Liugong Excavator Faults: Troubleshooting Hydraulic, Electrical & Engine Issues


Liugong excavators are widely used for their reliability and competitive pricing. However, like any heavy machinery, they are not immune to common mechanical and electrical issues. Whether you manage a fleet, operate on a job site, or are considering a used Liugong excavator, understanding the frequent fault types can help you diagnose problems early, minimize downtime, and reduce repair costs. This blog outlines the most common Liugong excavator faults and offers practical troubleshooting advice.

1. Frequent Liugong Excavator Fault Categories

1.1 Hydraulic System Failures

  • Hydraulic Leaks: One of the most reported issues is leakage in hydraulic cylinders, hoses, or connections. Over time, seals may wear, or hoses can crack under pressure.

  • Slow Response or Sluggish Controls: When the boom, arm, or bucket moves slower than normal, it may indicate pilot circuit problems or air trapped within the hydraulic system.

  • Hydraulic Overheating: Operators have observed high hydraulic oil temperature during heavy or continuous operation, which can degrade fluid quality and impair efficiency.

1.2 Engine & Powertrain Issues

  • Starting Difficulties / Low Power: Some Liugong models experience hard starts, especially in cold weather, or lose power during operation. This behavior may be linked to fuel system issues, weak batteries, or air intake blockages. (For example, on certain Liugong models, starting problems are more frequent.)

  • Excessive Smoke Emission: Burning oil or fuel inefficiently can lead to abnormal smoke, which may suggest injector wear, poor combustion, or engine internal wear.

  • High Oil Consumption: A worn engine or weak seals can lead to increased oil usage over time.

1.3 Electrical & Sensor Problems

  • Wiring Wear / Corrosion: With age, wiring harnesses can deteriorate, causing intermittent electrical faults, sensor misreads, or erratic control behavior.

  • Battery Drain: Idle machines or long storage periods may lead to battery drain. Faulty alternators or parasitic draws can be the root cause.

  • Sensor Malfunctions: Engine temperature sensors, oil pressure sensors, or other monitoring components may fail or give incorrect readings, leading to false alarms or shutdowns.

1.4 Undercarriage and Structural Wear

  • Track and Roller Wear: On tracked Liugong excavators, track links, idlers, and rollers often show high wear, especially if not properly maintained.

  • Frame & Boom Fatigue: Welding repairs, repeated stress on the boom or arm, or poor structural inspections can lead to fatigue cracks — a serious safety and cost issue.

1.5 Maintenance Challenges

  • Parts Availability: Depending on your region, sourcing genuine Liugong parts can sometimes be slow, especially for older or less common models.

  • Access for Repairs: Certain components, such as hydraulic valves or engine parts, may be difficult to reach, making maintenance slower and more labor-intensive.

2. Troubleshooting & Diagnostic Guide for Liugong Excavator Faults

Here’s a step-by-step approach you can follow when diagnosing common Liugong faults:

  1. Document the Fault Symptoms
    Write down exactly what is happening, when it started, under what conditions (load, temperature), and any error lights or warnings.

  2. Perform a Visual & Physical Check

    • Inspect all hydraulic hoses, cylinders, and fittings for signs of leaks or damage.

    • Check fluid levels (hydraulic oil, engine oil, coolant).

    • Observe the undercarriage or tracks for wear, misalignment, or damage.

  3. Test Hydraulic Performance

    • Run the excavator under no-load and load conditions.

    • Observe the speed of boom/arm movement.

    • Monitor hydraulic oil temperature, and feel for any abnormal vibration or noise.

  4. Check Electrical & Sensor Systems

    • Use a multimeter or diagnostic tool to verify battery voltage, alternator output, and grounding points.

    • Inspect wiring harnesses for chafed insulation, corrosion, or loose connectors.

    • Verify sensor outputs (like temperature sensors or pressure sensors) against expected values.

  5. Run the Engine & Powertrain

    • Start the engine and listen for unusual noises.

    • Monitor exhaust for smoke color and density.

    • Check for erratic RPM behavior or sudden power drops.

  6. Review Maintenance History

    • Ask for the service log. How often were filters and fluids changed?

    • Look for past repairs related to hydraulics, electrical, or structural components.

  7. Perform Load Testing & Field Trial

    • Move a real load (dig, lift) to test under real working conditions.

    • Monitor all critical parameters (temperature, leak, control response).

    • Verify whether any fault or warning reappears.

  8. Take Corrective Action

    • Replace worn seals, hoses, or bad sensors.

    • Adjust or clean hydraulic filters.

    • Repair or replace damaged wiring or connectors.

    • Address any structural fatigue or frame cracks immediately.

3. Preventive Maintenance Strategies to Avoid Recurrence

  • Regularly drain and replace hydraulic fluid per manufacturer schedule.

  • Use the correct hydraulic oil grade designed for your machine’s working environment.

  • Perform periodic undercarriage inspections—tighten tracks, replace worn rollers, and re-lube pin joints.

  • Schedule routine electrical inspections: check battery health, inspect connectors, and test sensors.

  • Maintain a maintenance log to track repairs, service intervals, and component replacements.

  • Train operators to use the machine gently, avoid aggressive control inputs, and report early signs of leaks or performance drop.

4. Why Knowing These Faults Matters (Especially for Used Machines)

  • Cost Savings: Early diagnosis prevents small leaks or sensor issues from turning into major system failures.

  • Reliability: Well-maintained Liugong excavators stay productive longer and operate more predictably.

  • Resale Value: A documented repair history and proactive maintenance boost resale value, especially important if you’re buying or selling second-hand machines.

  • Safety: Hydraulic failures, overheating, and structural fatigue can pose serious safety risks on job sites. Identifying issues early reduces that risk.

  • Downtime Reduction: Knowing what to check first speeds up troubleshooting, minimizing downtime and maximizing machine utilization.

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