LiuGong CLG835H User manual

201801001
CLG835H WHEEL LOADER
PERKINS POWER T4f / LIUGONG WET AXLE / ZF158A GEARBOX /
ZF160 GEARBOX
(
英语 )
OPERATION AND
MAINTENANCE MANUAL

Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown following.
The meaning of this safety alert symbol is as follows:
Attention. Be alert. Your safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
LiuGong cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by LiuGong is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged or
made unsafe by the operation, lubrication, maintenance or require procedures you choose.
The information, specification, and illustrations in this publication are on the basis of information
available at the time when it was written. The specification, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service
given to the product. Obtain the complete and most current information before starting any job. LiuGong
has the most current information available.
CALIFORNIA PROPOSITION 65
Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.

1
January 12, 2018 CONTENTS
CLG835H
CONTENTS
Preface
Safety Information
Safety Decals and Decal Locations ...................7
General Hazard Information.............................21
Crushing and Cutting Prevention .....................25
Burn Prevention ...............................................25
Fire & Explosion Prevention.............................26
Fire Extinguishers and First-aid Kit ..................27
Electrical Storm Injury Prevention....................28
Tire Explosion Prevention ................................28
ROPS/FOPS ....................................................29
Operator Station...............................................29
Steering Frame Lock........................................29
Attachment Cautions........................................29
Cautions about machine operation ..................29
Cautions about Machine Maintenance.............36
Sound and Vibration ........................................38
Key Spare Parts to be Periodically Changed ...39
Application and Specification
Applications......................................................40
Main Specifications ..........................................41
Operation Manual
Before Operation ............................................. 47
Operator Controls and Instrument Panels ....... 48
Engine Starting .............................................. 108
Operation Techniques ................................... 110
Transportation Information ............................ 119
Maintenance Manual
Maintenance Guidance.................................. 123
Run-in ............................................................ 125
Maintenance Interval Schedule ..................... 126
General Torque Specifications ...................... 130
Tire Inflation Information................................ 131
Lubrication Specifications .............................. 132
Important Maintenance Procedures .............. 134
INDEX

2
CONTENTS January 12, 2018
CLG835H

1
January 12, 2018 Preface
CLG835H
Preface
This manual includes important instructions
concerning operation, lubrication, checking
testing, adjusting the machine and permanent
key components.
This manual should always be kept safe, clean
and with the machine where it is convenient to
find for operators to use. This manual should not
be separated from the machine even when
reselling or leasing.
Some photographs and illustrations in this
manual show details of attachments that may be
different from your machine. Guards and covers
may have been removed for the purpose of
illustration.
Read this manual carefully and follow all
instructions for proper operation and
maintenance of this machine. Instructions in this
manual should help the reader avoid possible
personal injury or damage to the machine. The
operator should proficiently and correctly operate
the machine to ensure safety.
Use this machine only for the purpose described
in this manual. Contact your Liugong dealer for
approval before making any modifications or
adding attachments to the machine. The addition
of any unauthorized attachment may cause
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi
Liugong accepts no liability for any damage
resulting from the use of unapproved
attachments or working practices.
Guangxi Liugong ensured that the engine
system and aftertreatment device of the machine
leaving the factory are in full compliance with the
authentication configuration. Do not allow any
unit or individual to modify the engine
aftertreatment device or change parts suppliers
freely, otherwise, LiuGong will bear no
responsibility.
Only trained or experienced personnel should be
allowed to operate or maintain this machine.
Correctly record the machine type, serial
number, engine serial number and all major
component serial numbers for your reference
when ordering parts or in the event of theft.
Record the correct numbers to both the
operator’s manual and a secure place outside
the machine.
Safety
The safety section lists basic safety precautions.
In addition this section identifies the text and
locations of warning signs and labels used on the
machine.
Read and understand the basic precautions
listed in the safety section before operating or
performing lubrication, maintenance or repairs
on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. Read, understand and reference it
whenever necessary. This section includes a
description of gauges, machine controls,
switches and other controls at the operators’
station. It also provides transportation and towing
information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication
are basic. Skill and techniques develop as the
operator gains knowledge of the machine and its
capabilities.
Maintenance
The maintenance section is a guide for
equipment care. The illustrated, step-by-step
instructions are grouped by servicing intervals.
Items without specific intervals are listed under
the "When Required" service interval. Items in
the "Maintenance Intervals" are referenced to
detailed instructions that follow.

2
Preface January 12, 2018
CLG835H
For the replacement of environment-friendly key
parts and components when maintaining an
engine, please use the OEM parts and
components of the same type and the same
specifications. Otherwise, LiuGong accepts no
legal liability for any consequence resulting from
the use of unapproved parts.
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
January 12, 2018 Preface
CLG835H
Main Components
1. Bucket
2. Rocker arm
3. Bucket cylinder
4. Front combination lights
5. Front work lights
6. Cab
7. Rear fender
8. Counterweight
9. Rear wheel
10. Hydraulic oil tank
11. Front frame
12. Front fender
13. Boom cylinder
14. Front wheel
15. Boom
16. Engine hood
17. Rear combination lights
18. Ladder
19. Rear work lights
5
6
43
2
1
87
910
11
13
12
1514
19
17
16
FRONT
LEFT
RIGHT
REAR
18

4
Preface January 12, 2018
CLG835H
Type and Serial Number of the Machine and Parts
Note: After receiving the machine the user should fill out the above table according to the specific configuration.
Manufacturer's Name Guangxi Liugong Machinery Co., Ltd.
Type of the Machine
Serial Number of the Machine
Type of Engine
Serial Number of Engine
Type of Transmission
Serial Number of Transmission
Type of Front Axle
Serial Number of Front Axle
Type of Rear Axle
Serial Number of Rear Axle
Type of Hydraulic Pump
Serial Number of Hydraulic Pump
Cab Manufacturer
Serial Number of Cab

5
January 12, 2018 Preface
CLG835H
CE Marking, EMC Directive
CE Marking
(Declaration of Conformity)
(Only applies to machines
marketed within the EU/EEA)
This machine is CE marked. This means that
when delivered the machine meets the EU
Machinery Safety Directive 2006/42/EC,
Electromagnetic Compatibility Directive 2014/30/
EU and Noise Emission Decree 2000/14/EC.
Any person carrying out changes that affect the
safety of the machine, is also responsible for the
same.
As proof that the requirements are met, the
machine is supplied with an EU Declaration of
Conformity, issued by LiuGong CE for each
separate machine. This EU declaration does not
cover attachments manufactured by LiuGong.
The LiuGong attachments is declared by
manufacturer. The documentation is a valuable
document, which should be kept safe and
retained for at least ten years. The document
should always accompany the machine when it
is sold.
If the machine is used for other purposes or with
other attachments than described in this manual,
safety must at all times and in each separate
case be maintained. The person carrying out
such action is also responsible for the action
which, in some cases, may require a new CE
marking and the issue of a new EU Declaration
of Conformity.
The EU EMC Directive
The electronic equipment of the machine may in
some cases cause interference to other
electronic equipment, or suffer from external
electromagnetic interference, which may
constitute safety risks.
The EU EMC directive on "Electromagnetic
Compatibility", 2014/30/EU, provides a general
description of what demands can be made on
the machine out of a safety point of view, where
permitted limits have been determined and given
according to international standards.
A machine or device which meets the
requirements should be CE marked. Our
machines have been tested particularly for
electromagnetic interference. The CE marking of
the machine and the declaration of conformity
also cover the EMC directive.
If other electronic equipment is fitted to this
machine, the equipment must be CE marked and
tested on the machine with regard to
electromagnetic interference.
CE marking on nameplate (Only applies to
machines marketed within the EU/EEA)
This CE marking is located on the right side of
the front frame.
WHEEL LOADER
Guangxi Liugong Machinery Co.,Ltd.
No.1 Liutai Road, Liuzhou, Guangxi 545007, PR China
PRODUCT
IDENTIFICATION
NUMBER

6
Preface January 12, 2018
CLG835H
EC DECLARATION OF CONFORMITY
THE FOLLOWING EQUIPMENT:
IS HEREWITH CONFIRMED TO FULFILL ALL THE RELEVANT PROVISIONS OF MACHINERY
DIRECTIVE 2006/42/EC AND ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2014/30/EU AND
COMPLY WITH NOISE EMISSION DIRECTIVE 2000/14/EC, AMENDED BY 2005/88/EC AND THE
FOLLOWING HARMONIZED STANDARD HAVE BEEN COMPLIED WITH:
EN 474-1:2006+A4:2013+AC:2014
EN 474-3:2006+A1:2009
EN 13309:2010
AND THE DETAILS AS FOLLOWS HAVE BEEN CONFIRMED:
RESPONSIBLE FOR MARKING THIS DECLARATION IS THE:
MANUFACTURER □REPRESENTATIVE ESTABLISHED WITHIN THE EU ■
PERSON RESPONSIBLE FOR COMPILING AND KEEPING THE TECHNICAL FILES ESTABLISHED
WITHIN THE EU:
PERSON RESPONSIBLE FOR SIGNING THIS DECLARATION:
PRODUCT NAME: WHEEL LOADER
MODEL: CLG835H PRODUCT IDENTIFICATION NUMBER: CLG00835HFL551352
ENGINE MODEL: Perkins 1204F RATED NET POWER: 97.9KW
MEASURED SOUND POWER LEVEL: 103dB(A) GUARANTEED SOUND POWER LEVEL: 104dB(A)
CATEGORY IN 2006/42/EC: NOT REFERRED TO IN ANNEX IV, 2006/42/EC
CONFORMITY ASSESSMENT PROCEDURE: ANNEX VIII, 2006/42/EC
NOTIFIED BODY ISSUED CERTIFICATE FOR
SAMPLE:
CATEGORY IN 2000/14/EC: ARTICLE 12, ANNEX III, ITEM 37, 2000/14/EC
CONFORMITY ASSESSMENT PROCEDURE: ANNEX VII, 2000/14/EC
NOTIFIED BODY ISSUED CERTIFICATE FOR
SAMPLE:
MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD.
MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA.
AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.
AUTHORIZED REP'S ADDRESS ZUIDPLEIN 36 4.16/4.17H, 1077 XV AMSTERDAM, THE NETHERLANDS
SURNAME, NAME DENG TAO
ADDRESS ZUIDPLEIN 36 4.16/4.17H, 1077 XV AMSTERDAM, THE NETHERLANDS
SURNAME, NAME LIANG GUANGMING
POSITION/TITLE SENIOR PROJECT DESINGER

7
January 12, 2018 Safety Information
CLG835H Safety Decals and Decal Locations
Safety Information
Safety Symbol
The symbol for safety alerting appears
on machines, safety signs, manuals or
for important safety information at
other places. When you see this
symbol, you should follow the instructions in the
safety information, guarding against any
possibility of personal injuries or death.
Safety Signs
Definitions of the safety signs with the words
"Danger", "Warning" and "Caution" which appear
in this manual and on the machine are as
follows:
●Danger: this word denotes an impending
danger, failure to observe instructions could
result in death or serious injuries.
●Warning: this word denotes potential danger,
failure to observe instructions could result in
death or serious injuries.
●Caution: this word denotes potential danger,
failure to observe instructions could result in
minor to medium degree of injury.
"Caution" is also used to indicate safety
information relating to unsafe operations which
may cause personal injuries. "Danger"
represents the most dangerous conditions. The
safety signs "Danger" or "Warning" are placed
near particular dangerous places. General notice
information is placed on the safety sign
"Caution."
Safety Decals and Decal
Locations
There are several specific safety decals on your
machine. The exact location of and description of
the hazards are reviewed in this section. Take
time to read, understand and familiarize yourself
with each and every one of these safety decals.
Make sure that you can read all safety decals.
Clean or replace if you cannot read the words or
see the pictures. When cleaning the decals use a
cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the
safety decals. Solvents, gasoline or harsh
chemicals could loosen the adhesive backing of
decals causing them to fall off the machine.
You must replace a decal if it is damaged,
missing or cannot be read. If a decal is on a part
that is replaced, make sure a new decal is
installed on the replacement part. Pay attention
to the instructional and safety decals located in
the cab before starting.

8
Safety Information January 12, 2018
Safety Decals and Decal Locations CLG835H
Decal Location
1. WARNING DECAL
2. DANGER DECAL
3. DANGER DECAL
4. DECAL
5. WARNING DECAL
6. NOTICE DECAL
7. NOTICE DECAL
8. SYMBOL
9. NOTICE DECAL
10. NOTICE DECAL
11. WARNING DECAL
12. DECAL
13. CAUTION DECAL
14. WARNING DECAL
15. WARNING DECAL
16. WARNING DECAL
17. DANGER DECAL
18. DECAL
19. DECAL
20. SYMBOL
21. SYMBOL
22. SYMBOL
23. WARNING DECAL
24. SYMBOL
25. SYMBOL
26. SYMBOL
27. WARNING DECAL
28. WARNING DECAL
29. SYMBOL
30. SYMBOL
31. SYMBOL
32. WARNING DECAL
33. WARNING DECAL
34. SYMBOL
35. DANGER DECAL
36. WARNING DECAL
37. DECAL
38. DECAL
39. WARNING DECAL
40. CAUTION DECAL
41. NOTICE DECAL
42. SYMBOL
43. SYMBOL
44. WARNING DECAL
45. SYMBOL
46. WARNING DECAL
47. NOTICE DECAL
48. SYMBOL
45
46
47

9
January 12, 2018 Safety Information
CLG835H Safety Decals and Decal Locations
Decal Location
1. WARNING DECAL
2. DANGER DECAL
3. DANGER DECAL
4. DECAL
5. WARNING DECAL
6. NOTICE DECAL
7. NOTICE DECAL
8. SYMBOL
9. NOTICE DECAL
10. NOTICE DECAL
11. WARNING DECAL
12. DECAL
13. CAUTION DECAL
14. WARNING DECAL
15. WARNING DECAL
16. WARNING DECAL
17. DANGER DECAL
18. DECAL
19. DECAL
20. SYMBOL
21. SYMBOL
22. SYMBOL
23. WARNING DECAL
24. SYMBOL
25. SYMBOL
26. SYMBOL
27. WARNING DECAL
28. WARNING DECAL
29. SYMBOL
30. SYMBOL
31. SYMBOL
32. WARNING DECAL
33. WARNING DECAL
34. SYMBOL
35. DANGER DECAL
36. WARNING DECAL
37. DECAL
38. DECAL
39. WARNING DECAL
40. CAUTION DECAL
41. NOTICE DECAL
42. SYMBOL
43. SYMBOL
44. WARNING DECAL
45. SYMBOL
46. WARNING DECAL
47. NOTICE DECAL
48. SYMBOL

10
Safety Information January 12, 2018
Safety Decals and Decal Locations CLG835H
Decal Information
Fig.1 WARNING DECAL
(Located near the crush area)
CRUSH HAZARD. Keep clear.
74A3167
Fig. 2 DANGER DECAL
(Located on the arm)
CRUSH HAZARD. Keep away from raised
loader arm or bucket.
74A3153
Fig. 3 DANGER DECAL
(Located on the arm or arm cylinder)
CRUSH HAZARD. Install arm support before
maintenance or repair with loader arm raised.
74A3165

11
January 12, 2018 Safety Information
CLG835H Safety Decals and Decal Locations
Fig. 5 WARNING DECAL
(Located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations. Operate only from
operator’s seat. Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral. Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator’s compartment, park on level
ground, lower attachmentsto ground, make
sure hydraulic control lever is in lockout
position. All control levers are in neutral.
Engage parking brake. Never operate
machine downhill with stalled engine and
gear in neutral. Avoid contacting overhead
obstacles when operating or hauling
machine. 74A4777
Decal Information

12
Safety Information January 12, 2018
Safety Decals and Decal Locations CLG835H
Fig. 6 NOTICE DECAL
(Located in the cab)
DW-3 shifting lever plus FNR switch
operating instruction:
To Start Machine:
1. Apply parking brake
2. Move DWG-3 shifting lever on steering
column to “N”position
3. Press the “N” button on the FNR switch
4. Turn key to “on” position
5. Turn key switch to “start” position
To move machine with DW-3:
1. Keep FNR switch in “N” position
2. Apply service brake and hold
3. Release parking brake(P)
4. Move the DW-3 shifting lever to “↑”or” ↓”
position as desired
5. Release service brake and press
accelerator
To move machine with FNR switch:
1. Keep DW-3 shifting lever in “N2” position
2. Keep FNR switch in “N” position
3. Apply service brake and hold
4. Release parking brake(P)
5. Move the FNR switch to “F” or “R” position
as desired
6. Release service brake and press
accelerator
Notice:
1. Only the DWG-3 shifting lever is in “N2”
position, the FNR switch can be used
normally
2. DW-3 shifting lever has absolute priority. 74A6093
Decal Information

13
January 12, 2018 Safety Information
CLG835H Safety Decals and Decal Locations
Fig. 7 NOTICE DECAL
(Located in the cab)
ULTRA LOW-SULFUR
DIESEL FUEL (ULSD) ONLY
If ULSD is not used, the engine could
possibly not meet emission regulations and
the aftertreatment system could possibly be
damaged. 74A7736
Fig. 9 NOTICE DECAL
(Located in the cab)
Do not clean inside of cab with water under
pressure, electrical component damage will
result. Prevent loss of electrical power, turn
battery disconnect switch to off position when
machine not in use or being parked overnight. 74A4780
Fig. 10 NOTICE DECAL
(Located in the cab)
Avoid damaging electronic components when
welding: Position machine on level ground,
engage parking brake. Shut off engine and
turn off battery disconnect switch. Remove
electrical connectors from transmission,
engine control units and instrument panel
plug.
74A4769
Decal Information

14
Safety Information January 12, 2018
Safety Decals and Decal Locations CLG835H
Fig. 11 WARNING DECAL
(Located in the cab)
Improper engagement of worktools could
result in serious injury or death. Do not
operate this machine until you have positive
indication that: 1. Tool is firmly attached to
coupler. 2. Handle of diverter valve is in Aux
position as pictured. 3. Mechanical lock on
control lever of coupler is in locked position.
Never operate machine withoutlocks in
locked position. To change tool, turn hydraulic
diverter valve to Coupler position. Ensure that
work area is clear of personnel. Tool must be
in rolled back position and indicators visible to
operator. Release mechanical interlock on
control lever and withdraw locking pins.
Lower tool to ground and roll forward to
release. When attaching tool, roll back fully
and extend locking pins. Check attachment
by rolling tool forward against ground. Tool
should remain attached. Bucket engaged,
indicators point towards each other at top.
Bucket disengaged, indicators point away
from each other at top. Relock the
mechanical interlock on the coupler control
lever and reset the hydraulic diverter valve to
Aux position. Do not operate machine with a
faulty coupler or with the
menchanicalinterlock on the control lever not
engaged at all times. 74A4779
Fig. 12 DECAL
Refer to the manufacturer plate on the
machine for the machine mass.
The steering frame lock must be in place for
lifting.
Use proper rated cables and slings for lifting.
position crane for level machine lift.
Spreader bar witch should be sufficient to
prevent contact with machine. 74A9890
Decal Information