column (adjustable up and down) .. 107
Accumulator--Check .....................................279 Steering Column (not adjustable up and down)
Preface ..............................................................1 ....................................................................... 106
Preparation before Operation .......................145 Steering Cushion Accumulator Pre-charge
Pressure--Check ........................................... 284
Steering Cushion Accumulator--Charge ....... 285
Q Steering Frame Lock ..............................29, 123
Steering Handle (Optional) ........................... 103
Quick Coupler(Optional) ...............................131 Steering Operation of the Machine ............... 143
Steering Wheel ............................................... 88
Stopping the Machine ................................... 154
R Storage ......................................................... 155

Radiator Group--Clean ..................................262 T

Rear View Mirrors .........................................120
Refrigerant Level--Check ..............................303
Return Oil filter Element of Hydraulic Oil Tank-- Tire Explosion Prevention ............................... 28
Replace .........................................................277 Tire Inflation Information ............................... 232
Ride Control Accumulator Pre-Charge Pressure- Top Instrument Panel ..................................... 70
-Check ...........................................................281 Towing Information ....................................... 158
Ride Control Accumulator--Charge ...............283 Towing Operation ......................................... 148
Right Front Upright Column Switch Panel ......65 Towing the Machine ..................................... 158
Right Instrument Panel ...................................69 Towing with a Running Engine ..................... 160
Right Instrument Panel ...................................69 Transmission Oil Filter--Replace .................. 268
320
INDEX September 4, 2020
CLG877H

Transmission Oil Level--Check .....................264

Transmission Oil--Replace ............................266
Transportation Information ............................156
Transportation of Materials ...........................147
Transportation of the Machine ......................156
Turning off the Engine ...................................154
Type and Serial Number of the Machine and
Parts ..................................................................4

Water and Impurity--Remove ........................251

Welding Operation ........................................314
Window Washer Reservoir--Fill ....................313
Window Wiper--Inspect / Replace .................313
Windows--Clean ............................................313
Work Implement Control Lever ................ 96, 98

Liu Gong 835H - Service Manual
No ratings yet
Liu Gong 835H - Service Manual
590 pages
Clg6611e 6612e (Dcec Ii) Om 202108003-En
No ratings yet
Clg6611e 6612e (Dcec Ii) Om 202108003-En
132 pages
Grader Liugong CLG414
No ratings yet
Grader Liugong CLG414
156 pages
CLG2020H 2035HCLG2020G 2035G Service Manual EN 202307000
No ratings yet
CLG2020H 2035HCLG2020G 2035G Service Manual EN 202307000
366 pages
CLG856III Wheel Loader Service Manual
100% (8)
CLG856III Wheel Loader Service Manual
446 pages
CLG835H (T2) Service Manual 201806001-En
No ratings yet
CLG835H (T2) Service Manual 201806001-En
764 pages
CLGB320 (Double Cylinder) OM 201703001-EN
No ratings yet
CLGB320 (Double Cylinder) OM 201703001-EN
100 pages
Luigongclg2015a 15a-t 18a 18a-t 20a双驱电叉使用维护说明书 201403003-En
No ratings yet
Luigongclg2015a 15a-t 18a 18a-t 20a双驱电叉使用维护说明书 201403003-En
138 pages
816C Operation and Maintenance Book
No ratings yet
816C Operation and Maintenance Book
142 pages
ZL50CN Weichai&Yuchai&DCECII Operation Manual 201401002-En
No ratings yet
ZL50CN Weichai&Yuchai&DCECII Operation Manual 201401002-En
150 pages
CLG414 (India Cummins) OM 201603002-EN.
No ratings yet
CLG414 (India Cummins) OM 201603002-EN.
156 pages
CLG856H (Cummins T4f ZF Wet Axle ZF Gearbox) OM 202104008-En
No ratings yet
CLG856H (Cummins T4f ZF Wet Axle ZF Gearbox) OM 202104008-En
364 pages
CLGB230C (Ccec) Om 201807000-En
No ratings yet
CLGB230C (Ccec) Om 201807000-En
132 pages
CLG855H (Gcic T2) Om 201712000-En
No ratings yet
CLG855H (Gcic T2) Om 201712000-En
168 pages
CLG 922e Omm
No ratings yet
CLG 922e Omm
259 pages
M18ZB0088-1 Liugong
No ratings yet
M18ZB0088-1 Liugong
148 pages
CLGB260 Service Manual 202305000-En
No ratings yet
CLGB260 Service Manual 202305000-En
442 pages
Clg835h t2 (Weichai & Dcec China II Middle) Om 201806001-En
No ratings yet
Clg835h t2 (Weichai & Dcec China II Middle) Om 201806001-En
190 pages
CLG2010AS 30AS 35AS电叉产品使用维护说明书201801002-EN
No ratings yet
CLG2010AS 30AS 35AS电叉产品使用维护说明书201801002-EN
137 pages
CLG4215D (Gcic Ii) Om 201902000-En
67% (3)
CLG4215D (Gcic Ii) Om 201902000-En
160 pages
CLG2015AS 18AS 20AS 25AS电叉产品使用维护说明书201801002-EN
No ratings yet
CLG2015AS 18AS 20AS 25AS电叉产品使用维护说明书201801002-EN
154 pages
manua-CLGW915E (Cummins II ) OM 202006002-EN
No ratings yet
manua-CLGW915E (Cummins II ) OM 202006002-EN
258 pages
CLG862 200904001
83% (6)
CLG862 200904001
129 pages
CLGB320C (Ccec Iii) Om 201808000-En
No ratings yet
CLGB320C (Ccec Iii) Om 201808000-En
128 pages
CLG6015 Operation Manual 201405000-EN
No ratings yet
CLG6015 Operation Manual 201405000-EN
84 pages
Manual Retro
No ratings yet
Manual Retro
172 pages
CLG418 (35F0004) e
No ratings yet
CLG418 (35F0004) e
145 pages
LiuGong Operator and Maintenance
No ratings yet
LiuGong Operator and Maintenance
238 pages
ZL50CN-opertation Manuel PDF
100% (1)
ZL50CN-opertation Manuel PDF
121 pages
CLGB230 (Double-Cylinder) SERVICE Manual 201307000-En
No ratings yet
CLGB230 (Double-Cylinder) SERVICE Manual 201307000-En
95 pages
CLG842 (Dcec Ii) Om 201501006-En
No ratings yet
CLG842 (Dcec Ii) Om 201501006-En
192 pages
CLG6009 Operation Manual 201311000-EN
No ratings yet
CLG6009 Operation Manual 201311000-EN
60 pages
CLG4140 (Dcec Ii ZF) Om 201805001-En
No ratings yet
CLG4140 (Dcec Ii ZF) Om 201805001-En
154 pages
ZL50CN-maintemance Manuel
67% (3)
ZL50CN-maintemance Manuel
128 pages
Omm CPD15 20 25 30 30as
No ratings yet
Omm CPD15 20 25 30 30as
115 pages
CLG890H (Cummins T2&T3) OM 201904002-EN
No ratings yet
CLG890H (Cummins T2&T3) OM 201904002-EN
218 pages
CLG766A 777A (Perkins) OM 201811004-EN
100% (1)
CLG766A 777A (Perkins) OM 201811004-EN
172 pages
CLG904D (Yanmar ) OM 201505000-EN
No ratings yet
CLG904D (Yanmar ) OM 201505000-EN
156 pages
Manual Retro 1.9
No ratings yet
Manual Retro 1.9
20 pages
CLG856H (GCIC 2 ZF Axle ZF210) OM 201910000-EN
No ratings yet
CLG856H (GCIC 2 ZF Axle ZF210) OM 201910000-EN
190 pages
CLG856H GCICII Standard Configuration O&M 201505000-EN
50% (2)
CLG856H GCICII Standard Configuration O&M 201505000-EN
150 pages
CLG836 (Weichai ) OM 201703003-EN
100% (1)
CLG836 (Weichai ) OM 201703003-EN
116 pages
Luigong - CLG2040H, 45H, CLG2050H
No ratings yet
Luigong - CLG2040H, 45H, CLG2050H
134 pages
Autoelevador 20,25,30,35
No ratings yet
Autoelevador 20,25,30,35
136 pages
CLG908E (Yanmar ) OM 202003002-EN PDF
No ratings yet
CLG908E (Yanmar ) OM 202003002-EN PDF
178 pages
Omm Clg856 Dcec II
100% (3)
Omm Clg856 Dcec II
140 pages
Mom Liu Clg842 (E)
100% (4)
Mom Liu Clg842 (E)
175 pages
CLG4140 (Dcec Ii) Om 201711001-En
100% (2)
CLG4140 (Dcec Ii) Om 201711001-En
154 pages
CLG920D/922D Hydraulic Excavator: Cummins Ii Power
86% (7)
CLG920D/922D Hydraulic Excavator: Cummins Ii Power
175 pages
HW114 CLG856 Wheel Loader 580373 O&M Manual
100% (2)
HW114 CLG856 Wheel Loader 580373 O&M Manual
152 pages
Clg764a-775a Om 201805000-En
100% (1)
Clg764a-775a Om 201805000-En
144 pages
CLG230 Bulldozer
No ratings yet
CLG230 Bulldozer
114 pages
CLG925LC-925LL Operation Manual 201309003-EN
100% (3)
CLG925LC-925LL Operation Manual 201309003-EN
172 pages
Clgb230 Omm
No ratings yet
Clgb230 Omm
102 pages
Clg509a (China ) Om 201602000-En
No ratings yet
Clg509a (China ) Om 201602000-En
136 pages
CLG414 (DCEC II Hangzhou) OM 201805003-EN
100% (1)
CLG414 (DCEC II Hangzhou) OM 201805003-EN
154 pages
CLGB320 (Double-Cylinder) Operation Manual 201307000-EN
100% (1)
CLGB320 (Double-Cylinder) Operation Manual 201307000-EN
95 pages
Mom Liu CLG842 (E) PDF
No ratings yet
Mom Liu CLG842 (E) PDF
175 pages