CLG414 MOTOR GRADER

INDIA CUMMINS BS Ⅲ POWER / MERITOR AXLE & ZF GEARBOX

INDIA CUMMINS POWER / MERITOR AXLE & HANGZHOU GEARBOX
( 英文 )

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

The meaning of this safety alert symbol is as follows:

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

CALIFORNIA PROPOSITION 65

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

CONTENTS

Preface Operation Manual

Before Operation ............................................. 40
Safety Information
Operator Controls and Instrument Panels ....... 41
Safety Decals and Decal Locations ...................5
Engine Starting ................................................ 74
General Hazard Information .............................14
Operation Techniques ..................................... 75
Crushing and Cutting Prevention .....................18
Transportation Information .............................. 89
Burn Prevention ...............................................18

Fire & Explosion Prevention .............................19 Maintenance Manual

Fire Extinguishers and First-aid Kit ..................20 Run-in .............................................................. 93

Electrical Storm Injury Prevention ....................21 Maintenance Intervals Schedule .................... 94

Tire Explosion Prevention ................................21 General Torque Specifications ........................ 97

ROPS/FOPS (If equipped) ...............................22 Tire Inflation Information .................................. 98

Operator Station ...............................................22 Lubrication Specifications ................................ 98

Steering Frame Lock ........................................22 Pressure--Release ......................................... 100

Attachment Cautions ........................................22 Important Maintenance Procedures .............. 101

Cautions about Machine Operation .................23

INDEX
Cautions about Machine Maintenance .............28

Key Spare Parts to be Periodically Changed ...31

Applications and Specifications

Applications ......................................................32

Main Specifications ..........................................33

2
 1
Preface

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
component serial numbers for your reference
when ordering parts or in the event of theft.
Record the correct numbers to both the
operator’s manual and a secure place outside
the machine.
2
Preface

Maintenance Intervals

Use the service hour meter to determine

servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 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
Preface

Main Components

1. Front blade 18. Battery box

2. Front axle 19. Transmission
3. Front frame 20. Rear frame
4. Worm gearcase 21. Rear axle, tandem as
5. Hydro-motor 22. Tire
6. Hydraulic lock 23. Steering cylinder
7. Mold board blade lift cylinders 24. Parking brake lever
8. Swing arm assembly 25. Seat
9. Platform 26. Evaporator
10. Right control box assembly 27. Control valve
11. Radiator 28. Swing cylinder
12. Engine 29. Plunger cylinder
13. Air filter 30. Mold board blade
14. Fuel tank 31. Swivel fitting
15. Hydraulic oil tank 32. Traction frame
16. Working pump 33. Blade cylinder
17. Rear ripper
4
Preface

Type and Serial Number of the Machine and Parts

Manufacturers Name Guangxi Liugong Machinery Co., Ltd.

Type of the Whole Machine

Serial Number of the Whole 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
Safety Information
Safety Decals and Decal Locations

Safety Information "Caution" is also used to indicate safety

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

● Caution: this word denotes potential danger,

failure to observe instructions could result in
minor to medium degree of injury.
6
Safety Information
Safety Decals and Decal Locations

Decal location

GR ADER

1. SYMBOL 14. SYMBOL 27. WARNING DECAL

2. DANGER DECAL 15. SYMBOL 28. DANGER DECAL
3. SYMBOL 16. SYMBOL 29. SYMBOL
4. SYMBOL 17. WARNING DECAL 30. WARNING DECAL
5. LUBRICATION CHART 18. WARNING DECAL 31. WARNING DECAL
6. WARNING DECAL 19. SYMBOL 32. SYMBOL
7. WARNING DECAL 20. NOTICE DECAL 33. SYMBOL
8. SYMBOL 21. WARNING DECAL 34. NOTICE DECAL
9. SYMBOL 22. WARNING DECAL 35. SYMBOL
10. NAME PLATE 23. WARNING DECAL 36. SYMBOL
11. RIVET 24. SYMBOL 37. CAUTION DECAL
12. SYMBOL 25. WARNING DECAL 38. WARNING DECAL
13. WARNING DECAL 26. SYMBOL 39. WARNING DECAL
 7
Safety Information
Safety Decals and Decal Locations

Decal information

Fig. 2 DANGER DECAL

(Located on the beam)
Keep away from the swing area of the
machine.

74A3671

Fig. 6 WARNING DECAL

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

74A3171

Fig. 7 WARNING DECAL

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

74A3161
8
Safety Information
Safety Decals and Decal Locations

Decal information

Fig. 13 WARNING DECAL

(Located at the rear end of the machine)
RUNOVER HAZARD. Keep clear.

74A3177

Fig. 17 WARNING DECAL

(Located on the engine hood)
No step

74A3192

Fig. 18 WARNING DECAL

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

74A3082
 9
Safety Information
Safety Decals and Decal Locations

Decal information

74A2868

Fig. 20 NOTICE DECAL

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

74A2863

Fig. 21 WARNING DECAL

(Located on high pressure container)
CONTAINS HGHT PRESSURE GAS. To
avoid explosion and personal injury, do not
expose to fire, do not weld, do not drill.
Relieve pressuer before discharging.
74A3075
10
Safety Information
Safety Decals and Decal Locations

Decal information

Fig. 22 WARNING DECAL

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

74A3163

Fig. 23 WARNING DECAL

(Located at the articulation frame)
CRUSH HAZARD. Engage articulation lock
before service or transport.

74A3176

Fig. 25 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.

74A3169
 11
Safety Information
Safety Decals and Decal Locations

Decal information

Fig. 27 WARNING DECAL

(Located near the pressurized hoses)
Pressurized system. Relieve pressure before
maintenance.

74A3170

Fig. 28 DANGER DECAL

(Located near battery)
Fumes given off by batteries are combustible.
Keep flame and sparks away, do not store
tools or metal objects near batteries. Risk of
explosion if metal objects cause a short
circuit. Sulphuric acid contained in batteries is
poisonous, do not allow acid to contact skin,
clothing or your eyes. If you spill acid on
yourself, immediately: Flush your skin with
water. Apply a neutralizing agent such as
lime. Flush eyes with water for 10-15 minutes.
Immediately seek medical attention.
74A3188

Fig. 30 WARNING DECAL

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

74A3760
12
Safety Information
Safety Decals and Decal Locations

Decal information
Fig. 31 WARNING DECAL
(Located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations.Operate only from
operator's seat. Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral.Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator's compartment, park on level
ground, lower attachments to ground, make 74A3160
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.

Fig. 34 NOTICE DECAL

(Located in the cab)
Prevent damage to electronic parts, turn off
the battery disconnect switch when machine
is not being used. Always disconnect
batteries and upplug controllers before
welding on machine. 74A2866
 13
Safety Information
Safety Decals and Decal Locations

Decal information

Fig. 37 CAUTION DECAL

(Located near hot surface)
Hot surface, keep clear.

74A3168

Fig. 38 WARNING DECAL

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

74A3179

Fig. 39 WARNING DECAL

(Located near the pin lock)
Don't do latch unless blade is completely on
ground.
74A3058
14
Safety Information
General Hazard Information

General Hazard Information

Be familiar with all safety cautions, failure to

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

Wear relevant personal protective equipment

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

Do not operate the machine if you feel sick,

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

Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high
G
IN

pressure liquids, when maintaining storage

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

d

remove springs or resilient parts, add acid/

r:
te
ra
pe

electrolyte to batteries, you should wear a full

O

:
ate
D

face protective mask. When carrying out welding

operations or gas cutting operations with a
Do not wear loose fitting clothing, dangling
welding torch, wear specific safety goggles
jewelry or long hair that can catch on controls or
suitable for the task being performed. Consult
in other moving parts of the machine.
your welding equipment dealer for more
information.
 15
Safety Information
General Hazard Information

Pay attention when opening fluid compartments

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

When working under high noise conditions, wear

appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high
Know the appropriate worksite hand signals and
noise on your hearing.
who gives them. Accept signals from one person
only.
No smoking and keep open flames away when
maintaining air conditioner or if there is
refrigerant gas, the flames contact the refrigerant
and the cigarette smoke will cause personal
injury or death.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
Make sure all protective guards and covers are fuels, coolants, solvents, filters, batteries and
secured in place on the machine. Always replace other materials.
protective guards and covers removed for Use all cleaning solutions with care. Do not use
servicing or maintenance. Repair damaged any flammable material to wash components, for
guards and covers before operation. example, diesel oil or gasoline. They may easily
Keep the machine, especially the panels, catch fire.
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.

Report all required repairs in time.

16
Safety Information
General Hazard Information

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

Compressed Air

Compressed air can cause personal injury. When

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

High-pressure Fluid

Avoid injury from high-pressure oil. When

repairing hydraulic lines, ensure that
system pressure is completely released
before beginning the repair. Hydraulic oil
under pressure contacting the skin could Disposal of Waste Fluids
cause serious injury or damage.
Improper handling of the waste fluid will cause
Use caution before disconnecting hydraulic lines pollution of the environment. Obey all local
or connectors. High pressure oil that is released regulations for disposal of waste fluids.
can cause a hose to whip.
Collect all waste fluids when performing
Always support attachments and release inspections, maintenance, testing, adjusting and
residual pressure before attempting to repairs to the machine.
disconnect hydraulic lines. Pressure applied by
Prepare to collect fluids with suitable containers
loads on attachments could cause hydraulic oil to
before opening any compartment or
spray when lines are removed.
disassembling any component that contains
fluids.
 17
Safety Information
General Hazard Information

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

Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
● Never use compressed air to clean up
asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.
Cautions about Accumulators ● A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
High-pressure nitrogen is contained in the can also be used.
accumulators making them dangerous articles.
Read the following requirements and pay ● Do not grind materials that contain asbestos.
attention to the proper use of accumulators. ● Operate the machine on the windward side of
Check accumulators before charging with the asbestos as far as possible.
nitrogen. Safe use cannot be guaranteed if there ● Obey environmental regulations for the
is not a nameplate attached to the accumulator. disposal of asbestos.
Never charge accumulators that have an
incomplete nameplate or that are of an ● Shower after contact with asbestos.
unidentified type. ● Wear an approved respirator if there is no
Accumulators are charged with nitrogen. The other way to control the dust.
use of oxygen, compressed air or other
flammable air in the accumulator could cause an
explosion and possible injury, death and damage
to the machine.
When charging accumulators with nitrogen, care
should be taken not to damage the diaphragm.
The accumulator's valve should be installed
facing vertically upward. Do not attempt to fix
accumulators by welding them.
Do not drill any hole in the accumulator or close
a hole by welding.
Do not weld a boss on the accumulator.
Accumulators are high-pressure vessels and
should be repaired only by trained specialized
personnel.
18
Safety Information
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
At operating temperature, the engine coolant is
hazard. Keep clear or stop engine before
hot and under pressure. The radiator and all
servicing.
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.
 19
Safety Information
Fire & Explosion Prevention

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

Oil

Hot oil and components can cause personal

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

Fire & Explosion Prevention

All fuels, most lubrication and some coolant

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

Batteries
Clean and tighten all electrical connections.
Batteries give off flammable fumes which can Check daily for loose or frayed electrical wires.
explode. Have all loose or frayed electrical wires
Batteries and battery terminals may contain lead; tightened, repaired or replaced before operating
do not touch batteries with your bare hands. the machine.
Always wash your hands right after maintaining a Check the electric circuit periodically to avoid fire
battery. caused by overload or short circuit.
Do not smoke when observing the battery Keep all fuels and lubrications stored in properly
electrolyte levels. marked containers and away from all
Electrolyte is an acid and causes personal injury unauthorized persons.
if it contacts skin or eyes. If contact occurs flush Store all oily rags or other flammable materials in
with water and seek medical attention right away. a protective container away from naked flames
or other sources of ignition.
Do not weld or flame cut pipes that contain
flammable fluids. Clean the flammable fluids
before welding or flame cutting on them.
20
Safety Information
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.
 21
Safety Information
Electrical Storm Injury Prevention

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

AT LEAST 15m(50ft) AT LEAST 500m(1500ft)

Tire Explosion Prevention

Maintenance, removal, repair and installation of

the tires and wheel rims must be performed with Dry nitrogen is recommended for inflation of
special equipment and a trained repairer. tires. If the tires were originally inflated with air,
Therefore, it is better to repair and maintain the nitrogen is still preferred for adjusting the
tires in a tire service shop. pressure. Nitrogen mixes properly with air.
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.
22
Safety Information
ROPS/FOPS (If equipped)

ROPS/FOPS (If equipped) Operator Station

This machine is equipped with a cab that meets
ROPS/FOPS of Guangxi Liugong Machinery
with industry standard: ISO 3411.
Co., Ltd (if equipped) are located above or are
the operator's compartment and are secured to Any modifications or aditional equipment added
the machine. Any ROPS or FOPS structure fitted to the inside of the operator station should not
to a machine by Liugong will have a name plate project into the operator space. The addition of a
attached. radio, fire extinguisher and other equipment must
be installed so that the defined operator space is
maintained. Any item that is brought into the cab
should not project into the defined operator
space. A lunch box or other loose items must be
FOPS & ROPS secured. Objects must not pose an impact
Guangxi Liugong Machinery Co.,Ltd.
No.1 Liutai Road, Liuzhou, Guangxi 545007, PR China hazard during travel over rough terrain or in the
MODEL event of the machine tipping.
MAX. RECOMMENDED MASS
STANDARD
TEST REPORT Steering Frame Lock
SERIAL NUMBER

Connect steering frame lock when the machine

is being lifted and shipped. Also connect the
The FOPS meets the requirements of ISO 3449
steering frame lock when performing repairs
(level II). The strength of the structure will be
near the articulation joint.
reduced if it is damaged due to a rollover. ROPS
are certified structures and cannot be repaired. Disassemble the steering frame lock before
Any damage to the ROPS structure will require operating the machine.
replacement of the structure to retain the
More information refers to Steering Frame Lock
certification.
in Operation Manual.
Always fasten your seat belt when you operate
the machine.
Attachment Cautions
It is forbidden to drill holes or weld inside or
outside or change anything of the cab. This will
damage the integrity of the ROPS structure. Attachments should only be installed by
authorized people who have been trained to
If the cab is to be modified in any way, contact operate and maintain the attachment according
your local Liugong dealer to avoid damaging the to the operator’s manual.
ROPS structure.
Refer to the instructions in the operation manual
and any other related information when installing
and using attachments.
Incorrect installation of attachments or optional
parts not only will result in safety problems, but
also will negatively influence the operation and
service life of the machine and the attatchments.
It is forbidden to modify the machine or any
attachments without permission from your
Liugong dealer.
 23
Safety Information
Cautions about Machine Operation

Liugong bears no responsibility for injuries, Understand the purpose of all control systems,
accidents or machine damage resulting from the instruments and indicators.
use of unauthorized attachments.
Understand the rated load, speed range, the
characteristics of braking and steering, turning
Cautions about Machine radius and the space clearance for operation.

Operation Remember that rain, snow, ice, gravel and soft

earth may change the performance of the
machine.
Mounting and Dismounting
Understand the safety signs on the machine
Before mounting or dismounting the machine, (Danger, Warning, Caution) and any other signs.
check the condition of handrails, ladders and
steps. Clean them of grease, lubricants and dirt Understand Your Working Area
before use. Repair any damaged parts and
tighten loose bolts. Before starting, inspect the area where you will
be working. You should check: adequate
Mount and dismount the machine only where ventilation the position of any slopes, visible
there are handrails, steps or ladders. ditches, falling or hanging objects, conditions of
Face the machine when getting on or off, grab soils (soft or hard), accumulated water and
the handrails with both hands and step onto the swamp areas, rocks or stumps, hidden
steps or ladders. Touch three points groundwork, posts or the outer limits of walls, the
simultaneously (two feet and one hand or two outer limits of the areas where garbage is buried
hands and one foot) to ensure stability of the or that are filled in with earth, holes or openings,
body. 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
engine, ensure all systems are in good
Never get on or off a moving machine. operational condition. Make sure nobody is on or
Be careful not to touch any control levers when around the machine before starting the engine.
getting on or off the machine. Keep the steps and handrail clean. Clear any dirt
Do not try to climb on or off the machine when and sands from your shoes before mounting the
carrying tools or supplies. Use a rope to pull machine.
equipment up onto the platform or have an Check all structural members, covers and
assistant pass them to you. fenders for deformation or damaged.

Understand Your Machine Check the condition of safety guards such as

doors, guards and covers. Repair any damage
Be able to operate all the equipment on your as necessary.
machine.
24
Safety Information
Cautions about Machine Operation

Check the hydraulic system for oil leakage. Do not start the engine until seated in operators
Check the condition of hoses and pipes. seat and the seat belt is firmly fastened.
Check all fasteners for security.
Check the condtion of electrical wiring harness
and fuses, replace or repair as neccessary. Also
check the connectors for good connection.
Check the fuel level and fuel system for normal
condition, drain any water or sediment in the
water/fuel separator. Dispose of fluids in
accordance with local regulations.
Replace all damaged or lost parts and carry out Ensure the hydraulic control levers are all in the
lubrication according to the maintenance interval NEUTRAL position and the shift control lever is
schedule. in the NEUTRAL position before starting the
Remove all loose objects from the cab. Loose engine.
objects may affect the operation and cause Sound the horn to alert personnel before starting
accidents. the engine.
Make sure that all the windows if fitted are clean
and the screenwiper works normally.
Adjust the operators seat to a position that is Beep
most comfortable and provides for easiest
operation of the machine. Check the seat belt
and the condition of mounting hardware. Repair
or replace any items that are damaged. Replace
the seat belt after three years of use or any time
the belt shows signs of wear or damage.
Check all the illumination equipment before
operation in low light, and ensure that the Only start the engine from the operators seat in
illumination system is in good condition. the cab. Never start the engine by short-circuiting
Check to make sure the steering frame lock is in the starter motor terminals. Starting the engine
the RELEASED position. by short-circuiting could result in damage of the
electrical system, personal injury or death.
Engine Starting After the engine is started, you should observe,
instruments and warning lights, and make sure
Do not start the engine if there is a DO NOT that they work and every reading is within
OPERATE or similar tag attached to the start working range.
switch or control levers.
G
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 25
Safety Information
Cautions about Machine Operation

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 fix 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.
Know the maximum dimensions of your
machine.

Never run the engine in a closed or poorly

ventilated environment. If working inside a
building, open the doors and windows to ensure
enough ventilation and try to prevent exhaust
gas poisoning. Use a power exhaust system
when working in an enclosed area. Only operate the machine while seated. The seat
belt must be fastened while you operate the
machine. Only operate the control levers while
the engine is running.
Before driving the machine, you should carefully
observe the surroundings to make sure that
nobody will be endangered.
Do not allow another person to sit on the
machine unless an additional seat, seat belt and
Rollover Protective Structure (ROPS) are
provided.
Before Operating the Machine

Make sure the machine is free of personnel and

fasten the seat belt before operation.
Keep all the windows, lightshades and rearview
mirrors clean. Secure doors and windows in
either the open or shut position.
Adjust the rearview mirrors for best vision,
especially close to the machine.
Clear all obstacles from where the machine will Before operating the machine, you should
be working. Be aware of hazards such as high operate the machine slowly in an open area,
voltage wires, ditches, etc. check for proper operation of all control levers
and all protective devices.
Make sure the horn, backup alarm (if equipped)
and all other alert devices are working properly. 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 signals.
26
Safety Information
Cautions about Machine Operation

Note any needed repairs during machine

operation such as an abnormal noise, vibration,
smell, wrong reading of gauges, gas or oil
leakage, etc.. Stop what you are doing and report
any needed repairs in time.
Always raise all implements as much as possible
while driving. Keep the mold board blade inside
the width of the machine, to ensure the wheels
don't touch the mold board blade when turning.
During continuous operation after rain, always
remember the ambient condition has been
changed, be extra careful.
Be extra careful during operation in snow or
cleaning snow, because a small slope can cause
sideslip. When snow is pushed to one side of the
machine, pay extra attention to the obstacles
buried under snow.

Do not go close to the edge of a cliff, a dyke, or a

hillock to avoid collapse.

Avoid any conditions that can lead to the

machine tipping. The machine can tip when you
work on hills, on banks and on slopes. Also, the
machine can tip when the machine goes across
ditches, hillocks or other unexpected
obstructions.
Avoid operating the machine across a slope. If it
is necessary, operate the machine directly to up
and down a slope, do not turn on the slope.
 27
Safety Information
Cautions about Machine Operation

If the machine begins to slip sideway when Consider any overhead hazards such as the
working on a slope, immediately stop working posibility of falling rocks, any powerlines or any
and drive the machine downhill. other overhead hazards that may exist.
Do not perform neutral coast when going Consider the ground conditions. Do not park the
downhill, always keep control of the machine, do machine near the edge of a cliff, close to an open
not control with the brake. excavation or pit.
The machine can only be used within its Consider environmental conditions such as the
capability. Any operation beyond its capability will posibility of flooding, heavy snow fall, electrical
bring damage to the machine. Refer to storms and exposure to wind and cold. Any of
Specification section for the capabilities. these conditions may cause damage to the
machine.
Always keep the Rollover Protective Structure
(ROPS) installed during machine operation. Do not cause an obstruction, consider the site
access and other emergency conditions the
Be careful when working beside high voltage
machine may obstruct.
wire. If it is possible to contact the electrical wire
while working, consult the Electricity Company If it is necessary to park the machine on a slope
before working. or incline, lower the implement to the ground,
engage the parking brake and shut off the
When transporting, make sure that the hooks
engine. Place chocks under the wheels at the
and the towing devices are adequate. Connect
downhill side on both sides to prevent the
trailing equipment to a drawbar or hook only.
machine from moving.
Never straddle a wire rope cable or similar
device, nor allow others to do so.

Understand and obey all regulations relating to

public roads, if the machine is parked on a public
No personal should be between the machine and
road. Additional signage or lighting may be
trailing equipment when maneuvering to connect
required.
them. Block the tongue or hook of trailing
equipment to align it with the drawbar or hook. Always lower attachments or other equipment
before leaving the machine, apply the parking
Parking the Machine brake.
Put the hydraulic control levers to NEUTRAL
When possible, choose flat level ground to park
position and the shift control lever to NEUTRAL
the machine, apply the parking brake (if
position.
equipped), always lower any attachment to the
ground and ensure the machine will not move, Engage the parking brake (if equiped).
possibly causing damage or injury. Keep the engine running at idle speed for five
minutes to let the engine cool down gradually.
28
Safety Information
Cautions about Machine Maintenance

Stop the engine, and take out the key from the Store Accessories Safely
switch.
Store accessories and tools safely so as to
Turn the battery disconnect switch to OFF
prevent them from falling and causing serious
position to avoid battery discharge.
injury or death. Keep playful children and
When leaving the machine lock all equipment bystanders away from the storage area or any
covers and doors with the key. Remove the key area accessories are being stored whilst in use.
and keep it with you.

Cautions about Machine

Lowering the Attachment/ Implement with
Engine Stopped
Maintenance

Prepare the Working Area

Please choose a clean and flat area with

For a machine controlled by electro- adequate space, enough light, and good
hydraulically control lever, in order to lower ventilation to carry out any repair work. Clean the
the implement, the engine start switch must ground surface, wipe up fuel, lubricating oil and
be on ON position .Turn the engine start water, and spread sands or other absorptive
switch to OFF position after lowering the materials on the slippery ground. Keep the work
implement. area clean and dry.

In order to lower the implement to the ground or Support the Machine Correctly
trailer, move all control levers to DOWN position.
When release them, they will return to HOLD Lower to the ground or support any attachments
position. with stands or other methods. Ensure that any
attachment can not move during maintenance or
repair work, use wheel chocks or other devices
to prevent machine movement.
Do not work under any part of the machine or
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use
stands or other measures that are secure and
can support the weight being applied to them.

Transportation Information

Obey the appropriate laws that govern the

parameters of the load (weight, length, width,
and height).
 29
Safety Information
Cautions about Machine Maintenance

Understand the correct procedures for loading Lifting device should be big enough to prevent
and unloading. the machine from being damaged in lifting.
Carry out the loading and unloading operations
Welding Operation
on flat ground.
Chock the wheel of the trailer to make it unable Any personnel engaging in welding operations
to move. must have occupational certificates and carry out
the operation at a place with appropriate devices
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.
1. Wedge
2. Block Never weld pipes, close to rubber hose and
3. Angle (Max. angle is 15°) electrical wires.
4. Distance between the ramps
5. Ramp Always remove residual pressure from the
Use loading ramps appropriate for the machine machine. Never weld pipes that are fitted to the
being moved. Consider: size, strength, departure machine.
angle and proper height. Make sure that the Always wear correct PPE for welding, protect
loading ramp is anti-slip and free of mud and bystanders by using screens and signs advising
snow. of the operation being performed.
Use chains and blocks to secure the machine to Ensure good ventilation.
the trailer.
Remove all the flammable materials, supply the
Keep the bystanders away. work area with a fire extinguisher.
Place all the working equipment in the
transportation position, secure all the equipment
and attachments or additional equipment with
chains or other secure methods to prevent
accidental movement.

Lifting the Machine

Refer to the machine nameplate for the machine

mass.
Before lifting, secure the front and rear frame
with the steering frame lock so that the machine
can not move.
Use proper rated cables and lifting device, keep
levelling in lifting.
30
Safety Information
Cautions about Machine Maintenance

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.
When carrying out the cleaning operation, wear
suitable PPE. Consider exposure to: chemicals,
slippery surfaces, high pressure water spray and
material splash.

Do not spray the water directly onto sensors,

connectors or instruments of the electrical
system. If water enters the electrical system
malfunction may occur.
 31
Safety Information
Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically Changed

Key spare parts to be periodically

No. Q’ty Changing intervals
changed
Every year or every 2000h(To see which one
1 Filter element of hydraulic oil tank 2
comes earlier)
2 Fuel hose 3
3 Steering cylinder seals 2
Every 2 years or every 4000h(To see which one
4 Hose assembly 9
comes earlier)
5 Brake cylinder seals 1 set
6 Brake hose 9
Every 3 years or every 6000h(To see which one
7 Accumulator 3
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.
32
Applications and Specifications
Applications

Applications and Specifications

Applications

Motor grader is a kind of engineering machinery

mainly used for leveling roads and squares such
as leveling road surface and trimming
embankment sections, etc.
This grader is a kind of general-purpose
engineering machinery and is not suitable for the
flammable, explosive, dusty and air poisonous
environments.

Requirements of Work Environments

1. Altitude: ≤ 3048m
2. Environmental temperature: -15°C~40°C (No
additive auxiliary cold starting device)
3. Water Depth: ≤ 420mm

Preventive measures for operation,

maintenance and safety rules outlined on this
manual are only suitable for the stipulated
applications of the machine. Do not use the
machine beyond the stipulated application
scope, Guangxi Liugong Machinery Co., Ltd
will not bear any safety liability, and these
safety liabilities will be born by users. Under
any cases, do not use the forbidden
operation outlined in this manual.
 33
Applications and Specifications
Main Specifications

Main Specifications

All rated operation is based on the criteria of the machine being level on a firm supporting ground. When
the machine is operated in conditions that deviate from these criteria (e. g. on soft or uneven ground, on
a slope or when subject to slide loads), these conditions shall be taken into account by the operator.
Exterior drawing(Without front blade and ripper)
34
Applications and Specifications
Main Specifications

Exterior drawing(Equipped with front blade)

 35
Applications and Specifications
Main Specifications

Exterior drawing(Equipped with ripper)

36
Applications and Specifications
Main Specifications

Exterior drawing(Equipped with front blade and ripper)

 37
Applications and Specifications
Main Specifications

Machine Specifications
Machine weight kg 12400
Front axle load weight kg 3250
Rear axle load weight kg 9150
Max. traction force (wheel slipping) kN 65
Mold board blade earth pressure kg ≥5400
Min. turning radius mm 7200
A: Max. machine height mm 3370
B: Wheel base mm 5900
C: Overall length (without front blade and ripper) mm 8340
C: Overall length (with front blade) mm 9294
C: Overall length (with ripper) mm 9210
C: Overall length (with front blade and ripper) mm 10160
D: Blade base mm 2440
E: Distance between tandam axles mm 1540
F: Mold board blade max. lifting height mm 460
G: Mold board blade max. depth in ground mm 600
H, I: Chamfer angle ° 40°~70°
J: Distance outside tires mm 2465
K: Distance between tire centres mm 2110
L: Mold board blade width mm 3660
Mold board blade height mm 610
Mold board blade thickness mm 19
M: Mold board blade side shift (left) mm 650
N: Mold board blade side shift (right) mm 520
O: Articulation turning angle ° 20°
P: Front wheels max. turning angle ° 45°
Q: Front blade width mm 2741
R: Front blade lift height mm 370
S: Front blade max. depth in ground mm 351
T: Ripper width mm 2083
U: Ripper max. depth in ground mm 423
V: Ripper lift height mm 316
W: Ripper lift height at transport position mm 367
38
Applications and Specifications
Main Specifications

Main Components Specifications

CLG414(35F0022*) CLG414(35F0041*)
Diesel engine India Cummins 6BTAA5.9-C150 diesel engine
Rated power 112kW
Rated speed 2200r/min
No. of cylinders In-Line six cylinders
Bore× stroke 102×120mm
Power system Engine Overall piston displacement 5.9L
Max. torque 650N.m/1500r/min
Torque-storage 34%
Rated fuel consumption
263g/kw.h
(Bench test)
Fuel No. 0 or -35 light diesel oil
Diameter of fan 660mm
Model 6YD130 ZF 6WG200
Three-member single Three-member
Hydraulic torque Type
phase single turbine
converter
Converter stall torque ratio 2.31: 1 2.15: 1
Cooling Type Air-cooled, forced circulation type
Model 6YD130 ZF 6WG200
Type Fixed shaft power shift
Transmission Gear Six forward speeds and three reverse speeds
Operating pressure of shift oil
1.5~1.7MPa 1.6~1.8MPa
pump (gear pump)
Forward 6th speed 41km/h 40km/h
Forward 5th speed 29km/h 24km/h
Forward 4th speed 20km/h 19.5km/h
Power train
system Forward 3rd speed 13km/h 11.4km/h
Max. travel speeds Forward 2nd speed 8km/h 8.6km/h
Forward 1st speed 5km/h 5km/h
Reverse 1st speed 5km/h 5km/h
Reverse 2nd speed 13km/h 11.4km/h
Reverse 3rd speed 29km/h 24km/h
Automatic locking release American NO-SPIN limited slip differential, rear axle
Differential and final housing hardened treatment, full floating design
drive Final drive type Spiral bevel gears reduction
Wheel reductor type Spur gear planetary reduction
Type Four-wheel drive
Axles and wheels Tire 13.00-24
Tire pressure 0.30±0.01MPa
 39
Applications and Specifications
Main Specifications

Main Components Specifications

Type Load sensor steering gear
Steering cylinders---bore ×
Steering hydraulic 2-φ25×258mm
stroke
system
System pressure 15~17MPa
Hydraulic Steering angle 45°±1° each
system Working pump Park Lemke gear pump
Multi-valve Husco
Work implement Max. flow 132L/2300r/min
Max. operating system
18MPa
pressure
Brake pump Park Lemke gear pump
Service brake Full hydraulic shoe type brake
Brake oil pressure 10±0.3MPa
Cut-in pressure of charge
12.8±0.35MPa
valve
Service brake Cut-off pressure of charge
Brake system 15.9±0.35MPa
valve
Low pressure alert pressure of
10MPa
service brake
Nitrogen pre-pressure of
9.2MPa
accumulator
Parking brake and
Type Manual mechanical shoe type
emergency brake
Medium Diesel engine coolant
Heater
Warming capacity 5000W
Air-
Medium R134a
conditioning Cooler working
Cooling capacity 4000W
System voltage 24V
System voltage 24V
Electric Batteries 2-6-QW-120T
system Voltage bulbs 24V
Starting of diesel engine 24V starting
40
Operation Manual
Before Operation

Operation Manual Never get on or off a moving machine.

Be careful not to touch any control levers when
getting on or off the machine.
Before Operation 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
Direction assistant pass them to you.

In this manual, 'left' A and 'right' B mean your left Daily Inspection
and right when you are seated correctly in the
machine. For a maximum service life of the machine,
complete a through walk-around inspection
B before you mound the machine and before you
start the engine.
Inspect the area around the machine and under
the machine. Look for loose bolts, trash buildup,
hydraulic oil, coolant leakage, broken parts or
worn parts.
A
Inspect the condition of the implement and the
hydraulic components.
Mounting and Dismounting
Check all of the oil levels, the coolant level and
the fuel level.
Before mounting or dismounting the machine,
check the condition of handrails, ladders and For additional information, refer to "Maintenance
steps. Clean them of grease, lubricants and dirt Intervals Schedule" on page 94.
before use. Repair any damaged parts and
tighten loose bolts.
Mount and dismount the machine only where
there are handrails, steps or ladders.
Face the machine when getting on or off, grab
the handrails with both hands and step onto the
steps or ladders. Touch three points
simultaneously (two feet and one hand or two
hands and one foot) to ensure stability of the
body.

Never jump off the machine.

 41
Operation Manual
Operator Controls and Instrument Panels

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 in located on the

right side of the rear frame. It can be seen by O I
opening the side cover of the battery box.

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.
Turn the battery disconnected switch to the OFF
position and remove the key when you service
the machine or when the machine will not be
used for an extended period of a month or more.
Disconnect switch--ON This will help to prevent discharge of the battery.

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

Turn off the battery disconnect switch if the

machine is stopped over 3 hours.
42
Operation Manual
Operator Controls and Instrument Panels

Engine Start Switch

The start switch is located on the control panel

on the right side of the cab and it has four If the engine fails to start, turn the start
positions. switch to the “OFF” position before a restart
or the start switch could be damaged!
Do not engage the start switch for more than
15 seconds at one time. Wait at least 30
seconds and then attempt to restart. 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 choke solenoid.

AU——This position is not applicable in this

machine at present.
OFF——The engine is shut down and the power
is cut off. All of the electrical appliances will be
cut off except that the turn signal lights still can
be controlled by the hazard flasher switch and
turn signal light switch.
ON——The first position when the key is
inserted in the start switch and turned clockwise.
The electrical system of the machine can turn on
and work normally.
START——The second position when the key is
inserted in the start switch and turned clockwise.
The engine will be turned on and run. Release
the start switch key after starting the engine. The
key will reset to the "ON" position automatically
after being released.

Before starting the engine, make sure the

battery disconnect switch is at ON position
and the shift control lever is at NEUTRAL
position.
 43
Operation Manual
Operator Controls and Instrument Panels

Instrument Panels

1. Central instrument panel

2. Right instrument panel
44
Operation Manual
Operator Controls and Instrument Panels

Central Instrument Panel

2 When checking the engine fan, belt and

3 water tank level, be extremely careful to
1 avoid injury. Keep away from the moving
4 parts to avoid being injured and keep away
5 from hot parts to avoid being burnt.

Transmission oil temperature gauge

This gauge is used to indicate the oil

temperature of the transmission. The
green zone shows normal work temperature; the
yellow zone shows low temperature and the red
1. Speed meter
2. Engine coolant temperature gauge zone shows high temperature.
3. Transmission oil temperature gauge
4. Warning indicator group
5. Front switch panel

Speed meter When the pointer of the transmission oil

temperature gauge points to the red zone,
This meter shows the actual speed of the park the machine on a safe and convenient
machine. Slow down the machine when the place for repair. Check the transmission and
speed is too fast. If the speed meter doesn’t transmission oil level. Never go on working
change when the machine speed changes, stop or driving the machine before eliminating
the machine to check for fault. the problem.

Engine coolant temperature gauge Warning indicator group

This gauge indicates the coolant Refer to section "Warning Indicator Group" on
temperature of the engine. The green page 45 for more information.
zone shows normal work temperature; the yellow
zone shows low temperature and the red zone Front switch panel
shows high temperature.
Refer to section "Front Switch Panel" on page 46
for more information.

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.
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Operation Manual
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Warning Indicator Group Service brake low pressure alert

indicator
1 2 3 4 1
When the service braking oil pressure
is too low, this indicator flashes to alert,
and the buzzer sounds at the same time. Stop
the machine to check unless the fault is
eliminated.

Engine coolant temperature alert

indicator
5 6 9 7 8
When coolant temperature exceeds
1. Turn indicators (green)
2. Service brake low pressure alert indicator (red) 100°C , this indicator flashes to alert, and the
3. Engine coolant temperature alert indicator (red) buzzer sounds at the same time. Stop the
4. Parking brake low pressure alert indicator (red) machine to check.
5. Front floodlight high beam indicator (blue)
6. Charge indicator (red)
7. Engine oil pressure alert indicator (red) Parking brake low pressure alert
8. Transmission oil pressure alert indicator (red) indicator
9. Main fault alert indicator (red)
When the hydraulic oil pressure of the
There are two warning categories in this
parking brake is too low, this indicator
monitoring system which is divided according to
flashes to alert, and the buzzer sounds at the
the severe degree.
same time. Stop the machine to check.
● Warning Category I: Indicators flash.
Front floodlight high beam indicator
This warning category includes alert from turn
indicators, charge indicator, and front floodlight The indictor indicates the front
high beam indicator. floodlights are at high beam when the
● Warning Category II: Indicators flash and indictor lights.
buzzer sounds.
Charge indicator
This warning category includes service brake low
pressure alert indicator, parking brake low This indicator will go out when the
pressure alert indicator, engine oil pressure alert generator is charging the battery and it
indicator, transmission oil pressure alert will light when the battery supplies
indicator, engine coolant temperature alert electricity for the appliances separately.
indicator, and main fault alert indicator.
Engine oil pressure alert indicator
Turn indicators
When the engine oil pressure is too
The left indicator flashes when the low, this indicator flashes to alert, and
machine turns left, the front & rear left the buzzer sounds at the same time. Stop the
turn signal light will also flash engine to check.
simultaneously.
The right indicator flashes when the
machine turns right, the front & rear
right turn signal light will also flash
simultaneously.
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Operation Manual
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Transmission oil pressure alert Front floodlight high beam switch

indicator
This switch controls the ON and OFF
When the transmission oil pressure is of the front floodlights high beam. Before use this
too low, this indicator flashes to alert, switch, must turn the position light / front
and the buzzer sounds at the same time. Stop floodlight low beam switch to its front floodlight
the engine to check. position.

Position light / front floodlight

switch
Park the machine on a safe and convenient
place for repair when the transmission oil This switch has three positions. It
pressure alert indicator is flashing. Check controls the on and off of the position lights and
the transmission and transmission oil level. front floodlights.
Never go on working or driving the machine
before eliminating the problem. OFF 1st postion 2nd postion

Main fault alert indicator

When any one of the above-mentioned

warning indicator flashes, this indicator
will flash to alert, and the buzzer will sound at the
same time. Stop the machine to check. When the switch is at OFF position, the position
light and the front floodlight are off.
Front Switch Panel When turning the switch to the first position, the
position light switch turns on, and the four
position lights of the machine are turned on.
When turning the switch to the second position,
1 3 the front floodlights are turned on and at low
2 beam state. Use the front floodlight high beam
switch can change the front floodlights to high
beam.
4
5 Rear work light switch
6

7 This switch controls the ON and OFF

of the left and right rear work lights on
the rear top of the cab simultaneously.
1. Front floodlight high beam switch
2. Position light / front floodlight switch Front work light switch
3. Rear work light switch
4. Front work light switch
This switch controls the ON and OFF
5. Headlight switch
6. Turn signal light switch of the left and right front work lights in
7. Cigar lighter front of the cab simultaneously.
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Headlight switch Right Instrument Panel

This switch controls the ON and OFF
of the front left and right headlights on The right instrument panel, located at the right
the front top of the cab simultaneously. side of the driver's seat, is composed of fuel level
gauge, voltmeter, service hour meter, engine
Turn signal light switch start switch and air conditioner panel.
1 2 3 4
Move the turn signal light switch downwards
when machine needs to turn left, the left turn
indicator flashes, the front and rear left turn
signal lights of the machine will also flash
simultaneously.

5 6
L
1. Fuel level gauge
2. Voltmeter
3. Service hour meter
4. Engine start switch
L: Left turn 5. Right switch panel
R: Right turn 6. Air conditioner panel
Move the turn signal light switch upwards when
machine needs to turn right, the right turn Fuel level gauge
indicator flashes, the front and rear right turn
signal lights of the machine will also flash This gauge indicates the fuel level of
simultaneously. the machine. “1” indicates the high fuel
level. “0” indicates the low fuel level. Add fuel in
Move the turn signal light switch to Neutral time when the fuel level is lower than “0.2”.
position to turn off the turn indicator and turn
signal lights. Voltmeter

Cigar lighter It indicates the voltage of the machine.

Normal voltage is about 26 volts. When
This machine is equipped with a cigar lighter. the voltage is below 24 volts or over 30 volts, the
Push down the lighter, the lighter will be turned voltage indicator will flash to alarm.
on and begins to heat. The lighter will spring out
when it is hot enough. Pull out the lighter for
smoking, return it to socket after use.

Park the machine in a safe and convenient

place to check for fault if the voltage
indicator gives an alarm.
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Operation Manual
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Service hour meter Front windshield wiper switch

Service hour meter indicates the total This switch controls the ON and OFF
work hours of the machine, unit in of the front windshield wiper of the cab.
hour. The time range of the hour meter is 0 to
9999.99 hours. When turning on the start switch, Front windshield washer switch
the power of the panel is turned on and the
service hour meter starts to time. The LCD Press this switch, the washer will spray
display shows the accumulated work hours of the water from the reservoir to the front
machine. The recording value by the service windshield. The washer will stop spraying when
hour meter can be used to determine the the switch resets automatically after being
machine maintenance intervals. released. The washer reservoir is located on
lower left side of the cab.
Engine start switch

Refer to section "Engine Start Switch" on page

42 for more information of this switch.

Right switch panel

Refer to section "Right Switch Panel" on page 48

for more information.

Air conditioner panel

Refer to section "Air Conditioner Panel" on page

50 for more information. Check the washer reservoir frequently to
ensure enough water in it, otherwise dirty
Right Switch Panel windshield may impact the visibility of the
operator.
The washer reservoir should be emptied or
filled with antifreeze when the ambient
7 temperature is below 0 °C, or the washer will
1 not work or even be damaged by being
4 frozen.
2 As the washer with additive may be harmful
5 to human body, dispose of it according to
3 the local laws and regulations.
6
Rear windshield wiper switch
1. Front windshield wiper switch
2. Front windshield washer switch There are three positions of the rear
3. Rear windshield wiper switch windshield wiper: OFF, LOW and HIGH.
4. Buzzer mute switch The wiper can reset automatically at OFF
5. Rotating beacon switch position.
6. Hazard flasher switch
7. Engine intake air filter alert indicator
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Operation Manual
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Buzzer mute switch

Press the buzzer mute switch, the

buzzer stops beeping, and the alert
mute indicator lights at the same time; press the
buzzer mute switch again, the buzzer beeps and
the alert mute indicator goes out.
When any one of the service brake low pressure
alert indicator, parking brake low pressure alert
indicator, engine oil pressure alert indicator, and
transmission oil pressure alert indicator on the
central instrument panel lights, the buzzer will
beep to alert. Stop the machine to repair until the
fault is eliminated.

Do not turn on the buzzer mute switch when

the machine is working or travelling,
otherwise there will be potential safety
hazard.

Rotating beacon switch

The rotating beacon switch controls the

ON or OFF of the rotating beacon
located on the top of the cab.

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.

The left and right turn lights switch will not

work after turning on the hazard flasher
switch. Therefore, turn off the hazard flasher
switch before starting the machine.

Engine intake air filter alert indicator

When the air filter is blocked, this

indicator will light. Stop the engine and
maintain the air filter.
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Operation Manual
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Air Conditioner Panel Mode Switch

Using Mode Switch, you can change

the mode of air flow.

Recirculating/ Fresh Air Mode

Using Air Mode, you can adjust the

fresh damper open or close.

Def Mode
ON/OFF
In Def Mode, the output is directed to
To turn on or off the controller, push defrost windows.
this button. A short self test sequence
takes place during the first 5 seconds in order to Temp Switch
protect the system.
Using Temp Switch, you can set the
Auto Mode Switch temperature that you want. Hold the
button, the set temperature steps
In Auto mode, the output is continuously until the max/min set point.
automatically controlled by presets.
Fan Switch
Cool Mode Switch
Using Fan Switch, you can set the fan
In Cool Mode, you can adjust the speed that you want. It is not necessary
output independently of the setpoint. to set it in auto mode.

Display explaining

DISPLAY Screen

Display screen displays all the information, such as

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

AUTO Mode Display

A

In auto mode, the “auto” will be lit up and displayed

on the screen simultaneously.

Cool Mode Display

A

In cool mode, “A” will be lit up and displayed.

Warm Mode Display

A

In warm mode, “A” will be lit up and displayed.

Fan Mode Display

In fan mode, “A” will be lit up and displayed.

A
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Operation Manual
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Display explaining

Fresh Air Mode Display

In fresh air mode, “A” will be lit up and displayed.

Recirculating Mode Display

A

In recirculating mode, “A” will be lit up and

displayed.

DEF Display
A

In DEF mode, “A” will be lit up and displayed.

Mode Display
A

“A” will light up and display the mode of air flow.

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Operation Manual
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Display explaining

Fan Speed Display

A

“A” will light up and display the fan speed.

Set Temp Display

A

“A” will light up and display the set temperature.

Inside /Outside Temp Display

“A” will light up and display the inside / outside

temperature.
There is an operating range of -9°C~70°C, a “L” or
“H” will appear if beyond this range.

Error Display
A
B C

If “A” lights up and displays, it means there is an

alarm out; if “B” lights up and displays
simultaneously, it means there is an error in the
system and “C” light up and display the error code.
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Operation Manual
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Starting the ontroller explanation Temp inside≤Temp set -5°C, warm mode;
Temp inside≥Temp set +3°C, cool mode.
With power on, displaying the inside
temperature, or an error code while starting the
engine of vehicle is normal. During the first 5 sec,
all the functions will be locked with the air
conditioner system waiting. The controller will Due to the compressor having to wait 60
return to the last setting, and then start the air seconds, at least, to restart again, the
conditioner system. controller will keep locking the system for
60 seconds, when restarting the
Auto mode flowchart explanation compressor.

Under Auto Mode, the controller will control the

system automatically.

The flow chart regarding the temperature, air flow, compressor functions, hot water valve operation is as
follows:
Warm control under AUTO mode

Temp in & Temp set Air flow Comp.&Cond.

ttemp inside≥tset+1°C compressor closes, hot water valve reduces 1 position every 5
fan low
sec.
ttemp inside =tset fan low compressor closes, hot water valve remain the same
compressor closes, hot water valve increases 1 position every
ttemp inside £tset-1°C fan mide-low
5 sec.
compressor closes, hot water valve reduces 1 position every 5
ttemp inside <tset-4°C fan mid
sec.
compressor closes, hot water valve reduces 1 position every 5
ttemp inside <tset-10°C fan high
sec.
compressor closes, hot water valve reduces 1 position every 5
…………… fan low
sec.

Cool control under AUTO mode

Temp in & Temp set Air flow Comp.&Cond.

ttemp inside≤tset-3°C fan low hot water valve closes, cool mode waiting
ttemp inside<tset fan low hot water closes, system is at cooling condition
ttemp inside≥tset fan mide-low hot water closes, system is at cooling condition

t 车内≥ t 设 +3°C fan mid hot water closes, system is at cooling condition

ttemp inside≥tset+6°C fan high hot water closes, system is at cooling condition
…………… fan low hot water closes, system is at cooling condition
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Operation Manual
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Cool mode explanation Press the warm button in 3 sec, 3 sound

reminding, to check the compressor used time, it
Under manual cool mode, the controller will returns to the original mode after 3 sec
apply the mode set by the user. However, when automatically;
the temperature of return flow is under 3°C of the
Time = display number X100(hr).
set temperature, the COOL MODE will switch to
AWAITING MODE. There is a yellow snow 2. Temperature at outlet flow.
image on the display, when the temperature of
return flow exceeds the set temperature, and the
system will turn to COOL MODE automatically Press the air-in button in 3 sec, 3 sound
again. reminding, to check the compressor used time, it
returns to the original mode after 3 sec
Warm mode explanation automatically;

Under manual warm mode, the controller will Shut-off the controller explanation
apply the mode set by the user. However, when
the temperature of return flow is over 1°C of the In order to protect the air conditioner system
set temperature, the hot water valve will close for such as the compressor, fan motor etc. the
5 sec. When the temperature of return flow is controller will stop those components according
under the set temperature 1°C, the hot wator with the following steps:
valve will open for 5 sec.; when the temp inside Compressor, condenser fan motor, evaporator
is equal to the temp set, the hot water valve will fan motor, fresh air damper motor.
keep its position.

Memo function

When restarting the controller, it will return to the Do not use it in other applications.
last settings automatically. This controller has no user serviceable
parts. Contact your supplier for repair.
Shift function (not available on this machine)
Do not use water or water based products
1. Time check to clean it.

The Sheet of Error Code

Error Under Over Pressure Cab temp Cab temp

DEF short short Troubleshooting
code voltage voltage switch
circuit circuit
Undervoltage (voltage ≤20±1VDC),
Er-01 #
check engine circuit
Overvoltage (voltage≤20±1VDC), chekc
Er-02 #
engine circuit
System pressure error, check pressure
Er-04 #
switch circuit and system pressure.
Er-04 check and repair Er-01, then
Er-05 # #
check Er-04.
Check and repair Er-02(overvoltage),
Er-06 # #
then check Er-04(pressure error)
Open-circuit or short-circuit of DEF
Er-16 #
sensor, check sensor circuit
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Operation Manual
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The Sheet of Error Code

Check and repair Er-01(undervoltage),
Er-17 # #
then check Er-16
Check and repair Er-02(undervoltage),
Er-18 # #
then check Er-16.
Check and repair Er-04(system pressure
Er-20 # #
error), then check Er-16.
Check and repair Er-01 (undervoltage),
Er-21 # # #
then check Er-04 and Er-16
Check and repair Er-02 (overvoltage),
Er-22 # # #
then check Er-04 and Er-16
Short-circuit of cab temp sensor, check
Er-H #
sensor circuit
Open-circuit of cab temp sensor, check
Er-L #
sensor circuit
● Er-04: Pressure trouble
At cooling state, if the coolant pressure is higher
or lower than the setting value, then pressure
trouble will occur. The system will stop cooling
All the error codes should be flickered automatically once the pressure trouble is
when they display, and where is also a detected. The output is turned to low level and
sound reminder. trouble codes will be displayed in the LCD. But
the fan speed and fresh air signal can work
Troubleshooting normally. Check the coolant pressure and
eliminate the trouble. The controller will update
This system uses voltage, pressure switches and after the pressure is correct for over 3 seconds.
sensors as the monitoring point for checking any
troubles. ● Er-05: Er-01 Undervoltage trouble and Er-04
pressure trouble occur simultaneously
Trouble is diveded into the following types:
This error code indicates that the undervoltage
● Er-01: Undervoltage trouble and pressure trouble occur to the air conditioning
When the input voltage is less than 20VDC+1V, system simultaneously. Check and eliminate the
and lasts more than 3 seconds, then undervoltage trouble first before troubleshooting
undervoltage happens. Then the air conditioning the pressure trouble.
system will stop automatically and all of the ● Er-06:Er-02 Overvoltage trouble and Er-04
output signals turn to low level and only ambient pressure trouble occur simultaneously.
temperature and trouble codes display in the
LCD. Check the alternator and supply circuit if This error code indicates that the overvoltage
this trouble happens. and pressure trouble occur to the air conditioning
system simultaneously. Check and eliminate the
● Er-02: Overvoltage trouble overvoltage trouble first before troubleshooting
When the input voltage is more than 32VDC+1V, the pressure trouble.
and lasts more than 3 seconds, then overvoltage ● Er-16: Defrost temperature sensor trouble
happens.Then the air conditioning system will
stop automatically and all of the output signals
turn to low level and only ambient temperature
and trouble codes display in the LCD.
Check the alternator and supply circuit if this
trouble happens
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Operation Manual
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This error code indicates that the controller has This error code indicates that the undervoltage,
not received the defrost temperature sensor pressure and defrost temperature sensor trouble
signal. Check the sensor circuit for short circuit occur to the air conditioning system
or open circuit, also check whether the sensor simultaneously. Check and eliminate the
has been damaged. When this trouble occurs, undervoltage trouble first, then the pressure
the air conditioner controls the cooling signal trouble and last shoot the defrost temperature
output on the basis of setting time, setting sensor trouble.
temperature and recirculating temperature, not
● Er-22:Er-02 overvoltage trouble, Er-04
on the defrost temperature sensor signal in order
pressure trouble and Er-16 defrost
to ensure that the compressor stops for 5
temperature sensor occur simultaneously
minutes of every 60 minutes of operation.
This error code indicates that the overvoltage,
● Er-17:Er-01undervoltage trouble and Er-16
pressure and defrost temperature sensor trouble
defrost temperature sensor trouble occur
occur to the air conditioning system
simultaneously
simultaneously. Check and eliminate the
This error code indicates that the undervoltage overvoltage trouble first, then the pressure
and defrost temperature sensor trouble occur to trouble and last shoot the defrost temperature
the air conditioning system simultaneously. sensor trouble.
Check and eliminate the undervoltage trouble
● Er-H or Er-L Recirculating temperature
first before shooting the defrost temperature
sensor trouble
sensor trouble.
“H” stands for short circuit of cab interior
● Er-18:Er-02 overvoltage trouble and Er-16
temperature sensor and “L” stands for open
defrost temperature sensor trouble occur
circuit. Check the sensor and sensor circuit for
simultaneously
good condition. When this trouble occurs, the air
This error code indicates that the overvoltage conditioning system will stop cooling for 5
and defrost temperature sensor trouble occur to mintues of every 60 minutes of operation. After
the air conditioning system simultaneously. this trouble is eliminated, the controller will work
Check and eliminate the overvoltage trouble first normally.
before shooting the defrost temperature sensor
trouble.
● Er-20:Er-04 pressure trouble and Er-16
defrost temperature sensor trouble occur
simultaneously
This error code indicates that the pressure and
defrost temperature sensor trouble occur to the
air conditioning system simultaneously. Check
and eliminate the pressure trouble first before
shooting the defrost temperature sensor trouble.
● Er-21:Er-01 undervoltage trouble, Er-04
pressure trouble and Er-16 defrost
temperature sensor trouble occur
simultaneously
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Operation Manual
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Warm Water Valve

The heating function of the air conditioner

system is realized by heat released by the When the machine stops working under a
evaporator of the air conditioner system when temperature below 0°C , empty the engine
the engine coolant flows through the evaporator. water tank and open the warm water valve
A manual warm water valve is provided and water solenoid valve to drain coolant
respectively for the water inlet and water outlet of from the evaporator if the engine coolant is
the engine. (Note: some machines only have one not added with antifreeze. Otherwise the
for the water inlet of the engine). radiator pipeline could be cracked by frost
due to low temperature.
3 2

1. Warm water valve

2. Warm water valve ON
3. Warm water valve CLOSE
When heating is needed, first open the manual
warm water valve to ON position (the warm
water valve direction is the same with the hose).
At the time, the water solenoid controls the ON
and OFF of warm air.

If it is necessary to repair the air

conditioning system due to fault, first close
the manual warm water valve (the warm
water valve direction is vertical to the hose)
to prevent coolant loss.
When replacing the engine coolant, open
the warm water valve and solenoid water
valve to replace the coolant inside the
evaporator together, and ensure the engine
coolant is at proper level.
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Control Devices

5 2

4 6

1. Steering wheel 5. Lock pin pedal

2. Accelerator pedal 6. Manual throttle
3. Service brake pedal 7. Shift control lever
4. Steering column adjusting handle 8. Work control levers
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Operation Manual
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Steering Wheel Service Brake Pedal

An ordinary steering wheel is provided on this

machine and it is connected to a fully-hydraulic The service brake pedal is located at the front
metering pump. right side of the driver's seat.
The steering wheel can not reset automatically Depress the service brake pedal, the wheel
after being released, and the machine steering brake of the front and rear axles will perform
angle will not change. Therefore, turn the braking. Then the brake lights will flash at the
steering wheel counterclockwise to let the same time. Release the service brake pedal to
machine travel in straight direction after finishing disengage the service brake. Repair the brake
turning. system in time if it has fault to ensure the
machine has enough brake power.
Accelerator Pedal
Steering Column Adjusting Handle

The steering column of the machine can be

adjusted up/down/forwards/backward within a
certain scope to meet different drivers’ operation
habit.
The adjusting handle is located in the middle of
the steering column.

The accelerator pedal is located at the front right

side of the driver’s seat. 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.

Adjust the steering column as follows:

1. Depress the adjusting handle downwards by
foot to loosen the steering column.
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Operation Manual
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2. Hold the adjusting handle still, adjust the Parking Brake Handle
steering column up and down, forwards and
backward to the proper position.
3. Release the adjusting handle to lock the
steering column.

Lock Pin Pedal

The parking brake handle is located on the left

side of the driver's seat. Pull it upward to engage
the parking brake. Press the lock button on the
end of the parking brake handle and release the
handle to disengage the parking brake.
The parking brake is also used as emergency
brake. If an emergency occurs when the
machine is working, pull up the parking brake
handle to engage the emergency brake. If the
machine is at the 1st or 2nd speed, the
During scraping, lock the mold board blade at
transmission will automatically shift to NEUTRAL
required position through depressing this pedal
simultaneously.
when the mold board blade is swinging around
the swing rack.

Manual Throttle
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.

When the engine accelerator pedal doesn’t work,

press the button on the top of the engine manual
throttle, pull the throttle lever backward, the
engine speed will increase, push it forwards, the
engine speed will reduce.
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Operation Manual
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Shift Control Lever Work Control Levers

Work cylinder control levers are located at two

sides of the steering wheel, which are used to
control the work cylinders.

Moving the lever forwards and backward can

operate the machine forwards (lever at "V"
position) and backward (lever at "R" position),
the middle position is neutral (lever at "N"
position).
1, 2, 3, 4, 5, 6 digits in the diagram shows the
different forward gear positions, 1, 2, 3 digits
shows the different reverse gear positions.

Neutral/ Start Interlock Protection Function

The electrical system of the machine is provided

with a neutral/ start interlock function, the engine
can be started only when the shift control lever is
at the neutral position in order to avoid accidents
due to sudden moves when the machine starts.

When the shift control system has a fault,

never remove the transmission system
without authorization. Consult with Liugong
dealer or Service Company if the fault can
not be eliminated.
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Operation Manual
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1. 2 Mold board blade lift control for HOLD--when the lever is released, it will reset to
the left side the hold position. The mold board blade is held at
the selected position.
Mold board blade LOWER
Mold board blade swing RIGHT--Pull
Push the lever forward in order to the lever backward to extend the mold
lower the left end of the mold board board blade to the right. When
blade. When releasing the lever, the releasing the lever, the lever resets to
lever will re turn to HOLD position. The the HOLD position. The mold board blade is held
mold board blade will remain at the selected at the selected position.
position.
7. 8 Mold board blade pitch anlge
HOLD--when the lever is released from LOWER
control
or LIFT position, it will reset to the HOLD
position. The mold board blade will remain at the
Pitch angle DECREASE--Push the
selected position.
lever forward to decrease the pitch
Mold board blade LIFT--Pull the lever angle of the mold board blade. When
backward to raise the left end of the releasing the lever, the lever resets to
mold board blade. When releasing the the HOLD position. The mold board blade is held
lever, the lever will return to the HOLD at the selected position.
position. The mold board blade remains at the
HOLD--when the lever is released, it will reset to
selected position.
the hold position.
3. 4 Ripper control lever (optional) Pitch angle INCREASE--Pull the lever
backward to increase the pitch angle of
the mold board blade. When releasing
Ripper LOWER--Pushing the lever the lever, the lever resets to the HOLD
forward to lower the ripper. When position. The mold board blade is held at the
releasing the lever, the lever resets to selected position.
the HOLD position. The ripper is held
at the selected position. 9. 10 Mold board blade rotate lever
HOLD--when the lever is released, it will reset to
the hold position. The ripper is held at the
Mold board blade rotate
selected position.
COUNTERCLOCKWISE--Push the
Ripper LIFT--pull the lever backward to lever forward to turn the mold board
lift the ripper. When releasing the lever, blade counterclockwise. When
the lever resets to the HOLD releasing the lever, the lever will return to the
position.The ripper is held at the HOLD position. The mold board blade is held at
selected position. the selected position.
HOLD--when the lever is released, it will reset to
5. 6 Mold board blade swing control
the hold position. The mold board blade is held at
lever
the selected position.
Mold board blade swing LEFT--Push Mold board blade rotate CLOCKWISE-
the lever forward to extend the mold -Pull the lever backward to turn the
board blade to the left. When releasing mold board blade clockwise. When
the lever, the lever resets to the HOLD releasing the lever, the lever resets to
position. The mold board blade is held at the the HOLD position. The mold board blade is held
selected position. at the selected position.
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Articulation RIGHT--Pull the lever

backward to move the rear of the
machine right. When releasing the
lever, the lever will reset to the HOLD
Do not allow the mold board blade to position. The machine is held at the selected
damage the ladder, wheels and trapezoidal position.
pull rod during operation process.

11. 12 Mold board blade sideshift

lever Do not pull the right articulation lever to
maximum position during operation.
Sideshift LEFT--Push the lever forward
to move the mold board blade left.
When releasing the lever, the lever will 15. 16 Wheel lean control lever
return to the HOLD position. The mold
board blade is held at the selected position. Wheel Lean LEFT--Push the lever
HOLD--when the lever is released, it will reset to forward to lean the wheel left. When
the hold position. releasing the lever, the lever will reset
to the HOLD position. The wheel is
Sideshift RIGHT--Pull the lever held at the selected position.
backward to move the mold board
blade right. When releasing the lever, HOLD--when the lever is released, it will reset to
the lever will reset to the HOLD the hold position. The wheel is held at the
position. The mold board blade is held at the selected position.
selected position. Wheel Lean RIGHT--Pull the lever
backward to lean the wheel right.
13. 14 Articulation control lever When releasing the lever, the lever will
reset to the HOLD position.The wheel
Articulation LEFT--Push the lever is held at the selected position.
forward to move the rear of the
machine left. When releasing the lever,
the lever will reset to the HOLD
position. The machine is held at the selected Do not lean the wheels and turn the steering
position. wheel at the same time, as much as possible
HOLD--when the lever is released, it will reset to during working. When you need to lean the
the hold position. The machine is held at the front wheels to the limit position with front
selected position. wheels turned, first lean the front wheels to
the limit position,then operate the steering
wheel to turn. Otherwise the steering
cylinder could easily be damaged.
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17. 18 Front blade lift control Other Devices

(optional)

Front blade LOWER--Push the lever Seat

forward to lower the front blade. When
releasing the lever, the lever will reset
to the HOLD position. The front blade
is held at the selected position.
HOLD--when the lever is released, it will reset to
the hold position. The front blade is held at the
selected position.
Front blade LIFT--Pull the lever
backward to lift the front blade. When
releasing the lever, the lever will reset
to the HOLD position. The front blade
is held at the selected position.

19. 20 Mold board blade lift control

for the right side The seat provided on this machine meets the
standard of ISO7096.
Mold board blade LOWER--Push the
lever forward to lower the right end of The driver seat has a suspension shock
the mold board blade. When releasing absorbing function. It can be adjusted in the
the lever, the lever will reset to the aspects of direction, height, backrest angle and
HOLD position. The mold board blade is held at headrest angle to meet the need of different
the selected position. drivers in various working conditions. Make sure
HOLD--when the lever is released, it will reset to that the operator can depress down the pedals to
the hold position. The mold board blade is held at a full stroke after adjusting the seat. Always
the selected position. adjust the seat by sitting in it.

Mold board blade LIFT--Pull the lever 1. Fore-and-aft adjustment

backward to lift the right end of the
mold board blade. When releasing the Fore-and-aft adjustment max. (-60mm~60mm)
lever, the lever will reset to the HOLD
position. The mold board blade is held at the
selected position.
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2. Armrest angle adjustment 4. Rear seat height adjustment

(0~90°horizontal, for reference) (0~60mm)

5. Headrest Height Adjustment

The maximum supporting capacity of the (0~40mm, 40mm~80mm).

armrest is 50KG.

3. Front seat height adjustment

(0~60mm)

6. Headrest Angle Adjustment

(0~10°)
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Operation Manual
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7. Backrest Angle Adjustment Seat Belt

(0~45°vertical, for reference)

The machine is equipped with a seat belt by

Liugong before transporting it to its
destination. Its quality and installation
instructions have met the standard of
ISO6683.

This seat belt supplied by Liugong is

nonretractable.
Fasten the seat belt before operating the
machine.
8. Retractable Seat Belt
Before using the seat belt, check the seat belt for
wear and security, replace if necessary. Contact
your LiuGong dealer for seat belt replacement.
Adjust the length of the seat belt before use to
ensure that the seat belt functions safely and
provides comfort. Adjust the length of the seat
belt by turning the buckle on the seat belt.
The retractor of the seat belt is located on the
right rear side of the seat; insert the buckle into
the opening, the retractor will lock the buckle.

9. Body Weight Adjustment

(50Kg~120Kg)
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A red button is beside the opening of the Sound System

retractor, press it down, the buckle will spring up
from the retractor. The sound system located inside the cab
consists of main unit, loudspeaker and antenna.

1 2

1. Left speaker
2. Right speaker
Before using the seat belt, first check the buckle
of the seat belt, that it can normally be locked 1 2 13 14 15
and released.

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

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,
sirens and so on) when adjusting the volume.
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Source/mute key VOCAL——Speech

POP——Pop music
Press to switch on the power. Press
this key for more than 2 seconds to CLASSIC——Classical music
switch off the power. Press this key shortly to
ROCK-Rock music model
mute or cancel the mute (silence) .
3. The LED display will shown the sound type
Time set key that has been selected.

1.Press SET key for long to enter or

escape SETUP menu.
2. Press SET key shortly to enter hour or No sound mode will be shown on the display
minutes selection of TIME. if no sound mode is selected.
3. Select or  to adjust hour or minute and
the digital will flash. New time setting will be Volume balance adjustment
memorized.
1. Press the SOUND key continuously to select
4. Press SET key at least 2 seconds to escape the balance modes:
SETUP menu.
BASS—TREBLE—BAL—FADER—LOUD
Sound adjustment BASS--low volume control, -7, +7.

Volume Key TREBLE--high volume control, -7, +7

BAL--left and right balance control. -7-- -0- --7
Press the VOLUME+/- key to adjust - - -0- 7
the volume. FADER--horn control, 7
LOUD--undertone volume control. Four choices
Sound are available: OFF LOW MID HI.

1. Press SRC/SOUND key for long to 2. Press VOLUME+/- shortly to adjust the
enter BASS-TRE. selection mode.

2. Press VOLUME+/- key shortly to select your If no other sound mode is selected, BASS/
own sound style TREBLE will show on the display.

The sound system will escape from the

sound mode and momerize the last setting if
BASS-TRE——Your own settings of bass and no further operation within 5 seconds.
treble.
FLAT——Original
JAZZ——Jazz music
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Operation Manual
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Radio USB

Waveband USB interface is provided on this machine.

Features:
Press BAND to select the desired
band. Support MP3 format only.
Support 32Mbyte~4G memory disc.
Support MPEG Audio 1, 2and 2.5.
Support Layer 3.
Support FAT16 and FAT 32 partition memorizing.
Automatic search Sampling frequency range: 8k,16k, 32k, 11.025k,
22.05k, 44.1k, 1k, 12k, 24k and 48kHz.
1.Press'''' to tune to a station of a
lower frequency or ''''to a higher Bit rate: 8k~ 320kbps and VBR(MP3 PRO).
frequency. To search for another station, Do as follows:
press the key again.
1. Insert the memory disc, USB PLUG will show
2. Press ''''or ''''of two seconds to change to on the display.
manual search.
3. Press'''' to turn to a station of lower
frequency or '''' to a higher frequency or a
desired frequency.
4. 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
Press any keys from 1 to 6 to store by 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 following
than 2 seconds to store the current tuned station. interface will be shown:
● Automatic store (AUTO STORE)
You can automatically store 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
stations previously stored in the FM AST band or 3. The display will show the album number
the MW (AM) AST band. before playing the songs.
Press down ''AST''key to activate auto- 4. When playing, the display will show the
store. song's name and playing time. After finish, it
will continue to play the next one.
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5. Press or to select the last song or the

next song to play.
6. Press SCAN key during playing, each song in
the same album will play for 10 seconds in
sequence, press SCAN key again to make it Speakers are easily damaged by water. Do
return to normal playing state. not squirt water on this sound system when
washing the machine. Loose cassettes can
7. During playing, press MENU key to show the damage the cassette player. Do not use C-120
the song sequence in the album, after 2 tapes.
seconds, it will return to normal playing state.
Do not place cassette tapes near anything
8. In playing state, press 3||, playing will magnetic. Be careful if you need to touch the
pause, press this key again to continue body of the unit as the temperature can
playing. exceed 160 degrees Fahrenheit (70°C) after
prolonged periods of operation.

Lights
Do not take out the memory disc when
playing, otherwise the file could be damaged. Lights of the machine consist of front
It is better to take out the memory disc after combination lights (left & right each), rear
turning off the sound system. combination lights (left & right each), dome light,
work lights (left & right each) and rear floodlights
(left & right each) and rotating beacon.
The front combination lights consist of front
It is recommended not to extend the USB headlights, front position lights, front floodlights,
cable because USB agreement has high front turn signal lights and front work lights.
requirement on the length, resistance and
signal delaying of the cable, other cables may
not meet the requirement, which could result
in reading failure of the memory disc. 2 1

Audible signal input

3
A 3.5 mm audible signal input interface
is provided on the sound system, 4
which can be used to connect other music 5
players. Press SRC key and select AUX IN
mode. The volume can be adjusted under AUX
IN mode. 1. Front headlights
2. Front position lights
3. Front floodlights
4. Front turn signal lights
5. Front work lights
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Operation Manual
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The rear combination lights consist of rear Before locking the door, first close it. Insert the
headlights, rear turn signal lights, brake lights/ key and rotate counterclockwise to 180 degrees,
reversing lights, rear position lights. then take it out. After the door is locked, the lock
pin can't be pressed down.

6 Latch

When opening the right and left doors to 180

degrees, the latch on the door is locked by the
7 buckle behind. Then the door is locked in this
8 position.
9 The latch handle is located in the middle of the
door frame.
Lift the handle to release the latch to close the
6. Rear headlights door.
7. Rear turn signal lights
8. Brake lights / reversing lights
9. Rear position lights

10
2 1

1. Buckle
2. Latch

10. Dome light

Door Lock
3

3. Handle

The key of the right & left doors of the cab is the
same. Before the driver operates the machine,
always close the right & left doors first to
Insert the key and rotate it to 180 degrees ensure safety.
clockwise and 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.
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Rear View Mirrors Backup Alarm System

Left and right rear view mirrors are separately

located at the top of the machine cab. Before
operating the machine, adjust the rear view
mirrors and make sure the driver has a good rear
view when sitting on the seat.

The backup alarm is fitted close to the rear turn

signal light. When the shift control lever is turned
to the REVERSE position, the backup alarm will
sound automatically.

Adjustment of Rear View Mirrors

1. Loosen the connection bolts between the

rear view mirror brackets and the cab, turn
the brackets to adjust the rear view mirrors to
the proper position.
2. Loosen the connection bolts between rear
view mirrors and the brackets, turn the rear
view mirrors to adjust the elevation.
3. After completing the above mentioned
adjustment, tighten the bolts.
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Operation Manual
Engine Starting

Engine Starting 2. Go up and down the ladder according to the

safety regulations.

Check Before Starting the Engine

Check the level of the engine coolant.

Check the engine oil level.
Check the oil level of the hydraulic tank.
Check the oil level of the transmission system.
3. Adjust the driver's seat to a proper position.
Check each oil pipe, water hose and fuel hose
for leakage . 4. Close the left and right doors of the cab.
Make sure the air pressure of the tires is normal. 5. Check the seat belt for normal condition and
fasten it.
Check the batteries for damaged wiring and
loose connectors.
Check the accelerator pedal.
Adjust the articulation steering, make sure the
front and rear wheel are on a straight line.
Check the front wheel for lean condition, adjust
the front wheels to a straight direction.

Engine Starting

6. Make sure the shift control lever is at the

Neutral position. If not, turn the lever to the
Neutral position.
Before starting the engine, Clear personnel
around the machine. Clear away any
obstacles. Make sure the machine is under
control by the operator. The electrical system has a Neutral/Start
Interlock protection function; the engine can
1. Turn on the battery disconnect switch. After start only when the shift control lever is at
the battery disconnect switch is turned on, NEUTRAL position. This can avoid an
the key will point to I position. accident produced when the machine is
started.

O I
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Operation Manual
Operation Techniques

7. Turn the fan speed switch and air conditioner 11. During severe cold weather, preheat the
switch to the OFF position. hydraulic oil. Operate all of the control levers
repeatly to preheat the oil in hydraulic oil
cylinder and hydraulic pipe.
12. Listen to the engine and the transmission for
abnormal noise during operation at low
speed.
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
8. Insert the key into the start switch and turn wiper and brake lights work normally.
clockwise to "ON" position to turn on the
power. Sound the horn to warn that the 14. Check the service brake, parking brake
machine is going to run and to keep away system for normal condition.
from it. 15. If there are no obstacles around the machine,
slowly turn the steering wheel and observe
for left and right turning.

Operation Techniques

Operation Information

Follow these basic instructions when you are

operating the machine.
9. Slightly depress the accelerator pedal, turn ● To prevent injury, make sure that no one
the key clockwise to START position to start works on the machine or is near the machine.
the engine. Normally, the engine will start Always keep control of the machine.
within 10 seconds. Release the key at once
to let it reset. ● Raise the implement high enough to go over
any obstacle.
● Before you disengage the parking brake,
depress the service brake pedal in order to
Starter motor operation should not exceed 15 prevent the machine from moving.
seconds. If the engine doesn't start after 15 ● Drive the machine forward for best visibility
seconds, release the start switch at once. and the best stability.
Wait 30 seconds before trying to start again.
If the engine can not be started after three ● Reduce the engine speed if turning or going
tries, wait for at least three minutes before over a hill.
trying again to prevent damage to the starter
motor.

10. Warm up the engine at an idle speed of

Personal injury or death can result from
650~750 rpm after the engine is started.
falling material. Remove any suspensions
Operate the engine with full load only after
and watch out for sliding material.
the coolant temperature of the engine
reaches the green zone.
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Operation Manual
Operation Techniques

Traveling Operation of the 6. Check engagement of all the gears. This

machine is equipped with a manual electro-
Machine hydraulical power shift control system, the
following rules should be observed for each
1. Operate the cylinder control lever, raise the gear shift.
work implement such as the mold board
blade and front blade high enough to pass Start Speed Limit Rules
any obstacles to drive on flat ground.
To ensure operating safety, the machine start
2. Depress the service brake pedal and release
speed is limited to 2nd gear. The machine can
the parking brake lever to disengage the
shift to 3rd or 4 th speed only after it reaches the
parking brake. Slowly release the service
maximum limit speed, otherwise its operating
brake pedal and observe the machine
speed is still kept at 2nd gear.
movement.
Direct Forward/Reverse Change

When changing the traveling direction, the

If the machine moves, depress the service machine speed is required to be below 10km/h.
brake pedal at once, and pull up the parking At forward 1st or 2nd gear, directly engage the
brake lever to engage the parking brake. corresponding reverse (F1?=?R1 and F2?=?R2)
Then check the transmission system for any time.
malfunctions.
At 3F and 4 F, The driver should operate the shift
3. Move the shift control lever to get the proper control lever according to the operating speed as
direction and running speed. the following rule:
When the machine exceeds the preset speed
(normally 2nd gear is set as the maximum
running speed), the operator must first reduce
The machine can move only when the F1, F2 speed below 10km/h, shift to 2nd gear and then
or R1, R2 is selected. the operator can shift to (R2) reverse.
4. Drive the machine to an open and flat area;
turn the steering wheel to check whether the
machine has spot right and left turn ability.
When changing the gear, first release the
5. Check the brake performance of the
accelerator pedal, then operate the shift
machine. Drive the machine with 1st or 2nd
control lever to shift gears in order to protect
forward, release the accelerator pedal,
the clutch.
smoothly depress the service brake pedal,
the machine should obviously reduce speed
and stop.

After depressing the service brake pedal, if

you can not feel the machine obviously
reduce speed, to ensure safety, engage the
parking brake at once to force the machine to
stop.
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Operation Manual
Operation Techniques

Steering Operation of the Machine Brake Operation of the Machine

1. Release the accelerator pedal to slow down When performing the brakes, first release the
the engine running speed. accelerator pedal, then smoothly depress the
brake pedal to perform service brake operation.
2. Depress down the service brake pedal to
slow down the running speed.
3. Move the steering combination switch
downwards when turning left; move the
When the machine travels at high speed, do
steering combination switch upwards when
not rapidly depress the brake pedal unless an
turning right. (see the following picture) Then
emergency occurs, so as to avoid accidents
the turn signal lights on both the front and
or damage the machine.
rear of the machine and the turn indicators on
the instrument panel will flash to warn the
neighboring vehicles and passerby that the Downhill Operation
machine is going to turn.

To avoid lubrication interruption or insufficient

lubrication of the engine, the working gradient for
the grader is not allowed to exceed the following
angle, damage to the engine could be caused
A due to poor lubrication.
Lateral slope Longitudinal slope
Left or right Forward Backward
Permissible
B 20 degrees 25 degrees 25degrees
angle

Select a proper gear before going down a hill. Do

A. Turning left
B. Turning right
not change gears during the downhill process.
Most of time, the gear for downhill is the same.
4. Turn the steering wheel for direction needed.
Turn the steering wheel in opposite direction Maintain a proper speed that is slow enough for
for straight driving after turning operation is the conditions. Use the service brake to control
finished. the travel speed. Use of service brake when the
machine travels at a high speed may result in
5. After the turning is finished, turn the overheating of the brakes and driving axles. This
combination switches to NEUTRAL position. will bring serious damage to the brakes.
The turn signal lights and the turning
indicators will turn off.
6. Press down the accelerator pedal to get the
desired running speed of the engine.

Never turn the machine on a slope. Park the

machine on flat ground, then turn it.
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Operation Manual
Operation Techniques

Machine Operation Adjustment of tilt angle of the mold board blade

can ensure proper movement of materials and
smooth leveling work to obtain the most suitable
Preparation before Operation effects.

Before operation, first level the work site with the

machine. Remove ballooning, fill-in the pits and
shovel away the wet and slide ground surface.
Clear the area of large, sharp rocks to avoid
damaging the machine's tires or the machine
itself. A

Mold Board Blade Adjustment

Operate the swing cylinder so that the mold

board blade can have various working positions
to suit the working conditions, the mold board
Fig. A shows the acute angle between the mold
blade can extend or retract to the left and right. It
board blade edge and ground. This position is
can obtain any angle with 360 degree turning.
used to excavate and move wet earth, dig
ditches and scatter mound.

When moving the mold board blade, always

be careful not to damage the frame ladder,
wheels and trapezoid pull rod.
If a scarifier is equipped on this machine, pay B
attention to adjust the scarifier position while
moving the mold board blade traction frame.

Mold Board Blade Tilt Angle Adjustment

This grader is equipped with a mold board blade

tilting device. Operate the mold board blade Fig. B shows the medium angle between the
control lever inside the driver's cab to extend or mold board blade edge and ground. This position
retract the mold board blade pitch cylinder to suit is used to level and scatter loose earth.
the requirement of the working conditions.
Mold board blade pitch cylinder

1. Backside of the mold board blade

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Operation Manual
Operation Techniques

Fig. C shows vertical angle between the mold

board blade edge and ground. This position is
used to maintain sand and stone road surfaces
and level road surfaces at great length.
When the main mold board blade is worn
down during the friction with the pressure
plate behind, replace the main mold board
blade.
Do not use the backside of the mold board to
work, otherwise the mold board and mold
board support will be damaged. Rotate the Rear Ripper Operation (Optional)
mold board for 180° first if scrape backwards.
If this machine is equipped with rear ripper, a
rear ripper lift indicator will be fitted under the
steering wheel (see the picture), you can check
the lifting and lowering conditions of the ripper
through this indicator.
1 The rear ripper is provided with five teeth.
Generally, three teeth are used for solid road
2 surface, each tooth should be used
symmetrically. For example, use one tooth in the
middle or two teeth outside or three teeth used
together.
1. Tilt angle adjusting cylinder
2. Backside of the mold board

Scrape backwards

4
3 1. Spring pin
2. Pin
3. Main mold board blade
4. Pressure plate
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Operation Manual
Operation Techniques

Travelling position: remove spring pin, pull out Operation of Front Blade/Scarifier (Optional)
the pin, put each tooth to the preset position,
then push the pin, insert the spring pin so that The control lever controls the front blade/scarifier
the tooth retracts inward and lift the ripper (lifting and lowering), the front blade/scarifier is
thoroughly. connected to the front frame by high strength
bolts. Refer to "Work Control Levers" on page 62
for further operation.
Front blade

Ripping position: the machine is at level

condition, the tooth extends and lay on the
ground.

Scarifier

Ripping: place the ripper to ripping position,

press the ripper by control lever and hold at one
position. Drive the machine forwards, also lower
the rear ripper to dig the earth. The control lever
controls lifting or lowering of the rear ripper. The
earth hardness decides the ripper tooth used, When operating the scarifier (if equipped),
digging depth and machine running speed. pay attention to adjust the mold board blade
traction frame at the same time.

Lift the rear ripper before turning and

reverse the machine.
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Operation Manual
Operation Techniques

Special Application Whether the machine is on a flat road, ditch or

slope, simple rules to use the leaning function of
the front wheels: when the front of the machine
Application of the Leaning Front tends to deviate from the straight direction, lean
Wheels in Turning the wheel immediately to the opposite direction
to overcome this tendency and keep the machine
The leaning front wheels have a special help for on a straight line.
operators to operate the machine.
When driving on a flat road, keep the speed at
1st gear. Without operating the steering wheel,
turn the machine left or right by quickly leaning Do not lean the wheels and turn the steering
the front wheels. wheel at the same time as much as possible
The lean feature of the front wheels can provide during working. When it is necessary to lean
separate turning. When turning at 90° or turning the front wheels to the limit position with the
along the Y way, combining with the steering front wheels turned, first lean the front
wheel can obtain easier turning. For example, if wheels to the limit position, then operate the
you want to turn right, you just need to lean the steering wheel to turn. Otherwise the steering
front wheels rightwards. cylinder could easily be damaged.

Application of the Leaning Front

Wheels in Working

When the machine works, a lateral force may be

formed to lead load to the front of the machine.
Operation of the leaning front wheel can
supplement the lateral force formed in working
so that the machine can keep running on a
straight line. If the the machine is going to turn
right, then lean the front wheels left so that the
machine can keep running in a straight direction.
For example: when materials are moved left, a
big load will produce a left lateral force to drive
the front of the machine to deviate left, then lean
the front wheels to right hand to offset the lateral
force to stabilize the front of the machine. As
shown in the figure.
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Operation Manual
Operation Techniques

Application of Articulation Right turn with articulation function only.

When the machine travels on a flat road, the

articulation has two distinct advantages: First,
the leaning front wheels can offset the lateral
force; second, easier operation of the machine.
Generally, when the machine is digging, a lateral
force may be produced so that load will be fed
into the front of the machine. The articulation can Right turn with articulation function, steering
offset this tendancy so as to keep the machine wheel and leaning front wheel.
running in a straight line. If the machine turns
right, then turn the articulation left to let the rear
of the machine move left to keep the machine
running in a straight line.
Whether the machine is working on a flat road,
ditch or slope, simple rules to use the leaning
fuction of the front wheels: when the front of the
machine tends to deviate from the straight
direction, turn the articulation to the opposite
direction to drive the rear of the machine to the Scraping Operation
opposite direction also to overcome this
tendency and keep the machine on a straight 2
line.

1 3

When the machine travels on a flat road, keep

the running speed in 1st gear. When the rear of
the machine is on the center position, turning can
be realized by just ariticulating the rear end 1. Right lift cylinder
without operating the steering wheel. The 2. Swing frame
articulation can also be used with the leaning 3. Left lift cylinder
front wheels to further reduce the turning radius. 4. Swing cylinder
When turning with the leaning front wheels and
articulation function toghether, the maching
steering direction will be as same as the front
wheel and articulation hinge direction.
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Operation Manual
Operation Techniques

The left and right lift cylinders are fixed on the 6. When the swing frame turns to a certain
circle drive of the drawbar. The swing frame position, turn off the lock pin switch, insert
indicator is fitted toward the cab. The operator the swing frame lock pin into any of the six
can sit at the cab, to change the mold board long bores on the swing frame (the hole
blade, angle from the normal leveling position to position is also different according to the
the desired position 1, 2, 3, 4, 5, 6 shown in the working requirements).
figure below by using three control levers
together.

Do not release the lock pin pedal before the

swing frame lock pin is aligned with the bore.

Always observe the following steps when

scraping:
1. Start the machine on a flat position.
2. First lay the mold board blade flat on the
ground so that the mold board blade can fully
contact the ground. Make sure that the mold It is forbiden to raise the piston rod of the left
board blade is not interfered by the ladder, and right lift cylinder over the cylinder body
wheels and/or trapezoid pull rod etc. to avoid damaging the cylinder.
3. Always move the mold board blade left or
right.
4. Lower the mold board blade flat and securely When scraping, the max. permissible lean
on the ground. Operate the blade circle drive angle of the mold board blade is 90°. Do not
lever to let the mold board blade swing operate the blade with a lean angle above 90°,
beyond the frame. otherwise the cylinder could be damaged. To
5. Place the mold board blade on the ground, ensure safety, it's recommended to scrap
turn on a separate lock pin switch at the right from the right side when scraping a slope.
control box, gently operate the left and right
lift cylinder and swing cylinder in turn so that
the mold board blade can stand against the
ground by one side, the swing frame can turn
around the crossbeam so that the mold
board blade can swing to the desired working
position.
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Operation Manual
Operation Techniques

Digging Ditches 3. Mound Treatment

When the mold board blade obtains a tilt angle, After each digging is completed, the mound
the foremost end is called "Top Edge", the other should be heaped or scattered forward on the
end is called "Bottom Edge". middle of the road to keep away from the digging
operation. Do not attempt to operate by digging
soft earth or loose mounds to prevent reducing
traction force, which may lead to uneven digging.
Keep all dug earth away from the ditch so as to
save time.

4. Trimming Side Slope

After the ditch digging is finished, the side slope

should be inclined. Locate the circle drive and
mold board blade. The "Bottom Edge" is placed
1. Bottom edge on the slope bottom, the earth flows into the rear
2. Top edge right box shown in the illustration. The "Top
Edge" should be turned forward to the right front
1. Digging Depth Positioning wheels. The front wheel top should be inclined to
the side slope.
The digging marker must be calibrated according
to the plan. The marked depth should be shallow 5. Trimming Internal Slope
enough to make a straight ditch line easier. This
can help you to obtain an accurate straight line If a flat "V" bottom is required, then you need to
when you continue to dig deeper. trim the internal slope to remove earth on the
To effectively dig ditches, the mold board blade side slope.
should be located at 45°, also, the "Top Edge" If a flat bottom of the ditch is needed, keep on
should be directly located at the right rear of the trimming the remaining parts.
front wheels. The angle formed by the mold
board blade edge must meet the need of 6. Digging Ditch with a Flat Bottom
completing the required digging depth, the
"Bottom Edge" is able to form the mound at the 1. It's required to dig another "V" ditch on the
inner and outer side of the rear wheels. first "V" shape ditch of the internal slope.
Locate the mold board blade and move earth
to the top of the road.
2. When digging the flat bottom ditch, it's
The front wheel top should incline outside required to extend the mold board blade to
the ditch. the maximum limit so that the whole length of
the blade is placed inside the ditch scope.
2. Digging after depth positioning The "Top Edge" of the mold board blade is
located at the base level of the side slope
After cutting the primary ditch line, try to and "Bottom Edge" of the mold board blade
calculate the remaining ditch depth and apply is located at the base level of the internal
proper force to the "Top Edge". Operate the slope. This operation can move the earth to
machine with a proper position. Remember to the internal slope.
shove the mound to the inside or outside of the
rear wheels.
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Operation Manual
Operation Techniques

7. Moving the Loose Earth away from the Operation under Abnormal
Pile
Conditions
Perform the last trimming to the internal slope as
required, move the earth to the road and outside Operation during Cold Weather
of the rear wheels. Piled earth removal is
completed. Pile or scatter the remaining earth to
the road center.

Snow Plough Operation If the ambient temperature is too low, the

engine can not be started easily, the radiator
This machine is not equipped with a special may be frozen.
mouldboard to remove snow. If the mold board
blade is used to remove snow, always pay 1. Use fuel, hydraulic oil and lubrication oil with
attention to the road surface conditions to avoid low viscosity. Refer to "Oil Specifications" on
damaging the machine. page 99 for particular oil brand.
When removing snow, it's recommended that 2. Add antifreeze in coolant.
you always start operation from the road center.
After a channel is formed, shove snow with one
side of the mold board blade to further widen the
channel. When operating on a slope, the front
wheels should lean towards the snow slope to Do not use antifreeze containing methanol,
obtain the optimal effects. ethanol and propanol; do not use any water
leak preventer, do not mix the antifreeze with
The road covered with falling snow may form a a different brand.
layer of thick ice due to the weather and traffic
conditions. It's easier to remove snow by
adjusting the leaning angle of the mold board
blade so that a vertical angle is basically formed Keep antifreeze away from an open fire. Do
between the mold board blade edge and ground not smoke when adding antifreeze.
to cut ice, to greatly improve the working
efficiency. 3. In severe cold areas, use anti-cold batteries.
As the ambient temperature drops, the
electrolyte may be frozen. In order to prevent
battery capacity loss, cover the battery or
move it to a warm place and install it the next
day, then the engine can be started easily.
4. Thoroughly clean sludge, water or frozen
snow from the machine, to avoid it from
entering into the seam and damaging sealing
performance.
5. Park the machine on dry and hard ground. If
impossible, park the machine on wooden
board. The wooden board can prevent the
machine from being frozen.
6. After the weather turns warm, change fuel,
hydraulic oil and lubricant with half viscosity.
Refer to "Oil Specifications" on page 99.
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Operation Manual
Operation Techniques

Operation during Hot Weather

Operating the machine under high temperature

can cause overheating of the machine. Always
check the temperature of the engine and Always wear dustproof glasses when using
transmission, when necessary, stop working to compressed air.
provide a cooling interval for the machine.
2. When repairing the fuel system, be careful to
1. Often check and repair the fan and radiator. prevent dust and sand from entering the fuel
2. Coolant level should meet the requirements tank.
(keep 10mm from the radiator top), check the 3. Maintain the air filter periodically. Check the
radiator fins for impurities such as dust, sand air filter service indicator each day, and keep
or insects etc., if any, clear away to avoid the dust cap and valve clean, prevent dust
clogging the cooling. and sand from entering the engine parts and
3. Under extremely high temperature, oxidized engine house as much as possible.
skin corrosion can be easily caused in the 4. Lubricate and repair according to the
system. Always regularly change antifreeze, lubrication diagram on the machine. Before
ensure preservative has a good corrosion adding grease, clean all lubricating parts.
prevention performance.
5. Try to avoid sand and dust, park the machine
4. If necessary, regularly clean the cooling under the shed or cover with canvas to
system to keep the cooling system clean. Do prevent sand and dust from damaging the
not use water with large alkality to avoid machine.
quickening formation of the oxidized skin and
rust corrosion. Operation under Rainy or Humid Conditions
5. If the machine stops working for several
days, remove the battery and store in a cool 1. The protecting procedures of operation in
place. rainy or humid condition are the same to the
operation during hot weather.
6. Do not park the machine under the sun for a
long time. When parking, park the machine in 2. Protect all exposed surface. Coat with
a room as much as possible. If not, cover the preservative grease, especially be careful
machine with canvas to prevent dust from with the damaged and uncoated surface. Try
entering the engine compartment, to protect cracking paint as much as possible
transmission and hydraulic units. to prevent dust corrosion.

Operation in Dusty and Desert Areas Operation under Salt Corrosion Conditions

Almost all working areas are full of dust, but Salt water has a big corrosion effect. When
when working in a dusty and desert area, always working in salt corrosion areas, always observe
take extra preventive measures. the following notices:

1. Keep the radiator fins and cooling areas 1. When the machine is exposed in salt water,
clean, if possible, often clean with always thoroughly wipe the machine, and
compressed air. wash with clean water.
2. Apply corrosion proof grease on all exposed
surface, pay special attention to damaged
painted surface.
3. Keep all painted surface in good condition.
 87
Operation Manual
Operation Techniques

4. Periodically lubricate the machine according Turning off the Engine

to the lubrication diagram on the machine.

Operation in High Altitude Areas

1. Before operation, fuel and air mixture of the Do not turn off the engine when the machine
engine should be adjusted according to the is working with a load. Otherwise, the engine
corresponding manual of the engine. parts will be frayed quickly due to
2. Check the engine for overheating. The overheating.
pressure cap on the radiator should have a
good sealing ability to ensure coolant 1. Let the engine run at idle speed for 5 minutes
pressure in the system. to let the parts cool down.
2. Turn the start switch of the engine to OFF
Parking position and take out the key.
3. Turn all the switches to NEUTRAL or OFF
Parking the Machine position.

1. Park the machine on flat ground. If the Lowering the Work Implement with
machine is needed to be parked on a slope, Engine Stopped
place a wedge under the wheels to stop it
from moving.

Make sure that no personnel is around the

machine before lowering the implement.

2. Use the service brake to stop the machine.

3. Turn the shift control lever to NEUTRAL 2 1
position.
4. Engage the parking brake.
1. Bolt
5. Lower all the implement to the ground and 2. Locknut
press downwards slightly. If the machine has failure and it is impossible to
lower the mold board blade in common way, you
can operate the balance valve (if equipped) on
the blade lift cylinders to lower the mold board
blade according to the following steps:
1. Fix the bolt by tool or make a marker, and
then loosen the locknut of the balance valve.
88
Operation Manual
Operation Techniques

2. Loosen the bolt of the control valve spool Storage

counterclockwise for 2 turns.
3. Enter into the cab, and ensure no personnel Before Storage
is around the machine, operate the mold
board blade lift cylinder control lever to lower 1. Environmental temperature for machine
the blade slowly to the lowest position. storage: -15°C~40°C.
4. Tighten the bolt to original position and fix it 2. Clean and dry every part of the machine and
by tool, and then tighten the locknut. store it in a dry warehouse. If the machine
5. If the two lift cylinders are not synchronous has to be stored in the open air, park the
during operation, readjust the bolt of the machine on the concrete ground and cover
balance valve. Turn the bolt clockwise to with canvas.
decrease the cylinders lower speed and vice 3. Before storage, refill the oil tank, lubricate
versa. every moving pin & shaft and change
hydraulic oil.
Leaving the Machine
4. Paint a thin layer of grease on the exposed
1. Close the left and right door. part of hydraulic oil cylinder piston rod.

2. Use the ladder and the handrail when you get 5. Remove batteries from the machine and
off the machine. Face the machine and use store in a separate place.
both hands. Make sure that the steps are 6. If the air temperature is below 0°C, add
clear of debris before you dismounting. antifreeze in cooling water of the engine till it
3. Inspect the engine compartment for debris. reaches the engine body and evaporator of
Clean out any debris and paper in order to the air conditioner. Drain out water in the
avoid a fire. cooling system, also drain out water in the
evaporator of the air conditioner.
4. Remove all flammable debris in order to
reduce a fire hazard. Dispose all debris 7. Secure the front and rear frames with the
properly. steering frame lock so that the machine can
not move.
5. Turn the battery disconnect switch to the
OFF position. During Storage
6. If the machine is not filled with antifreeze,
after the machine parks in winter, open all 1. Start the machine once every month and run
water drain valves of the engine, discharge every system, and lubricate every parts of the
coolant in the cooling system and air moving pins and shafts. Meanwhile, charge
conditioner system so as to prevent the the battery.
machine from being cracked by frost. If the 2. Before starting the machine, wipe off grease
machine has been filled with antifreeze, refer on the hydraulic oil cylinder piston rod. After
to the instructions of the antifreeze labels. operation, paint a layer of grease on it.
7. Fix all covers, lock all equipment and remove 3. Paint antirust additive on rusted parts.
the key.

To avoid personal injury or death, when

working with antifreeze inside the room, open
the windows for ventilation.
 89
Operation Manual
Transportation Information

Before Re-usage Perform loading according to the following

steps:
1. Change the lubricant of the engine,
transmission, axles and the hydraulic oil, 1. Chock the trailer wheels or the truck wheels
brake oil and antifreeze of the engine. before you load the machine.
2. Lubricate all moving pins and shafts.
3. Before starting the machine, wipe off grease
on the hydraulic oil cylinder piston rod.

2. When the machine is loading on the trailer or

truck, it is forbidden to steering operations.

If the machine is not applied with antirust 3. After parking the machine, secure the front
additive per month during storage, please frame and rear frame with the steering frame
consult with Liugong dealer. lock so that the machine can not move.
4. Lower all the implement to the floor of the
trailer. Turn the shift control lever to the
Transportation Information NEUTRAL position.
5. Engage the parking brake.
Transportation of the Machine 6. Stop the engine, turn every switch to
NEUTRAL or OFF position and remove the
key.
7. Lock the door and remove the key.
Obey the correlative laws about the 8. Turn the battery disconnect switch to OFF.
parameters of the load (weight, width, and
9. Chock the wheels of the machine and fasten
length).
them with steel ropes to avoid movement
during transportation.
Investigate the travel route for overpass
clearances, Make sure that there will be
adequate clearance if the machine that is
transported has a ROPS, a cab, or a canopy.
Remove ice, snow, or other slippery material
from the loading dock and from the transport
machine before you load the machine. This will
help to prevent slippage of the machine, and
prevent the machine from moving during
transportation. 10. Cover the exhaust outlet to prevent the
turbocharger from rotating during
transportation. Damage to the turbocharger
can result.
90
Operation Manual
Transportation Information

Driving the Machine 3. The lifting decals can be seen on the front
and rear frame of the machine.

1. Before driving the machine on road, check

whether the machine meets the requirements
of the local laws and regulations for road
operation. Make sure that you get the road
operating permission from relevant road
administration offices. Observe the local
traffic regulations when driving the machine
on roads.
2. Before you drive a machine, consult your tire 4. Before lifting, secure the front and rear
dealer for recommended tire pressures and frames with the steering frame lock so that
speed limitations. the machine can not move.
3. 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
and the components.
1
4. Inflate the tires to the correct pressure. Refer
to "Tire Inflation Information" on page 98 for
tire inflation information.
5. Travel at a moderate speed. Observe all
speed limitations when you drive the
machine. 2

1. Pin
Lift the Machine 2. Steering frame lock

To connect the steering frame lock, the

Improper lift or securing could cause the
machine must be turned toward the right
machine to move and cause injury or
front position.
damage. Install the steering frame lock before
lifting. 5. The lifting device should be installed on the
lift eyes with lift decals on the machine.
1. Refer to "Main Specifications" on page 33 for
weight of the machine. Always calculate the
maximum lift weight of the crane and loading
capacity of the lifting device to ensure the lift Improper lifting could cause the machine to
safety. move accidentally and cause machine
damage, personal injury or death.
2. Adjust the length of the three ropes on the
lifting device to ensure the machine leaves
the ground smoothly. Make sure the ropes
won’t touch the cab and engine hood during
lifting.
 91
Operation Manual
Transportation Information

Towing Information

Towing the Machine

Before releasing the parking brake, chock the
wheel to prevent movement. Remove the
wedge before starting the machine.
2. The towing machine should be equipped with
Personal injury or death could result when
a protective guard to protect the towing
towing a disabled machine incorrectly. Chock
operator, if the towing ropes or towing bar
the wheels before releasing the brake to
cracks accidentally.
prevent the machine form moving.
3. Do not allow operators on the machine that is
Brake failure could cause personal injury or
being towed unless the operator is needed to
death. Before towing the machine to the
control the steering wheel or brake.
repair place, always ensure all necessary
repairs and adjustments are made. 4. Before you tow the machine, make sure that
the towing ropes or the towing bar is strong
enough for towing the machine. The towing
Do not tow the machine unless the machine has
ropes or towing bar must have a strength that
severe trouble. The machine can only be towed
is 1.5 times of the gross weight of the
for a short distance for repair. Never tow the
machine that is being towed.
machine for a long distance. The towing distance
should not exceed 10Km and towing speed 5. Use a rope cable or steel wire with rings as
should not exceed 2km/h; otherwise, the gear the towing tools. Order a person as an
box will be damaged due to insufficient observer in a safe position. Stop towing if the
lubrication. If the machine needs to be ropes begin to crack or come loose. Stop
transported for a long distance, a truck and trailer towing if the towing machine can move but
should be used. the towed machine can not move.
6. the minimum angle between the towing ropes
Do the following steps :
and straight direction should not exceed 30°.
1. Do not drive the machine if it is disabled by 7. Quick machine movement could cause the
an engine fault or a brake system fault. towing ropes or the towing bar to overload.
Remove the connecting shaft between the This could cause the towing ropes or the
parking brake cylinder and the parking brake towing bar to break. A smooth machine
linkage to disengage the parking brake by movement helps towing operation.
force.
8. Normally, the towing machine should be as
large as the disabled machine. The towing
machine must have enough brake capacity,
weight, and power for the grade and distance
that is involved.
9. During towing, all personnel should keep
away from the both sides of the towing ropes
so as to prevent injury in case of a break.
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Operation Manual
Transportation Information

10. It may be necessary to connect a large

machine or additional machine to the
disabled machine in order to provide
sufficient control and brake ability. This will
prevent the disabled machine from rolling
away on a downgrade.
11. It is impossible to list all the requirements for
all different situations. Refer to Liugong
dealer for more information about towing a
disabled machine.

Towing the Machine with a Running Engine

If the engine is running, the machine can be

towed for a short distance under certain
conditions. The power train and the steering
system must be operable. Tow the machine for a
short distance only. For example, pull the
machine out of mud or to the side of the road.
The operator on the towed machine must turn
the machine in the direction of the towing ropes.
Turn the shift control lever to NEUTRAL position,
lift all implements and strictly observe all the
instructions that are outlined in this topic.
 93
Maintenance Manual
Run-in

Maintenance Manual 7. Always pay attention to the temperature of

the transmission, torque converter, drive
axle, wheel hub, parking brake, hydraulic oil,
engine coolant and engine oil, if there is
overheating, find out the reason and
eliminate it.
Perform the maintenance procedures at the 8. Check the tightness of all bolts and nuts.
intervals according to this manual. Proper
maintenance will extend the service life of the The following must be done after the first 8
machine and provide safer operation. hours of operation during the run-in period.

1. Check the tightness of all bolts and nuts

especially the bolts of the cylinder head,
Run-in exhaust pipe, front and rear axles, drive
shaft, diesel engine, transmission, front and
rear frames joint, and wheel rim nuts etc..
The run-in of a new machine is an important
procedure for prolonging the service life of the 2. Check the tightness of the engine drive belt
machine, eliminating fault and avoiding and air conditioner compressor belt.
accidents. The user must read these guidelines
3. Check the oil level of the transmission, drive
for run-in of a new machine and how to operate
axle and diesel engine.
and maintain the machine after purchase.
4. Check the hydraulic system and brake
Run-in-Requirements for a New Machine system for oil leakage.
5. Check the connections of all control levers,
1. Run-in of a new machine is 100 hours.
throttle linkage and flexible shaft.
2. Run the engine at idle speed for five minutes
6. Check temperatures and connections of the
after starting the engine. Start the machine at
electrical system, power supply of the
low speed. Slowly increase speed.
alternator, lights and the turn signal lights.
3. Run-in should be done averagely in each
forward or reverse gear.
4. Start the machine at low speed. Slowly
increase speed. Always avoid starting, Check oil level according to the relevant
speeding up, turning and braking suddenly operation regulations.
except for emergency cases.
5. It is better to scrape loose material during the Work should be done after the finish of run-in
run-in period. Do not operate rushly and
exceed its rated capacity and rated max. 1. Check the tightness of all the bolts and nuts
travelling speed by 70%. especially the bolts of the cylinder head,
exhaust pipe, front and rear axles, drive
6. Check the lubricant periodically. Replace or shaft, diesel engine, transmission, front and
add lubricant according to the recommended rear frames joint, and wheel rim nuts etc..
period.
2. Check the tightness of the engine drive belt
and air conditioner compressor belt.
3. Check the hydraulic system and brake
system for oil leakage.
94
Maintenance Manual
Maintenance Intervals Schedule

4. Replace the transmission oil and axle 3. Check coolant level.

lubricant.
4. Check hydraulic oil level.
5. Replace the secondary filter and clean the
5. Check fuel level.
primary filter of the transmission.
6. Drain any water and impurity from the fuel
pre-filter and filter of the engine.
7. Daily inspection.
Replace transmission oil, axle lubricant and 8. Check the engine fan and belt.
secondary filter of the transmission
according to operation instructions. 9. Check working condition of the lights and
gauges.
10. Check tire inflation pressure and look for tire
Maintenance Intervals damage.
Schedule 11. Check the working condition of the backup
alarm.
12. Lubricate every articulation point according to
the instructions of the machine lubrication
diagram on the machine.
Read and understand all the safety
instructions, warnings and indications Every-50-Service hours or every week
before any operations or maintenance.
In addition to all previous service checks:
The maintenance intervals stated in this manual 1. Check the transmission oil level.
are determined according to the service hour
meter or calendar intervals shown (daily, weekly, 2. Check the wear condition of the brake friction
monthly, etc). Liugong recommends that disc at the first 50 service hours and replace
maintenance should be performed according to it if it has been worn away. Check once every
whichever of the above-mentioned intervals 250 service hours later on.
occurs first. 3. Tighten all connecting bolts on drive shafts.
Under extremely severe, dusty or wet operating 4. Clean the dust and sundries from the cab
conditions, more frequent lubrication than is recirculating air strainer and fresh air strainer.
specified in the "Maintenance Intervals" chart Wash them if it is necessary. Check the
may be necessary. compressor belt for tightness and check the
Perform service on items at multiples of the condenser for grease, dirt and sundries.
original requirement. For example, at every 500 5. Keep battery terminals clean and coat with
service hours or 3 months, also service those vaseline to avoid acid fog from corroding the
items listed under every 250 service hours or terminals.
monthly, every 50 service hours or weekly and
6. Check the lubrication condition of the
every 10 service hours or daily.
lubricating points and lubricate every
lubricating point according to the lubrication
Every-10-Service hours or every day
diagram on the machine. If the machine is
equipped with central lubrication system, for
1. Check the battery and the battery disconnect
those manual lubricating points, pump
switch.
grease by hand according to the lubrication
2. Check engine oil level. diagram on the machine.
 95
Maintenance Manual
Maintenance Intervals Schedule

7. Check the nitrogen precharge pressure of the 5. Check the intake air filter alert indicator. If the
brake system accumulators at the first 50 indicator blinks, change the filter element.
service hours.
6. Check the air intake system of the engine.
Every-100-Service hours or two weeks 7. Replace the engine oil and filter.
8. Check tension and wear conditions of the
In addition to all previous service checks:
engine belt and air conditioner compressor
1. Replace the transmission oil at the first 100 belts.
service hours, and change transmission oil
9. Check the refridgerant level in the air
once every 1000 service hours after that. If
conditioner refridgerant receiver.
the operating hours are below 1000 hours a
year, replace the transmission oil at least 10. Clean the recirculating air strainer and fresh
once every year. Change the transmission oil air strainer of the cab.
secondary filter while changing transmission 11. Check the service brake ability and parking
oil each time, and clean the primary filter on brake ability.
the bottom of the transmission.
12. Check the nitrogen precharge pressure of the
2. Change gear oil of the axles, tandems and brake system accumulators at the first 250
worm gearcase after the first 100 service service hours.
hours, change the gear oil of the axles,
tandems and turbine every 1000 service Every-500-Service hours or three months
hours. If the operating hours are below 1000
hours a year, change the gear oil of the axles In addition to all previous service checks:
at least once every year.
1. Check the density of antifreeze and coolant
3. Clean the engine cylinder head. Clean the additives.
radiator.
2. Replace the fuel pre-filter. Replace the
4. Clean the filter strainer of the fuel tank. primary filter and the secondary filter of the
5. Check the nitrogen precharge pressure of the engine.
brake system accumulators at the first 100 3. Tighten connecting bolts of the front & rear
service hours. axles and front & rear frames.
6. Operate the swing cylinder piston rod to 4. Check bolts on the articulation joint of the
extend and retract completely at least once. frame for loose condition.
Every-250-Service hours or every month 5. Check the nitrogen precharge pressure of the
brake system accumulators at the first 500
In addition to all previous service checks: service hours.
1. Check the tightening torque of the rim set Every-1000-Service hours or six months
bolts.
2. Check the tightening torque of the In addition to all previous service checks:
transmission and engine mounting bolts. 1. Adjust the engine valve lash.
3. Check the implement and the front & rear 2. Check the engine tensioner bearing and fan
frames for cracks and loose bolts. shaft housing.
4. Check the oil level of the drive axle, tandems 3. Change transmission oil, transmission oil
and worm gearcase. filter and clean the filter at the bottom of the
transmission.
96
Maintenance Manual
Maintenance Intervals Schedule

4. Change gear oil of the drive axle, tandems 4. Check fan hub, repair or replace if necessary.
and worm gearcase.
5. Inspect and repair the turbocharger.
5. Replace the return oil filter element of the
hydraulic system.
6. Clean the fuel tank.
7. Tighten all set bolts of the battery and clean
the battery surface.
8. Check the nitrogen precharge pressure of the
brake system accumulators.
9. Replace the fresh air strainer of the cab.

Every-2000-Service hours or every year

In addition to all previous service checks:

1. Replace hydraulic oil, clean the hydraulic oil
tank and the oil suction filter, check the oil
suction hose.
2. Check the service brake system and parking
brake system. Remove and check the friction
disc for wear condition and replace if
necessary.
3. Check airtight condition of the hydraulic lock
and work cylinder by measuring neutral
sediment of the cylinder.
4. For the machine equipped with air
conditioner, check the refrigerant pipe and
water hose of the air conditioner for cracks,
wear or foaming by oil. Check the connectors
and clamps for loose condition.
5. Replace the recirculating air strainer of the
cab.
6. Check flexibility of the steering system.
7. Replace engine coolant, clean engine
cooling system, replace engine coolant filter.

Every-6000-Service hours

In addition to all previous service checks:

1. Check the shock absorber of the engine
crank shaft pulley, replace if necessary.
2. Clean, repair or replace the engine nozzle.
3. Clean and adjust the fuel pump.
 97
Maintenance Manual
General Torque Specifications

General Torque Specifications

Tighten bolts used in the machine according to the torque requirements shown in the following table
unless otherwise specified.
Standard torque for metric threads

Standard Torque lb.ft (N·m)

Thread Size
8.8 Grade Strength 10.9Grade 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)

Standard torque for British system threads

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)
98
Maintenance Manual
Tire Inflation Information

Tire Inflation Information Lubrication Specifications

Liugong recommends the use of dry nitrogen for Oil Change Interval and Refill
tire inflation and tire pressure adjustments. It
includes all machines with rubber tires. Nitrogen
Capacities
is an inert gas that will not aid combustion inside
the tire.
The use of nitrogen for tire inflation can not only
reduce the risk of explosion, but also help to
Care must be taken in order to ensure that
prevent oxidation, aging of the rubber, and
fluids are contained during the performance
corrosion of the wheel rim parts.
of inspection, maintenance, testing,
adjusting and repair of the equipment.
Collect the fluid with a suitable container
before opening any compartment or
Training for using the equipment is disassembling any component. Obey all
necessary to avoid over inflation. A tire local regulations for the disposal of liquids.
blowout or a rim failure can cause personal
injury. Do not set the tire inflation equipment Interval Approximative
Item
regulator higher than 140 kPa (20 psi) over (service hours) quantity(L)
the recommended tire pressure. Engine oil 250 17
Transmission oil 1000 45
Check and adjust the tire inflation pressure after
the tire cools down completely. Ask all other Hydraulic oil 2000 186
persons to leave the danger area (around the Rear axle,
rim). tandem and 1000 85
worm gearcase
The inflation pressure for nitrogen and air are the
Fuel Every day 230
same when charing the tires. Consult your tire
dealer for operating pressures.
See the following table for the tire inflation
pressure under normal temperature.

wheel MPa Psi

13.00-24 0.3 ±0.01 43.5 ±1.5

The tire pressure will significantly change when

you drive the machine into freezing temperature
from a normal environment. If you inflate the tire
to the correct pressure under normal
temperature, the tire will be underinflated in
freezing temperature. Low pressure will shorten
the service life of tires.
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Maintenance Manual
Lubrication Specifications

Oil Specifications

Name of oil
Type of oil Position of use
In Summer In Winter
For roller bearings, sliding bearings, shafts
of work implements, steering cylinder shaft,
Grease ★ a 2# MOS2 lithium based grease frame shaft, swing frame of rear axle, drive
shaft spline, universal joint and water pump
shaft etc.
Transmission oil ★ Mobil 1300 or SAE15W-40 CF engine oil For torque converter and transmission
★ HM46 anti-wear HV46 low temperature For implement hydraulic system, steering
Hydraulic oil
hydraulic oil anti-wear hydraulic oil hydraulic system and brake system.
★ SAE/CF-4 above
Engine oil SAE/CF-4 above 5W-30 For diesel engine
15W-30
North No. 0 light diesel oil No. -35 light diesel oil
Fuel For diesel engine
South No. 0 light diesel oil No. 0 light diesel oil
Gear oil ★ SAE85W-90 GL-5 heavy load gear oil Axles, tandem, worm gearcase.

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

Do not mix oils of different brands even if they have the same specifications. Clean the system
before refilling with different oil.
If the machine is used at low temperature in severe cold areas for a long time, HV-46 low
temperature anti-wear hydraulic oil should be used, and ATF220 or DEXRON-III or Donax TC
transmission oil should be used.
Replace the lubricant periodically even though the lubricant is very clean because the lubricant
might go bad after long use.
Choose the oil according to the lowest air temperature in the local area where the machine is
used.
100
Maintenance Manual
Pressure--Release

Pressure--Release 3. Slowly loosen the oil filler cap on the

hydraulic oil tank top or coolant filler cap on
the radiator to release internal pressure.

The coolant has high pressure and

temperature during operation. Hot coolant
can cause a serious burn. Before opening the 1
coolant and/or fuel filler cap, stop the engine,
and wait until the radiator cools down. Then
loosen the cap slowly to release the
pressure.
Hydraulic oil piping is always in a under
pressure condition, therefore, when
inspecting or replacing pipes or hoses,
always release pressure in the oil path. If
pressure is not released, spraying of high
pressure oil could cause serious personal
injury.
2
After the engine is shut down, the coolant
and oil inside parts are under high pressure,
serious burns could be caused. Before
operation, wait until they cool down.
When removing the oil filler cap and radiator
1. Oil filler cap
coolant cap, oil or water could spray,
2. Coolant filler cap
therefore, slowly turn the cap before
removing to release internal pressure. 4. Loosen the lock nuts between hydraulic
piping to release residual pressure in the
hydraulic units, then tighten. Also pay
Particular operation methods of pressure attention to collecting residual oil in the
release: implements.
5. Refer to "Accumulator Pressure--Release"
1. Park the machine on flat and hard ground on page 126 for accumulator pressure
and lower all implements on the ground. release procedures.
2. Turn the start switch to ON position within 15
seconds after parking the machine, and fully
operate the control levers towards each
direction to release internal pressure of the
implements.
 101
Maintenance Manual
Important Maintenance Procedures

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 frayed or damaged parts, if necessary.
Adjust the rear view 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 levels more
frequently.

Check the cooling system and hydraulic system

hoses for leakage, repair or replace the hoses, if
necessary.
Check the engine compartment. Clean the
accumulated sundries on it and on the radiator.
Check the engine for damaged parts.
Check the tires for damage. Check for missing
air caps.
Check axles, tandem, worm gearcase and
transmission for leakage, repair the leakage
point.
Check the hydraulic oil tank, all of the tubes and
hoses, plugs, seals, connectors and oil nozzles
for leakages. Repair the leakage and replace the
hose if necessary.
Check all of the implements and linkage for
cracks and damages.
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 inlet and outlet of the evaporator in the
air conditioner. Clear away the cotton, paper,
plastic and film that can block the inlet.
Check the ROPS (if equipped) for visible
damage. Consult with your Liugong dealer for
repair information, if there is damage.
102
Maintenance Manual
Important Maintenance Procedures

Engine System 3. Check the seals of the coolant filler cap,

replace if damaged.

Coolant Level--Check 4. Screw in the coolant filler cap.

Check the cooling system of the engine for

Hot coolant can cause serious burns. To leakage if it needs to add coolant everyday.
open the cap, stop engine until the radiator If leakage is found, eliminate the leakage
cools down. Then loosen cap slowly to and add coolant until it reaches the proper
release the pressure. level.

The coolant is in the radiator located at the rear Anti-freeze density and coolant additive
of the machine. density-check

Anti-freeze has been added into the

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

If the temperature is forecasted to drop below

0°C (32° F), add anti-freeze suited to local
Checking method for coolant level: climatic conditions into coolant. If only anti-freeze
concentrate is available, it is needed to mix it
1. After the engine coolant temperature drops with soft water in a certain proportion. Refer to
down below 50°C, slowly screw out the the proportioning instruction for the mixing
radiator coolant filler cap to release pressure proportion of anti-freeze concentrate.
in order to avoid being scalded by high Before adding anti-freeze, use refractometer to
temperature vapor or splashing coolant. measure the freezing point of the well mixed anti-
freeze accurately to ensure that the anti-freeze
adapt to the local lowest temperature. The mixed
anti-freeze by experience is just a general range,
the anti-freeze measured by refractometer is
accurate, which can effectively avoid frost
cracking and damage to the radiator and engine.
When replacing anti-freeze, use high quality anti-
freeze and follow the instructions for filling.

2. Check if the coolant level is within 1 cm When adding anti-freeze, use the anti-freeze
below the water filler, add coolant if of the same brand.
necessary.
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Maintenance Manual
Important Maintenance Procedures

Coolant must contain additive (SCA) to prevent Water used in coolant must be soft water or
the engine parts which contact with coolant from distilled water, because ordinary fresh water and
rusting, scaling, pitting, and corrosion. Additive tap water contains a lot of calcium and
(SCA) of low density doesn’t have effect, additive magnesium materials, which will cause scaling of
(SCA) of high density will have a negative impact the cooling system radiator, engine and piping,
on engine, it may result in water pump leakage while excessive chlorine compounds and sulfate
and corrosion of cooling system solder and will corrode the cooling system and engine
aluminum parts. waterways. If there isn’t soft water or distilled
water, the quality of water used in coolant must
The density of coolant additive should be
meet all of the requirements listed in the
maintained at about 3%. Anti-freeze already
following table, and the density level of each
contains additive, but the additive will be
element shall not exceed the permitted
consumed up during running the engine.
maximum value in the following table.
Therefore, check the coolant density every 500
work hours or six months. Refill additive by Min. water quality requirement
changing the coolant filter periodically.
Permitted max. content
Item
Refer to the Operation and Maintenance Manual value
of Diesel Engine provided with the machine for
Calcium and
the additive density inspection method and magnesium
Max. content in (CaCO3 + MgCO3)
detailed instructions. is 170ppm
content (hardness)
Chlorine Max. content in (Cl) is 40ppm
Coolant--Add
Sulfur Max. content in (SO4) is 100ppm

If the temperature is forecasted to drop below

0°C (32° F), add anti-freeze suited to local
climatic conditions into coolant. If only anti-freeze
Hot coolant can cause serious burn. To open concentrate is available, it is needed to mix it
cap, stop engine until radiator cools down. with soft water in a certain proportion. Refer to
Then loosen cap slowly to release the the proportioning instruction for the mixing
pressure. proportion of anti-freeze concentrate.
Since the heat absorption capacity of anti-freeze
to the engine isn’t as good as water, add anti-
freeze into the engine before thoroughly mixed
Anti-freeze is flammable. Never expose anti-
with water will cause overheat of the engine.
freeze to an open fire. Never use water as
the coolant otherwise it will cause corrosion Before adding anti-freeze, use refractometer to
damage to the cooling system. 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.
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Maintenance Manual
Important Maintenance Procedures

Add coolant as follows: 6. Open the water radiator filler cap, slowly add
coolant until the level reaches 1 cm below the
1. Mix the water and coolant completely water filler of the radiator and keeps stable
according to desired density level of the for 10~15 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

3. Insert the key into the start switch and turn When adding coolant, exhaust air from the
clockwise to the ON position to turn on the cooling system lines of the engine.
power of the machine.
7. Keep the radiator filler cap open, start the
4. Turn the selector switch of the air conditioner engine and run at idle speed for 5~10
to WARM position. minutes, and at high speed for 5~10 minutes.
5. Turn the manual valve on the water inlet hose 8. Run the engine at idle speed and check the
of the engine to ON position. (The valve is at coolant level again. Add coolant if necessary.
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.
 105
Maintenance Manual
Important Maintenance Procedures

Coolant--Replace When coolant is polluted, engine overheated or

bubbles appeared in radiator, test the freezing
point of the additive and anti-freeze in the cooling
system to determine whether the coolant must
be replaced, replace the coolant if it exceeds any
Hot coolant can cause serious burn. To open permitted limit value in the coolant replacement
cap, stop engine until radiator cools down. limit table.
Then loosen cap slowly to release the Coolant replacement limit table
pressure.
Anti-freeze might hurt the skin, when Pollutants Permitted limit value
replacing it, wear goggles and protective Sulfate (SO4) Max. 1500ppm
clothing to avoid personal injury. Chloride (Cl) fluoride,
Max. 200ppm
bromide
Engine oil or fuel Coolant shall not contain
pollution engine oil or fuel
Care must be taken in order to ensure that pH value Min. 6.5 (see Note ★ )
fluids are contained during performance of
Grease, solder ,
inspection, maintenance, testing, adjusting Coolant shall not contain these
silicone, corrosion or
and repair of the equipment. Prepare to pollutants.
scaling
collect the fluid with suitable containers
before disassembling any hydraulic oil lines. Note ★ : The replacement limit of the min. pH value may
Obey all local regulation for the disposal of change with the product changes. Consult the product
manufacturer for the pH value limit. The pH value less
liquids. than 6.5 is unacceptable generally.
If the cooling system failed to be cleaned
Steps for cleaning the cooling system
thoroughly, the new coolant may be polluted
during refilling, and result in the cooling
1. Turn on the disconnect switch.
system and engine failure.
Do not mixed use multiple brands of coolant,
otherwise the consequent cooling system O I
and engine failures are not covered by
warranty.

Completely replace the coolant every 2000

service hours or one year (which ever comes
first) and clean the cooling system. Clean the 2. Insert the start switch key and turn clockwise
cooling system before that interval if the coolant to the ON position to turn on the power of the
is polluted, the engine is running excessively hot machine.
or bubbles appear in the radiator.
3. Turn the selector switch of the air conditioner
to WARM AIR position.
106
Maintenance Manual
Important Maintenance Procedures

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

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

When adding cleanser into the cooling

system, exhaust air from cooling system
lines of the engine. During cleaning of the
cooling system, never cover the water
radiator filler cap 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.
 107
Maintenance Manual
Important Maintenance Procedures

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 10~15 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. 1. Stop the engine and open the engine hood.
15. Replace with a new coolant filter, close all 2. Remove the inner & outer covers of the air
drain plugs, then add new coolant according filter.
to the operation rules previously described in
section “Coolant--Add”.

The coolant of the engine is poisonous and

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

Air Pre-Filter--Clean

The air filter is located under the engine hood of 3. Remove the nut on the top of the main filter
the machine. element then take it out.

Maintain the air filter if the yellow piston of

the service indicator rises to the red zone
when the engine is running at high speed.
Shut down the engine to avoid damage when
servicing the air filter.
108
Maintenance Manual
Important Maintenance Procedures

4. Clean the inner wall of the air filter. 6. After cleaning the main filter element, check
with an electric light, if small holes and
particles as well as damage of the washer
and seal are found, replace with a new main
filter element.

5. Clean the main filter element with

compressed air (below 300kPa). First wash it
out along the pleats inside the main filter
element, then repeat washing the pleats
along the inside and outside surface of the 7. Fix a clean main filter element into the air
main filter element. filter and ensure an even contact at the end
of the main filter element. Tighten the nut on
the top of the main filter element, do not use
tool to avoid damage to the main filter
element.
8. Clean and fix the cap of the air filter, make
sure that the inner cap gasket in the air filter
contacts evenly with the air filter housing.
9. After cleaning main filter element, start the
engine. If the yellow piston of the air filter
service indicator still rises to red zone or
black smoke still exists, then replace with a
new safety filter element.
10. Replace the main filter element after it has
Do not strike when cleaning the main filter been cleaned up for six times. Replace once
element, or filter and the engine damage every year even if it hasn’t been cleaned for
could result. six times. Change the safety filter element
while changing the main filter element.
 109
Maintenance Manual
Important Maintenance Procedures

Air Filter Safety Element--Replace

Air filter safety element

Replace the safety filter element together

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

Fuel Level--Check

The fuel level gauge is located on the right

instrument panel of the cab.
The fuel level gauge indicates the fuel level of
the machine, the gauge pointer points to 1/1
Always replace the safety filter element with a indicates the maximum fuel level, the gauge
new filter element. Never use again after pointer points to 0 indicates the minimum fuel
cleaning. level. Add fuel timely if the pointer points to the
left second position.
1. Stop the engine and open the engine hood.
Fuel level gauge
2. Remove the inner and outer caps of the air
filter.
3. Remove the main filter element.zeng
4. Screw out the nuts on the top of the safety
filter element, then carefully remove the
safety filter element.
5. Clean the inner wall of the air filter.
6. Fix a new safety filter element, make sure the Fuel--Add
seal ring on the top of the safety filter
element contacts evenly. Tighten the nuts on
The fuel tank is located at the rear middle of the
the top of the safety filter element with hands
machine.
only, do not use tool.
7. Install the main filter element and the inner
and outer caps of the air filter.
8. Press down the reset button under the
service indicator to let it reset.
110
Maintenance Manual
Important Maintenance Procedures

1. The fuel filler of the fuel tank is located at the 1. Clean the fuel tank by removing the flange
top of the engine hood. cover on the front of the fuel tank. Wash the
Fuel filler inner surface of the tank with clean fuel.

2. When opening the fuel filler cap, first pull up 1

the cap lock plate. Turn the cap
counterclockwise to the next position then 1. Drain plug
remove the cap. 2. Flange cover
3. Add fuel. 2. Screw out the drain plug to drain out the
remaining fuel.
3. Repeat washing until the drained fuel is
clean.
Do not take out the strainer of the fuel filler
when adding fuel. Water and Impurity--Remove

Fuel Tank--Clean The fuel pump and fuel injection nozzles are
precision devices, if the fuel is mixed with water
or impurity, the fuel pump and fuel injection
nozzles can’t work properly and quickly wear.
Measures should be taken to remove water and
Care must be taken to ensure that fluids are impurity from the fuel.
contained during performance of inspection, 1. If conditions are permitted, fuel should be
maintenance, testing, adjusting and repair of deposited for 24 hours before it is filled to the
the product. Be prepared to collect the fluid tank.
with suitable containers before
disassembling any component containing 2. Before filling, screw out the drain plug at the
fluids. Dispose of all fluids according to local bottom of the fuel tank to drain out water and
regulations. impurity deposited in the tank once every
week.
Periodically clean the strainer of the fuel inlet and 3. After completing daily work, add fuel and
fuel tank, clean the fuel tank according to the remove the humid air from the fuel tank.
following method: 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.
 111
Maintenance Manual
Important Maintenance Procedures

5. After completing daily work, loosen the water 2. Remove the fuel filter from the support with a
drain plug of the fuel pre-filter and the fuel wrench.
filter to drain out water and impurity.

3. Remove the gasket on the thread connector

1. Fuel filter of the support. Clean the seal surface of the
2. Fuel prefilter
support with a non-fibrous cloth.

Any residual fuel at the bottom of the fuel

tank contains water and impurity that will
affect the normal operation of the engine.
Drain and clean fuel tank before replenishing,
if necessary.

Fuel Filter--Replace
1. Gasket
4. Fix a new gasket on the thread connector of
the support of the fuel filter. Apply a coat of
engine oil on the seal surface of the filter. Fill
Do not fill with fuel before the fuel filter is the fuel filter with clean fuel.
installed. Fuel contamination will quicken
damage of the fuel system parts.

1. First clean the fuel filter and the support.

112
Maintenance Manual
Important Maintenance Procedures

5. Install the filter to the support with hand. After Engine Oil Level--Check
the gasket of the filter contacts with the
support, continue to tighten 1/2 ~ 3/4 turns.
Do not over tighten the filter with the wrench
to avoid damaging the filter.
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 dipstick and oil
filler of the engine are located on the right
Fuel Pre-filter--Replace side of the engine.

1. First clean the around area of the pre-filter

and support.
2. Remove the pre-filter from the support, and
clean the sealing surface of the support with 1
a non-fiber cloth.
3. Remove the recovery bottle from the bottom
of the fuel filter.
2
4. Clean the recovery bottle, then fix to a new
fuel pre-filter element 1. Engine oil inlet
5. Add fuel in the fuel pre-filter, and apply a coat 2. Engine oil dipstick
of engine oil to the gasket, then install it on 4. Take out the dipstick. Wipe it with a clean
the support. cloth and completely reinsert the dipstick into
the end of the engine dipstick tube. Take out
the dipstick again and check the oil level. The
oil level on the dipstick should be between
the low (L) and high (H) graduation marks.
Oil level range
 113
Maintenance Manual
Important Maintenance Procedures

5. If the oil level is below L, add oil. If the oil 5. Stop the engine and wait for about 10
level is above the H, screw out the oil drain minutes, let the engine oil fully return to the
plug at the bottom of the engine oil pan to oil pan, check the engine oil level again, if
release some oil. insufficient, add engine oil to the H on the
dipstick.
Engine Oil--Replace Check engine oil level

Care must be taken to ensure that fluids are

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

1. Park the machine on flat ground, run the

engine until the water temperature reaches When you turn on the start switch but don't
140 degrees Fahrenheit (60°C). start the engine, the engine oil pressure
indicator flashes and the buzzer beeps. After
2. Stop the engine and engage the parking successfully starting the engine, the engine
brake. oil pressure returns to normal and alert
3. The oil drain plug is located on the left side of indicator and buzzer automatically stop. If the
the rear frame. Loosen the engine oil drain alarm goes on, stop the engine at once to
plug to drain the oil into a suitable container. avoid damage of the engine and check to see
if the engine oil level is correct.
Engine oil outlet

4. Tighten the oil drain plug and add clean

engine oil to the engine oil filler till the engine
oil is at H on the oil dipstick. Run the engine
at idle speed to check the engine oil filter and
oil drain plug for leakage.
114
Maintenance Manual
Important Maintenance Procedures

Engine Oil Filter--Replace 5. Secure the engine oil filter on the support and
tighten the gasket of the engine oil filter until
1. Clean the area around the support of the it contacts with the support. Tighten the
engine oil filter. engine oil filter according to the specified
requirement with the spanner.
2. Remove the engine oil filter with a belt
spanner.
3. Clean the surface of the gasket of the
support with a clean cloth. If the old O-ring
Excessive tightening of the engine oil filter
adheres to the mounting support, remove it.
could result in damage to the threads or the
Cleaning the support seal of engine oil filter element.

Engine Valve Lash--Check

Adjustment of the engine valve lash must be

performed by trained personnel with special
tools only.

More information about the adjusting procedure

of the engine valve lash, refer to the Operation
4. Install a new O-ring, replenish the oil filter
and Maintenance Manual of the Engine.
with clean engine oil, and apply a coat of
clean engine oil on the gasket surface.
Engine Air Intake System--Check
Install a new engine oil filter
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 flaking material
falls off, replace it with a new belt. More
information about the replacing procedure, refer
to the Operation and Maintenance Manual of the
Engine.
Fill the filter with clean engine oil before the
engine oil filter is installed. If an empty
engine oil filter is installed, the engine could
be damaged due to a lack of lubricant.
 115
Maintenance Manual
Important Maintenance Procedures

Engine Tensioner Bearing and Fan Hub- Power Train System

-Check

Check the tensioner to ensure it can turn freely. Transmission Oil Level--Check
Check the fan hub, it should rotate without any
wobble or excessive clearance.

Engine Shock Absorber--Check Stop the machine on flat ground when

checking the oil level. Turn the shift control
Refer to the Operation and Maintenance Manual lever to NEUTRAL position, engage the
of the engine for further information. parking brake and install a steering frame
lock to stop the machine form moving or
turning.

The transmission is located under the fuel tank,

and the transmission oil filler is located on the
right side of the hydraulic oi tank. The
transmission oil dipstick is located under the oil
filler.

1. Transmission oil filler

2. Transmission oil dipstick

Before checking the transmission oil level,

ensure no body around the machine when
the engine is running. When checking the oil
level, always separately check cold oil level
and hot oil level. A too high or too low oil
level of the transmission could result in
damage to the transmission, make sure the
oil level of the transmission is at the proper
level.
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Check transmission oil level 5. After inspection, insert the dipstick into the oil
filing pipe of the transmission. Rotating it
1. Park the machine to flat ground. clockwise to tighten it.
2. Turn the shift control lever to NEUTRAL
position. Engage the parking brake and
install the steering frame lock to avoid
movement of the machine. Pay close attention to cleanliness of the
transmission oil when checking or replacing
3. Check the transmission cold oil level when
it and filter. Do not let impurity enter the
the engine runs at idle speed and the
transmission system to avoid damage to the
transmission oil is below 40°C. Turn the
transmission.
dipstick counterclockwise and take it out.
wipe off the oil with a clean cloth. Insert the Operating method to raise the transmission oil
dipstick into the end of the oil filling pipe and temperature quickly when checking the
then take it out again. The oil level of the transmission hot oil level:
transmission should reach the COLD zone of
the dipstick. 1. Park the machine on flat ground.
2. Turn the shift control lever to NEUTRAL,
disengage the parking brake.
3. Depress the service brake pedal completely.

4. When the engine transmission oil

temperature reaches 80~90 Celsius, take the
dipstick out of the oil filling pipe and wipe off
the oil with a clean cloth. Insert the dipstick
into the end of the oil filling pipe and take it
out again. The oil level should be at the HOT
graduation of the dipstick. If the oil level is
below HOT graduation of the dipstick, add 4. Turn the shift control lever to forward 6, then
transmission oil. If the oil level is above the the torque converter is under stall condition,
HOT graduation of the dipstick, loosen the the transmission oil temperature will raise
drain plug at the bottom of the transmission fast.
to release the excessive oil. 5. After the transmission oil temperature
reaches over 80°C, turn the shift control lever
to NEUTRAL again, and engage the parking
brake. Then check the hot oil level of the
transmission.
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Transmission Oil--Replace

Replace the transmission oil after the first 100

service hours. After that, change the
transmission oil every 1000 service hours or at Because the transmission oil temperature is
least once a year. still high when draining, wear protective
clothing and be careful to prevent injury.
4. Loosen the oil drain plug of the transmission
to drain the oil and collect it with a container.
Care must be taken to ensure that fluids are Loosen the air release plug on the torque
contained during performance of inspection, converter oil radiator to quicken the oil
maintenance, testing, adjusting the product. release speed.
Be prepared to collect the fluid with suitable
containers before disassembling any
hydraulic lines or component containing 2
fluids. Dispose of all fluids according to local
regulations.
1
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 oil temperature of the transmission
reaches the work temperature of 80~90°C, 1. Air outlet / oil filler
2. Torque converter oil radiator
stop the engine.
3. Loosen the oil drain plug at the rear bottom of
the transmission to drain the oil, and collect it
with an appropriate container.
Drain out the oil of the transmission, torque
converter and radiator simultaneously.
5. Replace the secondary filter of the
transmission.

1. Oil drain plug

2. Primary filter of the transmission
3. Oil suction pipe
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6. Remove the oil suction hose on the rear right

side of the transmission. Take the primary
filter out. Clean it with compressed air or fuel
and dry it.

11. Start the engine and run at idle speed. Check

the transmission oil level again and add
transmission oil until the oil level is above
COLD. 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.

1. Oil drain plug

2. Primary filter of the transmission
3. Oil suction pipe
7. Clean any iron filings attached on the drain
plug by the magnet. Insert the magnet into 12. When the transmission oil reaches the work
the transmission oil pan from the primary temperature of 80~90°C, check the oil level
filter mounting port. Clean the iron filings on again. The level should be at the HOT
the inner wall of the primary filter. graduation of the dipstick. If the oil is
8. Secure the primary filter, oil suction pipe, insufficient, add oil. If the oil is excessive,
drain plug and oil drain plug under the torque drain some excessive oil.
converter oil radiator and seal.
9. Loosen the drain plug above the torque
converter oil radiator. Add clean transmission
oil from the oil filler of the torque converter oil
radiator. After the radiator is fully filled with
transmission oil, tighten the air release drain
and oil drain plug.
10. Take out the dipstick of the transmission. Add
clean transmission oil until the level is above 13. Insert the dipstick and tighten it clockwise.
HOT mark.

Before replacing transmission oil, cover the

parking brake with a cloth to prevent the
friction disc from oil and ensure the parking
brake performance.
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Transmission Secondary Filter-- 3. Check the oil level of the axle. Make sure that
Replace the oil level reaches the middle of the oil level
sight glass. Add oil if it does not reach the
The secondary filter of the transmission is proper level.
located at the upper right side of the
transmission. Replace the transmission oil and
secondary filter simultaneously. 1

1. Oil filler plug

2. Oil level sight glass
3. Oil drain plug
1. Clean the surface around the transmission
secondary filter. Axle Oil--Replace
2. Remove the secondary filter from the support
with a wrench.
3. Clean the seal surface of the support with a
clean cloth. Care must be taken to ensure that fluids are
4. Apply a coat of transmission oil to the gasket contained during performance of inspection,
of the new secondary filter. maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
5. Install the secondary filter on the support until with suitable containers before
the gasket contacts the seal surface of the disassembling any hydraulic line or
support and then manually tighten it to a 1/3 component containing fluids. Dispose of all
or 1/2 turn. fluids according to local regulations.

Axle Oil Level--Check Drain oil after the machine stops running for
a period time to let the impurities deposited
in the oil are suspended.
1. Park the machine on level ground.
Be careful of splashing hot oil when refilling, 2. Stop the engine, turn the shift control lever to
draining, or loosening the plug. NEUTRAL position, engage the parking
brake to prevent movement of the machine.
1. Park the machine on level ground, clean the
surface around the oil filler before checking
the axle oil level.
2. Turn the shift control lever to NEUTRAL,
engage the parking brake to prevent
movement of the machine.
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3. Loosen the oil drain plug in the middle of the

rear axle to drain the oil, and collect it with a
container.

Because the axle oil temperature is still high

when draining, wear protective clothing and
be careful to prevent injury.

4. Tighten the oil drain plug in the middle of the

rear axle.
5. Add clean gear oil to the rear axle until the oil 4. Tighten the oil drain plug after oil is drained.
level reaches the middle part of oil level sight 5. Add clean gear oil to the tandem until oil level
glass. reaches the middle part of the sight glass.
6. After ten minutes, if the oil level remains 6. After ten minutes, if oil level remains stable,
stable, tighten the oil filler plug of the rear tighten the oil filler plug.
axle.

Tandem Oil Level--Check

Park the machine on flat ground. Turn the shift

control lever to Neutral position, engage the
parking brake. Observe the oil level sight glass
between the left and right wheels of the tandem,
oil level should reach the middle part of the sight
glass, otherwise oil level is improper.

Worm Gearcase Oil Level--Check

1. Place the worm gearcase on level position.

2. Observe the oil level sight glass. The oil level
should reach the middle part of the sight
glass.
3. Fill oil from oil filler when necessary.

Tandem Oil--Replace

1. Park the machine on flat ground.

2. Turn the shift control lever to NEUTRAL
position, engage the parking brake.
3. Loosen the oil drain plug on the tandem to
drain oil, and collect with a suitable container.
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4. Normally, check oil level after continuous Circle Drive Clearance--Adjust

work for 50 hours.
1. To ensure a reliable operation requirement
during the work device assembly, install
adjustment shim with appropriate thickness
between the traction frame and circle drive,
3 adjust the assembly clearance to 0.2~0.5
mm, wear limit should not more than 1mm
during work, and replace the worn shim
promptly.
2. Check adjustment shim wear condition and
clearance between traction frame and circle
drive after 500 service hours of the machine.

1 2

1. Oil drain plug

2. Oil level sight glass
3. Oil filler plug
1
Worm Gearcase Oil--Replace

1. To quicken oil drain speed, swing the mold

board blade and lean towards the oil drain
plug, and support the mold board blade on
the ground. 1. Adjustment shim
2. Remove oil drain plug to drain oil, also
Circle Drive--Lubricate
remove oil filler plug to quicken oil drain
speed and empty all oil.
1. 3# lithium based grease is filled before the
3. Clean oil drain plug, replace with new seals, product is delivered from the factory. 2#
install the new seals to the oil drain plug then lithium based grease can be filled instead,
tighten it. during low temperature working. If the
4. Place the worm gearcase on level position by working condition fails to meet the
the mold board blade lift cylinders. requirement, replace with the proper grease.

5. Fill oil from oil filler again untill the oil reaches 2. If abnormal noise in the circle drive is found,
the middle part of the oil level sight glass. Oil or the circle drive force increases
filling capacity is about 2.5 liters. continuously when the machine is working,
stop working and check. Remove the circle
6. Clean oil filler plug, replace with new seals, drive to inspect, when necessary.
and install the new seal to oil filler plug then
tighten it.
7. Be sure to change oil at least once a year.
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3. Lubricate the circle drive, drive gear and Hydraulic System

each spherical bearing once every 100
working hours or every two weeks.
Hydraulic Oil Level--Check
Lubricating point of drive gear

When checking the hydraulic oil level, park

the machine on level ground and lay the mold
board blade flatly on the ground. The front
and rear frame must be aligned in a straight
line.

The hydraulic oil tank is located on the rear of the

rear frame, the sight glass on the left of the
hydraulic oil tank is used to indicate the oil
volume. Normally, the hydraulic oil level should
Lubricating point of spherical bearing
reach to 2/3 on the sight glass.

1. Sight glass
2. Hydraulic oil tank
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Hydraulic Oil--Replace 4. Clean the oil drain outlet of the hydraulic oil
tank. Screw out the oil drain plug to drain the
hydraulic oil and collect with a container.
Meanwhile, open the oil filler cap on the oil
tank to quicken the oil drain speed.
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 the hydraulic lines or
components containing fluids. Dispose of all
fluids according to local regulations. 1
Pay close attention to cleanness during the
replacing of hydraulic oil, do not allow dirt to
enter the hydraulic system.

If the working condition is severe or the hydraulic

oil becomes deteriorated due to pollution, such 2
as black color and bubbles in the oil, change the
hydraulic oil in time.
1. Park the machine on level ground, engage
the parking brake and install the steering
frame lock.
2. Start the engine and let it run at idle speed for
10 minutes. Lift and lower the work 1. Oil drain outlet
2. Oil filler cap
implement, lean the front wheels leftwards or
rightwards and change the mold board blade
pitch angle repeatedly.
3. Adjust all cylinders to the limit position except
the articulation and front wheel steering Because the hydraulic oil temperature is still
cylinders, then stop the engine. high when draining, wear protective clothing
and be careful to prevent injury.
5. Remove the oil inlet pipe of the hydraulic oil
cooler and drain the residual hydraulic oil
from the cooler.
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6. Remove the cap of the return oil filter from Brake System
the hydraulic oil tank. Take out the return oil
filter element and replace with a new one.
Open the oil filler cap and take out the oil Service Brake Performance--Inspect
strainer and clean.

To ensure safety and accuracy, the service

brake performance test only can be carried
out by professional personnel.
Before checking the service brake ability,
make sure the machine's parking brake
system works normally, in case of an
7. Remove the flange cover of the hydraulic oil
emergency.
tank below the oil filler cap, wash the bottom
and four walls of the hydraulic oil tank with
fuel and dry with a clean cloth. Drive the machine at 30km/hr on a straight, flat
and dry road. Depress the service brake pedal to
8. Install the oil drain plug, oil return filter and its fully brake the machine. After the machine stops,
cap, oil inlet strainer, flange cover of the turn the shift control lever to NEUTRAL, engage
hydraulic oil tank, and the oil inlet pipe of the the parking brake then release the service brake
hydraulic oil cooler. pedal. The brake distance should not exceed
9. Add clean hydraulic oil to the hydraulic oil 13m.
tank until the oil level reaches the upper
graduation of the sight glass. Then tighten
the oil filler cap.
The machine moves while checking may
10. Remove the steering frame lock and start the
cause personal injury. Keep others away from
engine. Operate the control lever to raise and
the machine while checking the brabking
lower the implement for 2~3 times. Tilt the
system.
mold board blade forward and backward and
turn the machine from left to right to the
maximum angle to fully fill the cylinders with
hydraulic oil. Then run the engine at idle
speed for five minutes to drain air in the
system.
11. Stop the engine and open the oil filler cap of
the hydraulic oil tank. Add clean hydraulic oil
until the oil level reachs 2/3 of the oil level
sight glass on the hydraulic oil tank.
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Parking Brake Performance--Inspect Accumulator Pre-charge Pressure--

Check

Two accumulators are provided for the brake

system, the service brake accumulators are
Check the parking brake performance located on the right side of the front frame.
frequently to ensure the machine can safely Accumulators I and II are used for the service
stop and ensure its emergency braking brake circuit.
capability.

1. Adjust the air pressure of the machine tires to

the specified value, raise the implements,
such as mold board blade.
2. Start the engine and drive the machine to a
slope with a gradient of 15% (the angle is
about 8.5°). The slope surface should be
smooth and dry.

3 2 1

1. Accumulator I
2. Accumulator II
3. Accumulator cover

3. Depress down the service brake pedal and

stop the machine. Turn the shift control lever Check accumulator nitrogen pre-charge
to NEUTRAL position and then stop the pressure according to the intervals specified
engine. in the Maintenance Interval Schedule section
to ensure the proper performance of the
4. Engage the parking brake and slowly release service brake system and parking brake
the service brake pedal. Check to see if the system.
machine has moved from its original location.
Checking the pre-charge pressure should be
done by trained personnel with special tools
only.
The machine moves while checking may 1. Park the machine on flat ground, lower the
cause personal injury. Keep others away from mold board blade flatly on the ground, turn
the machine while checking the braking the shift control lever to NEUTRAL position
system. and stop the engine. Then turn the start
switch clockwise to the first position to turn
on power.
2. Continuously depress down the service
brake for about 20 times, then engage and
disengage the parking brake for about 20
times to release high pressure oil in the
accumulators.
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3. Slowly loosen the exhaust valve on the 6. Slowly open the valve on the inflation tool,
accumulator. Drain out the residual pressure the reading available on the pressure gauge
oil in the accumulator. is the pre-pressure of Nitrogen. The reading
should comply with the following table. Add
nitrogen if the pressure is low; if the pressure
1 is higher than expected, adjust the exhaust
valve to get the desired pressure reading.

Nitrogen pre-charge pressure

Accumulator I 9.2Mpa

2 Accumulator II 9.2Mpa

1. Protection cap of the charge valve 7. If pressure is low, add nitrogen.

2. Exhaust valve
8. Turn off the valve on the inflation tool, then
remove the inflation tool from the
accumulator. Install the protection cap of the
charging valve.
Do not let the residual pressure oil in the
accumulator spray any one, as this can cause
injury or death. Accumulator Pressure--Release

4. Remove the protection cap of the charging If the pre-charge pressure is higher than
valve from the accumulator. expected, then release the excessive Nitrogen
5. Block one end of the inflation tool which is pressure through the exhaust valve. Release the
connected to the nitrogen bottle by a plug, pressure slowly. An accurate reading can be
then connect the other end which has a obtained in serveral minutes after releasing the
pressure gauge to the charging valve of the pressure.
accumulator.

1. To accumulator charge valve

2. Exhaust valve
3. Valve
4. To nitrogen bottle
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Accumulators--Charge 5. Install the protection cap of the charging

valve on the accumulator.

If the nitrogen pre-pressure of the Do not turn the steering wheel while
accumulators is insufficient, charge in time, removing the charging valve protection cap.
otherwise the normal use of the brake system Ensure the engine is stopped to avoid
could be affected. Charging of the personnel injury.
accumulator should be done by trained
personnel with special tools only. Charge the accumulator with nitrogen only.
Do not charge the accumulator with oxygen,
compressed air or other flammable gas to
Operation steps are as follows: avoid explosion.
1. Connect one end of the inflation tool which
has a pressure gauge to the charging valve
on the accumulator, the other end to the
nitrogen bottle.
2. Open the nitrogen bottle valve. Slowly open
the valve (leftwards) to charge the
accumulator until the pointer of the pressure
gauge is stable.
3. The inflated pressure may be obtained in a
short time. Turn off the nitrogen bottle valve
to check whether the pressure on the gauge
has met the standard. Recharge if the
pressure is not sufficient and adjust exhaust
valve on the inflation tool to lower the
pressure to the appropriate value if the
pressure is too high.
4. Apply a coat of oil to the top of the charging
valve to check if any leakage occurs. There
should be a leak if an air bubble is found.
Slightly tap the charging valve stem with a
hammer and mini-screw driver, let it be
downwards and then it should return to
contact completely with the sealing surface.
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Important Maintenance Procedures

Brake Assembly--Maintain
Brake exploded view

Wear relevant personal protective equipment

during assembly, such as safety gloves,
safety shoes and safety glasses, etc.
Do not use chisel and hammer to remove the
fasteners which can be removed by air gun or
spanner.
The container should not damage the parts
that being placed, wooden boxes and
cardboard boxes, etc. can be used to place
the removed parts.

No. Title Code Do not use chisel and hammer to remove the
1 Pin 84513117 parts, otherwise the parts will be damaged,
moreover, it may result in personal injury.
2 Brake shoe 84513104
3 Bolt M10X16 50190001
Disassembly of the brake
4 Spring 84513108
5 Brake anchorage 84513101 1. Brake shoe disassembly
6 Shaft 84513109
7 Washer16 52000005
1. Remove the hex bolt (3) from the brake
anchorage (5) with a spanner, place it into a
8 Washer16 52020006
clean container.
9 Nut M16X1.5 51010005
10 Bolt M12X35 50009019
11 Washer12 52020004
12 Brake pump 84513110

The function of the brake

The function of the brake is to use the hydraulic

pressure provided by brake system to push the
brake shoe friction plates to the friction surface of
the brake drum, the friction generated to
decelerate and stop the rotation of the brake
drum, so as to realize the speed control of the
machine, and ensure the safety of the machine.
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Important Maintenance Procedures

2. Apply axial moving force to the pin (1) with a 2. Remove the brake pump (12), place it into a
puller or a copper bar, remove the pin, and clean container.
place it into a clean container.

3. Shaft disassembly
3. Remove the spring (4), and then remove the
brake shoe assembly, place the parts into a
Remove the hex nut (9) and washers (7), (8) that
clean container.
fixed the shaft (6) with a spanner, place them into
a clean container.

Assembly of the brake

1. Preparation before assembly

Comply with the manufacturer's instructions

carefully when cleaning parts with strong
solvents or water and alkaline solvent.
2. Brake pump disassembly
Clean the non-metallic parts with soap and
1. Remove the hex bolt (10) and washer (11) water. Do not allow mineral oil on the surface
that fixed the brake pump (12) with a of the friction plate.
spanner, place them into a clean container.

Wear relevant personal protective equipment

when cleaning, such as safety gloves, safety
shoes and safety glasses, etc.
Work in a well-ventilated place.
Do not use gasoline or solvents containing
gasoline to avoid explosion.

1. Cleaning and drying of parts

Clean the parts before assembly with
tetrachloride, emulsified oil or petroleum-based
cleanser.
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Maintenance Manual
Important Maintenance Procedures

Dry the parts with clean paper, cloth or 2. Brake assembly process
compressed air after cleaning.
Lubricate the fitted position of the parts with
grease before assembly to prevent corrosion,
coat the stored parts with anti-corrosion material
Wear relevant personal protective equipment
before storage.
during assembly, such as safety gloves,
2. Inspection and repair of parts safety shoes and safety glasses, etc.
Check all parts before assembly and reuse after Tighten the fasteners strictly in accordance
inspection, specific inspection is as follows: with the requirements of tightening torque in
(1) Check the friction plate for serious defects, the operator manual.
serious wear, cracks or burning, scrap it if Grease the relative motion position of the
any of the above conditions occured, do not parts during usage.
reuse it.
Install the fasteners in place with a copper
(2) Check the brake pump assembly for oil hammer during assembly.
leakage, do not reuse it if there is leakage,
Coat the fasteners with thread locking glue
replace the oil seal or eliminate the fault.
and coat the sealed end face with sealant
(3) Check the stress position of the brake shoe during assembly.
parts for cracks, scratches, dents or wear,
scrap it if any of the above conditions
occured, do not reuse it.
(4) Check the threads of the connecting The tightening torque of all fasteners must
fasteners for tooth shape damage, cracks or meet the torque requirement, otherwise it will
collision condition, scrap it if any of the above result in machine brake failure and serious
conditions occured, do not reuse it. quality accident.
(5) Do not reuse the removed oil seal, O-ring.
1. Brake pump assembly
(6) Check the brake anchorage for serious
defect or cracks, scrap it if any of the above (1) Coat the joint face of brake pump (12) and
conditions occured, do not reuse it. brake anchorage (5) with sealant, put the
round boss of brake pump (12) into the pump
(7) If the non-critical surface of the parts has burr mounting hole on the brake anchorage (5),
and collision condition, the parts can be align the threaded hole with the bolt
reused after being repaired. mounting hole on the brake anchorage.
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Important Maintenance Procedures

(2) Put bolt (10) through washer (11) and coat (2) Install pin (1) into the aligned pin hole, and
the surface of the bolt with thread locking assemble it in place with a copper bar.
glue, and then screw the bolt (10) into bolt
hole on the brake pump (12) and tighten it in
place.

(3) Coat the surface of bolt (3) with thread

locking glue, install it and tighten in place.

3. Shaft assembly
Grease the fitted outside circle of the shaft (6),
install the small end of the shaft outward into the
mounting hole from the inside of brake
anchorage (5), and align the off-centered side of
the shaft with the center of the brake anchorage.
Install washers (7), (8) on the small end of shaft
(6), install the nut (9) onto the shaft and tighten it
in place.
4. Brake shoe assembly
4. Spring assembly
(1) Install the gap of brake shoe (2) on the lug of
brake anchorage (5), and make the pin hole Install one end hook of spring (4) into the spring
centers of the two parts aligned with each hole on brake shoe (2), tense the spring, and
other, add a few grease in the pin hole cavity. install the other end hook of the spring into the
corresponding spring hole on the brake shoe.
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Maintenance Manual
Important Maintenance Procedures

Daily check of brake assembly 3. Measure the thickness of the friction plate,
replace it if its thickness is less than 7mm.
Friction plate thickness

Check the brake according to the following

steps every 250 service hours or one month,
replace the friction plate timely if it meets the
replacement standard.

1. The inside round hole of the brake is the

viewing window, it is protected by a rubber
cover, as shown in the picture below.
Rubber cover

2. Remove the rubber cover, access to the

viewing window.
Viewing window
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Important Maintenance Procedures

Centralized Lubrication System Electrical System

Lubrication Chart and Intervals

This machine is not equipped with a centralized

lubrication device. To ensure the normal work of Never let burning cigarette or open fire close
each part of the machine, add lubricant to the batteries. Wear safety glasses and
according to the lubrication chart and intervals. rubber gloves when touching batteries
The lubrication chart of this machine is located during work. Also wear protective clothes as
on the left side of the engine hood, near the cab. the vitriol in the battery can result in blind or
burn. See the doctor at once if you touch the
vitriol carelessly. Stop the engine before
working with batteries.

The batteries are located in the battery boxes on

the rear of the machine.

When working with the battery, always observe

the requirement of the safety decal near the
battery, and observe the requirement of safety
warning signs on the battery top cover.

Type of
3# Lithium based grease
lubricating oil
38. 39. 40. 41. 42. 43
The lubricating interval for the above
Recommended lubrication point is per 20 hours or
lubrication two days.
intervals The lubricating interval for other
lubrication points is 50 hours or every
week.
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Important Maintenance Procedures

4. Close the battery box cover.

The battery clamp plate, battery terminals

and cable leads will become loose due to the
machine vibration after operating the
machine for a period of time. Check the
1 2 3 tightness of the nut located in the middle of
the clamp plate. Tighten it if it is loose.
1. Danger warning sign
2. Safety warning sign
3. Battery hydrometer status Battery--Install

Battery--Check Before installing the battery to the machine,

make sure that the battery hydrometer is green.

Stop the engine before working with

batteries. The battery should not be inclined over 40°.
Do not place the battery reversely or by any
side of it.
1. Open the battery box cover to get access to
the battery. Make sure the hydrometer is green before
installing the battery. It is not allowed to
2. Check whether the clamp nut, battery
install the battery with a black hydrometer
terminal and cable lead are loose. Tighten
onto the machine.
them if they are loose.
Do not install a leaked battery onto the
machine.
1 1
1. Turn the start switch (also called ignition
2 switch) to OFF position then remove the key.
2 3 Turn disconnect switch to OFF position.
4 5 2. Clean the battery terminals and surface with
a clean cloth. Do not use petrol or other
organic impregnant or cleanser.
3. When connecting:
(a) Connect the positive post of one battery
1. Battery terminals to the negative terminal of the other
2. Terminal jacket battery with the cable.
3. Battery hydrometer
4. Clamp plate (b) Connect one end of the battery positive
5. Nut lead terminal to the battery positive post,
3. Check the battery hydrometer color. Green the other end to start motor.
indicates a full battery and the machine can
(c) Connect one end of the battery negative
be started normally. Black indicates a low
lead terminal to the battery negative post,
battery which need charging at once. White
the other end to the battery disconnect
indicates a discarded battery which needs to
switch.
replace.
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Important Maintenance Procedures

(d) Connect the battery disconnect switch to Battery--Charge

ground cable.
A maintenance-free battery is used in this
To start motor machine. Obey the following instructions when
dealing with the battery.
5 3
A long-time use of the electric appliances without
starting the engine or a long-time stop, electricity
4 leakage, or the alternator can not charge; all
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 battery battery if this happens.
1
disconnect
switch
2
Charge the battery to let it work normally if
1. Battery the above-mentioned phenomenon
2. Battery
3. Cable happens.
4. Battery negative lead
5. Battery positive lead Check the outlook of the battery before charging:
4. Tighten the nut. 1. Do not charge the battery if the battery
housing cracks or there is an acid leakage.
5. Turn on the battery disconnect switch. Insert
Check the reason and replace with a new
the key and start the engine.
one.
2. Do not charge the battery if the battery
terminal cracks. Check the reason and
A wrong installation of the negative and replace with a new one.
positive terminal will result in a serious
3. Do not charge the battery if the hydrometer is
damage to the battery. Distinguish the
clear. Replace with a new one.
positive (+) and negative terminal (-)
correctly. 4. Do not charge the battery if it is distensible by
over-charging or over-discharging. Replace
with a new one.
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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 disconnect switch to OFF position 11.50-11.30VDC 10h
and turn the start switch to OFF position and 11.30-11.00VDC 12h
take out the key. Below 11.00VDC 14h
2. Clean the battery terminals and surface with
a clean cloth, remove the oxidation surface. ● 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 is clear, bubble might exist
in the hydrometer. Shake the battery slightly
to remove the bubble. If the hydrometer is
When connecting the battery, first connect still clear, then electrolyte loses seriously,
its positive terminal; when disconnecting discard the battery and replace with a new
the battery, first disconnect its negative 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.
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Important Maintenance Procedures

8. As for the battery with a voltage under Battery--Store/ Service

11.0VDC, it may not be able to be charged at
the beginning. Due to the serious 1. Disconnect the negative terminal of the
insufficiency of electricity, the proportion of battery if the machine is stored over 15 days.
vitriol is close to water, therefore, the battery
2. Check the electricity state of the battery
resistance is higher. The vitriol proportion
every 3 months(with cable disconnected).
increases during recharge and the circuit can
get right gradually. ● Green hydrometer means the battery is in
normal condition. Black hydrometer means
the battery needs charging.
● Check the battery voltage every 3 months
Fix the two terminals tightly. Do not charge during machine storage. Recharge if the
the battery of 24VDC voltage in serial battery lacks for electricity. Recharge
connection. according to special procedures.
Stop charging immediately to check the 3. Recharge if the battery lacks for electricity.
reason if the battery discharge hole spurts Recharge according to special procedures
acid during the charging process.
4. As for the machine which has not
9. Stop charging if the battery temperature disconnected the battery terminals, check the
exceeds 45°C during the charging process. battery voltage state every month. If the
Halve the circuit before recharging after the voltage is under12.4V, recharge it according
battery temperature drops to the ambient to special procedures.
temperature.
5. As for the machine which is stored over 1
10. Check the battery voltage every hour during year, replace with a new battery and dispose
the charging process. The battery is fully the old one if the above- mentioned
charged if the hydrometer is green. requirements can not be followed.

Battery--Recycle

If the hydrometer is black, check for loose When discarding a battery, its inner material
cable and clean connecting terminal. Check such as lead, acid and plastic shell can pollute
whether the voltage has come to 16VDC. If the environment due to its outer frayed structure
the hydrometer is clear, it is likely that air or other reasons. Therefore, do not throw away
bubble exist in it. If the hydrometer is still the old battery randomly, deal with it by collecting
clear after slight shaking (indicates that the for a battery disposal station or put it into a
electrolyte loss), replace with a new battery. recycle can set by the manufacturer (if there is
any) in a local place.
11. It is recommended applying vaseline on the
battery terminals to avoid electric corrosion Battery, Cable, Battery Disconnect
after charge is completed. Switch--Replace

1. Turm the engine start switch key to OFF

position. Turn all of the switches to OFF
position. Take out the switch key.
2. Turn the battery disconnect switch to OFF
position.
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Important Maintenance Procedures

3. Disconnect the negative battery cable from

the battery disconnect switch.
4. Sequences for disconnecting the battery
cables:
If it is necessary to replace fuses frequently,
● Disconnect the negative battery cable from an electrical problem may occur. Contact
the battery. your Liugong dealer.
● Disconnect the positive battery cable from The fuse box is located in the cab, open the
the battery. cover to maintain the fuses.
5. Inspect the battery terminals for corrosion. Check and replace the fuse as follows:
Inspect the battery cables for wear or
damage. 1. Turn the start switch to OFF position.

6. Make any necessary repairs. If necessary, 2. Open the fuse box cover. Take off the broken
replace the battery cables or the battery. fuse with a clamp.

7. Sequences for connecting the battery cables: 3. Replace the broken fuse with a new one with
same specification.
● Connect the positive battery cable to the
battery. 4. Install the fuse box cover.

● Connect the negative battery cable to the The slice type fuse and flat type fuse that used in
battery. this machine should meet the regulation in
standard of QC/T420 Fuse-Links for Motor
8. Connect the battery cable with the battery Vehicles.
disconnect switch.
See the following table for the fuse color:
9. Install the switch key and turn the battery
disconnect switch to ON position. Model Color
BX2011C-5A Orange
Fuse--Check/ Replace
BX2011C-7.5A Brown
The fuses protect the electrical system from BX2011C-10A Red
being damaged due to circuit overload. If the BX2011C-15A Blue
fuse is broken, replace with a new one. Check
the circuit if the new fuse is broken again. Repair BX2011C-20A Yellow
the circuit, if necessary. BX2011C-30A Green

Replacing fuses with the same type and size

from different brands is allowed. Do not use
copper wire, otherwise the circuit could be
damaged.
It is recommeded to use fuse supplied by
Liugong if it needs to replace the fuse when
repairing. Do not buy the fuse randomly in
the market as fuse of poor quality will bring
bad effect to the machine, even could cause
a fire.
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Maintenance Manual
Important Maintenance Procedures

Air Conditioning System Compressor Belt Tension--Check

The compressor belt tension: apply (W=15N)

Air Conditioner Refrigerant Level-- force in the center span of the pulleys
Check (compressor pulley and engine pulley). The
deflation of the belt center distance should be
5±1mm. See the following picture:

Personnel injury or death could result due to

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

After turn on the air conditioner, check the

refrigerant in the refrigerant receiver for bubbles
through the sight glass to judge if the refrigerant
is sufficient or not. Many bubbles indicate Replace with a new belt if the belt is not tense.
refrigerant is insufficient while few bubbles or no That is, the deflation of the belt center distance is
bubble indicate the refrigerant is sufficient. more than 5±1mm when applying (W=15N) force
in the center span of the pulleys (compressor
pulley and engine pulley).
Replace the belt if the belt fluffs or cracks.

1. Refrigenrant receiver

2. Sight glass
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Maintenance Manual
Important Maintenance Procedures

Cab Air Strainers--Clean and Replace 3. Put the clean fresh air strainer into the
groove of the strainer cover, then install it
The cab air strainer consists of the fresh air with the guard net to the original position.
strainer. The block condition of the strainer is Tighten the screws.
entirely depending on the working environment Fresh air strainer location
of the machine.

The cab strainer is only intended to separate

particles (dust and sundries) from the air. Do
not use it for poisonous gas.
The fresh air will reduce if the fresh air
strainer is blocked.
It may be dangerous when using compressed
air or high-pressured water to clean dust or
dirty materials. Wear protective glasses, Fresh air strainer
shield or other protective devices.

The proper interval for the strainer cleaning is

200 hours. The cleaning interval of the strainer
can be prolonged or shortened properly
according to the dust condition of the working
environment.
Replace the fresh air strainer every 1000 hours.
Choose the air strainer which meets the standard
of ISO-10263-2 when replacing.

Clean /replace the fresh air strainer

1. Remove the mounting bolts on the strainer

cover, then remove the strainer cover, fresh
air strainer and guard net.
2. Clean the strainer cover, fresh air strainer
and guard net with compressed air or soft
brush. If the fresh air strainer is too dirty or
too oily, wash it with neutral detergent. Dry
the strainer completely before reuse.

If the fresh air strainer is still blocked or

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

Other Maintenance

mold Board Blade Cutting Edge and

End Bit--Check and Replace
1

Falling mold board blade will cause personal

injury or death, block the mold board blade
before replacing its cutting edge or end bit.

1. Screw
2. Strainer cover
3. Fresh air strainer 1. End bit
4. Guard net 2. Mold board blade cutting edge
Mold board blade cutting edge and end bit could
be damaged or excessively worn. Always
replace mold board blade cutting edge and end
bit when necessary.
1. Place a wedge under the mold board, lower
the mold board blade on the wedge, do not
block it too high in order to remove its cutting
edge and end bit more easier.
2. Remove the bolts, mold board blade cutting
edge and end bit.
3. Clean all contact surface.
4. Install new mold board blade cutting edge
and end bit.
5. Tighten the bolts to the specified torque.
6. Lift the mold board blade and remove the
wedge.
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Maintenance Manual
Important Maintenance Procedures

Mold Board Blade Bushing--Check and 3. Remove the mold board blade by slidding,
Replace then remove the bushing.
4. Clean all contact surface.
If mold board blade shakes easily during
operation, then you need to replace the baffle 5. Install a new bushing, install the mold board
and bushing. When replacing the baffle and blade.
bushing, always replace them in pairs. Removing 6. Install and tighten the bolts to the specified
roughness on the guide rail in time can reduce torque.
wear degree of the bushing. You can use a file to
smooth the guide rail. 7. Lift the mold board blade, remove the wedge.

Replacing the Bushing Mold Board Blade Swing Cylinder

Piston Rod--Tighten
1. Park the machine on flat and open ground,
and engage the parking brake to prevent the After the piston rod locks the slotted nut, the two
machine from movement during the repairing conical washers can be turned by hand. When
process. Place a wedge under the mold repairing or replacing this cylinder, the piston rod
board, lower the mold board blade on the can be installed by the same method.
wedge.
2. Remove the bolts that secure the baffle,
remove the baffle.

1 3 2
2 3
1 4

1. Cylinder piston rod

2. Conical washers
3. Slotted nut
4. Conical washers

1 2 3

1. Bushing
2. Bolt
3. Baffle
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Maintenance Manual
Important Maintenance Procedures

Rear Ripper Tip--Check and Replace Backup Alarm--Test

Check the rear ripper tip, replace the tip in time if Turn the engine start switch to ON position to
it is damaged or seriously worn. turn on the power of the machine.
Turn the shift control lever to REVERSE position,
the backup alarm should sound immediately.

Falling rear ripper will cause personal injury The backup alarm will sound continuously until
or death. Block the ripper before replacing the shift control lever is turned to NEUTRAL or
the tip. FORWARD position.

When knocking out the pin that connects the Seat Belt--Inspect
tooth and tip, the connecting pin could fly
away and injure a person nearby. Keep The driver should check the seat belt for its
personnel away from the rear ripper when condition and security before use. Replace it, if
operating the pin. To prevent eyes from necessary.
injury, wear protective glass when knocking
out the pin. Adjust the length of the seat belt to ensure its
restraint and comfort ability before use. Adjust it
1. When removing the tip, block the rear ripper through moving its buckle position on the belt.
to a proper height.
Replace the seat belt every 3 years even though
2. Remove the pin from the retainer lateral, then it is in a good condition. A valid date is provided
remove the tip and the retainer. 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.

Window Washer Reservoir--Fill

The washer reservoir is located under the cab on

the right side of the rear frame. Add washer
through the water filler of the washer reservoir.
3. Clean the tooth, pin and retainer. Install the
retainer on the lateral slot of the tooth.
4. Install a new tip on the tooth.
5. Drive the pin into the retainer, tooth, and tip
from the retainer lateral.
6. Replace the other tips according to the above
steps.
7. Raise the rear ripper, remove the block, lower
rear ripper to the ground after replacement.
144
Maintenance Manual
Important Maintenance Procedures

(4) Turn off the battery disconnect switch to turn

off the power of the machine.
(5) To avoid damage to LCD display instruments
Check the washer reservoir frequently to inside the cab and ZF transmission EST
ensure enough water in it, otherwise dirty control unit, always remove all connectors of
windshield may impact the visibility of the the instruments connected to the machine
operator. The washer reservoir should be harness and ZF transmission control unit
emptied or filled with antifreeze when the before welding.
ambient temperature is below 0 °C , or the (6) If your machine is equipped with other
washer will not work or even be damaged by electronic components such as a
being frozen. loudspeaker, remove all connectors of the
electronic components connected to the
Window Wiper--Check and Replace machine harness before welding to avoid
possible loss.
(7) Clear away paint of those parts to be welded
to prevent harmful air from being produced.
(8) Clamp the earth cables of the welder with the
parts to be welded, keep the earth position
close to the welded piece. Check and confirm
the circuit from the earth cables to the welded
parts don't get across any of the following
parts:
● Bearings
1. Front wiper blade
2. Rear window ● Hydraulic cylinders
Check the front windshield wiper blade for good ● Controls
condition. If the rear window of the machine is
equipped with a wiper, check the wiper blade of ● Internal circuit of other electronic parts
the rear window. If any marks are left on the front Any damage to the following parts could be
windshield by the wiper blade, replace the front avoided by doing so:
wiper blade. Also, if any mark is left on the rear
windshield by the rear wiper blade, replace the ● Bearing
rear wiper blade. ● Hydraulic parts
● Electronic parts
Welding Operation
● Other possible parts on the machine
To avoid possible damage to the electrical parts
(9) Keep any inflammable and explosive matters
and bearings, always observe the proper welding
away from the welding site, protect any
operation procedures. When welding on the
cable, do not allow sparks and solders
machine or engine which is equipped with
produced in welding splashing onto the
electrical parts, follow the operation steps below:
cables to cause a fire, thus resulting in loss
(1) Park the machine on flat ground. and harm.
(2) Turn off the start switch to shut down the
engine.
(3) Engage the parking brake.
 145
Maintenance Manual
Important Maintenance Procedures

(10)Use proper safety procedures for welding.

Never use the earth position of the electrical

parts on the machine as that of the welder.
When performing welding near the earth
position of an electrical part, always
disconnect the earth position of this
electrical part, and ensure to perform a
welding operation that doesn't get across
this electrical part. Otherwise this electrical
part could be damaged or even fire could be
caused.
Do not keep using voltage above 200V. Keep
the welding area and earth cables within 1m.
Avoid the seals and bearings located
between the welding area and earth cables.
Never weld any pipe with fuel, engine oil and/
or hydraulic oil. Never weld any sealed vessel
or vessel which is poorly ventilated.
146
Maintenance Manual
Important Maintenance Procedures
 147
INDEX

INDEX

A C

Accelerator Pedal ............................................60 Cab Air Strainers--Clean and Replace ......... 140
Accumulator Pre-charge Pressure --Check ..125 Cautions about Machine Maintenance ........... 28
Accumulator Pressure--Release ...................126 Cautions about Machine Operation ................ 23
Accumulator--Charge ....................................127 Central Instrument Panel ................................ 44
Air Conditioner Panel ......................................50 Centralized Lubrication System .................... 133
Air Conditioner Refrigerant Level--Check .....139 Check Before Starting the Engine .................. 74
Air Conditioning System ................................139 Circle Drive Clearance--Adjust ..................... 121
Air Filter Safety Element-Replace .................109 Circle Drive--Lubricate .................................. 121
Air Pre-Filter--Clean ......................................107 Compressor Belt Tension-Check .................. 139
Application and Specification ..........................32 Control Devices .............................................. 59
Application of Articulation ................................82 Coolant Level--Check ................................... 102
Application of the Leaning Front Wheels in Coolant--Add ................................................ 103
Turning ............................................................81 Coolant--Replace .......................................... 105
Application of the Leaning Front Wheels in Crushing and Cutting Prevention .................... 18
Working ...........................................................81
Applications .....................................................32
Attachment Cautions .......................................22
D
Axle Oil Level--Check ...................................119
Axle Oil--Replace ..........................................119 Daily Inspection ............................................ 101
Digging Ditches .............................................. 84
Door ................................................................ 72
B Downhill Operation ......................................... 77
Driving the Machine ........................................ 90
Backup Alarm System .....................................73 During Storage ............................................... 88
Backup Alarm--Test ......................................143
Battery Disconnect Switch ..............................41
Battery, Cable, Battery Disconnect Switch--
E
Replace .........................................................137
Battery--Charge ............................................135 Electrical Storm Injury Prevention .................. 21
Battery--Check ..............................................134 Electrical System .......................................... 133
Battery--Install ...............................................134 Engine Air Intake System--Check ................. 114
Battery--Recycle ...........................................137 Engine Belt--Check ....................................... 114
Battery--Store/ Service ..................................137 Engine Oil Filter--Replace ............................ 114
Before Operation .............................................40 Engine Oil Level--Check ............................... 112
Before Re-usage .............................................89 Engine Oil--Replace ..................................... 113
Before Storage ................................................88 Engine Shock Absorber--Check ................... 115
Brake Assembly--Maintain ............................128 Engine Start Switch ........................................ 42
Brake Operation of the Machine .....................77 Engine Starting ............................................... 74
Brake System ................................................124 Engine System ............................................. 102
Burn Prevention ..............................................18 Engine Tensioner Bearing and Fan Hub--Check
....................................................................... 115
Engine Valve Lash-Check ............................ 114
148
INDEX

F Lubrication Specifications ............................... 98

Fire &Explosion Prevention .............................19 M

Fire Extinguishers and First-aid Kit .................20
Front Switch Panel ..........................................46 Machine Operation ......................................... 78
Fuel Level--Check .........................................109 Main Components ............................................ 3
Fuel System Filter--Replace .........................111 Main Specifications ......................................... 33
Fuel System Pre-filter--Replace ....................112 Maintenance Intervals Schedule .................... 94
Fuel Tank--Clean ..........................................110 Maintenance Manual ...................................... 93
Fuel--Replenish .............................................109 Manual Throttle ............................................... 61
Fuse--Check/ Replace ..................................138 Mold Board Baffle and Bushing --Check and
Replace ........................................................ 142
G Mold Board Cutting Edge and End Bit--Check and
Replace ........................................................ 141
Mold Board Swing Cylinder Piston Rod---Tighten
General Hazard Information ............................14 ....................................................................... 142
General Torque Specifications ........................97

O
H
Oil Change Interval and Refill Capacities ....... 98
Hydraulic Oil Level--Check ...........................122 Operation Information ..................................... 75
Hydraulic Oil--Replace ..................................123 Operation Manual ........................................... 40
Hydraulic System ..........................................122 Operation Technology .................................... 75
Operation under Abnormal Conditions ........... 85
I Operator Controls and Instrument Panels ...... 41
Operator Station ............................................. 22
Other Devices ................................................. 65
Important Maintenance Procedures ..............101 Other Maintenance ....................................... 141
Important Safety Information .............................1
Instrument Panels ...........................................43
P
K
Parking Brake Handle ..................................... 61
Parking Brake Performance--Inspect ........... 125
Key Spare Parts to be Periodically Changed ..31 Parking the Machine ....................................... 87
Parking ........................................................... 87
L Power Train System ..................................... 115
Preface ............................................................. 1
Pressure--Release ........................................ 100
Latch ...............................................................72
Leaving the Machine .......................................88
Lift the Machine ...............................................90 R
Lights ..............................................................71
Lock Pin Pedal ................................................61 Rear Ripper Tip--Check and Replace .......... 143
Lowering the Work Implement with Engine Rear View Mirrors ........................................... 73
Stopped ...........................................................87 Right Instrument Panel ................................... 47
Lubrication Chart and Intervals .....................133 Right Switch Panel ......................................... 48
 149
INDEX

ROPS/FOPS ...................................................22 Welding Operation ........................................ 144

Run-in .............................................................93 Window Washer Reservoir--Fill .................... 143
Window Wiper--Check and Replace ............. 144
Work Control Levers ....................................... 62
S Worm Gearcase Oil Level--Check ................ 120
Worm Gearcase Oil--Replace ...................... 121
Safety Decals and Decal Locations ..................5
Safety Information .............................................5
Safety Signs ......................................................5
Safety Symbol ...................................................5
Scraping Operation .........................................82
Seat .................................................................65
Seat Belt .........................................................67
Seat Belt--Inspect .........................................143
Service Brake Pedal .......................................60
Service Brake Performance--Inspect ............124
Shift Control Lever ..........................................62
Snow Plough Operation ..................................85
Sound System .................................................68
Special Application ..........................................81
Steering Column Adjusting Handle .................60
Steering Frame Lock .......................................22
Steering Operation of the Machine .................77
Steering Wheel ...............................................60
Storage ...........................................................88

Tandem Oil Level--Check .............................120

Tandem Oil--Replace ....................................120
Tire Explosion Prevention ...............................21
Tire Inflation Informatio ...................................98
Towing Information .........................................91
Transmission Oil Level-Check ......................115
Transmission Oil --Replace ...........................117
Transmission Secondary Filter--Replace ......119
Transportation Information ..............................89
Transportation of the Machine ........................89
Traveling Operation of the Machine ................76
Turning off the Engine .....................................87
Type and Serial Number of the Machine and
Parts ..................................................................4

Warning Indicator Group .................................45

Water and Impurity--Remove ........................110
150
INDEX