201701001

CLG835H
WHEEL LOADER

SERVICE MANUAL

Applicable type and model: CLG835H PERKINS Engine 1204F-E44AT/ LIUGONG Wet Axle/ ZF
4WG158 Gearbox
January 24, 2017 Contents
CLG835H

Contents
General Information ........................................................................................................1-1
Power System ..................................................................................................................2-1
Power Train System ........................................................................................................3-1
Hydraulic System ............................................................................................................4-1
Air Conditioning System.................................................................................................5-1
Driver's Cab System........................................................................................................6-1
Structure...........................................................................................................................7-1
Electrical System.............................................................................................................8-1
Appendix ..........................................................................................................................9-1
Contents January 24, 2017
CLG835H
 1-1
January 24, 2017 General Information
CLG835H

General Information
How to Use the Manual ...................................................................................................1-3
Safety description ...........................................................................................................1-4
Identification of Complete Machine and System..........................................................1-5
Engine Identification .......................................................................................................1-6
Cable Code Identification ...............................................................................................1-8
Coating Materials...........................................................................................................1-10
Weight Table ..................................................................................................................1-12
Unit conversion table ....................................................................................................1-14
Standard Torque Table .................................................................................................1-15
Oils use specifications..................................................................................................1-18
Technical specification of the complete machine......................................................1-22
Technical parameter table of complete machine .................................................................................1-27
1-2
General Information January 24, 2017
CLG835H
 1-3
January 24, 2017 How to Use the Manual
CLG835H

How to Use the Manual ● Some accessories and optional parts in the
Manual may not be transported to relevant
areas, and consult your local LiuGong dealer
This manual is written for an experienced techni- if required.
cian. Essential tools required in performing cer-
tain service work are identified in this manual ● The materials and technical specifications in
and are recommended for use. the Manual are changed with variation of
products, and all information, diagrams and
This is the safety-alert symbol. When specifications in the Manual are the latest
you see this symbol on the machine product information obtained at the time of
or in this manual , be alert to the publication. The company reserves the right
potential for person injury. to make modification without any notice. If it
needs to obtain the latest technical informa-
Technical manuals are divided in several parts : tion, please consult the dealer of LiuGong in
repair and test . Repair sections tell how to repair local area or Service Department of LiuGong
the components. Tests sections help you identify Wheel Loader Marketing Co., Ltd.
the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of
all applicable essential tools, service equipment
and tools, other materials needed to do the job,
service part kit , specifications ,wear tolerances,
and torque values.
Technical Manuals are concise guides for spe-
cific machines. They are on-the-job containing
only the vital information needed for diagnosis,
analysis, testing, and repair .
Fundamental service information is available
from other sources covering basic theory of oper-
ation, fundamentals of troubleshooting, general
maintenance, and basic type of failures and their
causes.

Other reference manuals

● Parts manual
● Use and maintenance manual
● Cummins engine parts manual
● Cummins engine overhaul manual
● ZF axle case overhaul manual

User's Guidance

● Because the influences to the machine from

area or processing are different, it shall con-
firm which machine is applicable, and what
work implements it has.
1-4
Important Safety Information January 24, 2017
CLG835H

Important Safety Information

Most accidents involving product operation, LiuGong cannot anticipate every possible cir-
maintenance and repair are caused by failure to cumstance that might involve a potential hazard.
observe safety rules or precautions. An accident The warnings in this publication and on the prod-
can often be avoided by recognizing potentially uct are therefore not all inclusive. If a tool, proce-
hazardous situations before an accident occurs. dure, work method or operating technique not
A person must be alert to potential hazards. This specifically recommended by LiuGong is used,
person should also have the necessary training, you must satisfy yourself that it is safe for you
skills and tools to perform these functions prop- and others. You should also ensure that the
erly. product will not be damaged or made unsafe by
the operation, lubrication, maintenance or
Improper operation, lubrication, maintenance or
require procedures you choose.
repair on this product can be dangerous and
could result in injury or death. The information, specification, and illustrations in
this publication are on the basis of information
Do not operate or perform any lubrication, main-
available at the time when it was written. The
tenance or repair on this product, until you have
specification, torques, pressures, measure-
read and understood the operation, lubrication,
ments, adjustments, illustrations, and other items
maintain and repair information.
can change at any time. These changes can
Safety precautions and warnings are provided in affect the service given to the product. Obtain the
this manual and on the product. If these hazard complete and most current information before
warnings are not heeded, bodily injury or death starting any job. LiuGong has the most current
could occur to you or other persons. information available.
The hazards are identified by the "Safety Alert CALIFORNIA PROPOSITION 65
Symbol" and followed by a "Signal Word" such
as "WARNING" as shown following. Diesel engine exhaust and some of its constitu-
ents are known to the state of California to cause
cancer, birth defects and other reproductive
harm.

The meaning of this safety alert symbol is as fol- Battery post, terminal and related accessories
lows: contain lead and lead compounds, Always wash
hands after handling.
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.
 1-5
January 24, 2017 Manual Identification
CLG835H

Manual Identification

IMPORTANT: Use only supporting manuals When necessary, product serial numbers and
designed for your specific machine. If incorrect engine model numbers are listed on the front
manual is chosen, improper service may occur. covers of loader manuals. These numbers are
Verify product identification number (PIN) and used to identify the correct supporting manual for
engine model number when choosing the correct your machine.
manual.
Product Serial Number Identification
Choosing the Correct Supporting Manuals
The product identification number (PIN) plate is
LiuGong wheel loaders are available in different located on left side of machine front frame under
machine configurations based on the various the pin of boom . Each machine has a 17- char-
markets into which they are sold. Different sup- acter PIN or shown on this plate and under this
porting manuals exist for different machine con- plate, The last 6 characters of the PIN represent
figurations. the machine's product serial number.
Figure 1 PIN Plate Location

P11000001
1-6
Engine Identification January 24, 2017
CLG835H

Figure 2 Pin Plate (17-character with CE mark)

P11000002

Engine Identification

The engine serial number plate is located on the right side of engine model 1204F. Each engine has two
engine numbers (LIST NO. and SERIAL NO.) shown on this plate.

Engine Emission Level Identification

EMISSION CONTROL INFORMATION: In the U.S., this engine is solely for export and is therefore
exempt under 40 CFR 1068.230 from emission standards and related requirements. Outside the U.S.,
the engine may be subject to other emission regulations.
 1-7
January 24, 2017 Engine Identification
CLG835H

Figure 3 Engine Serial Number Plate Location

P11000003
Figure 4 Engine Serial Number Plate

P11000004
1-8
Cable Code Identification January 24, 2017
CLG835H

Cable Code Identification

The wire in circuit diagram is marked in combination with wire No., wire categories, color abbreviation
codes and wire gauge for maintenance. For example:

P28E00002

Wire No.

Wire No. is digital code for marking wire with three Arabic numbers in accordance with certain rules.

Wire categories

The wire categories selected for engineering machinery are AEX, AV, AVS, AVSS, and QVR in general.
For applicable range of ambient temperature of various wires, see following table.

Heat resis-
S/N Wire type Wire name Description
tance
70 °C (158°F) heat-resisting, cop-
1 QVR Low-voltage wire for road vehicles ≤ 70°C(158°F)
per core PVC-insulated
Thin-wall insulated low-voltage wire The thickness of insulation layer
2 AVSS ≤ 80°C(176°F)
for vehicles is 0.30~0.40mm
Thin-wall insulated low-voltage wire The thickness of insulation layer
3 AVS ≤ 80°C(176°F)
for vehicles is 0.50~0.70mm
The thickness of insulation layer
4 AV Insulated low voltage wire for vehicles ≤ 80°C(176°F)
is 0.60~2.0mm
Heat-resisting low voltage wire for Heat resistance and cross-linking
5 AEX ≤ 110°C(230°F)
vehicles polyethylene

Color abbreviation codes

Color English Abbreviation Color English Abbreviation

Black BLACK BK Blue BLUE BU
Grey GREY GY Green GREEN GN
Red RED RD Yellow YELLOW YL
Brown BROWN BR Pink PINK PK
 1-9
January 24, 2017 Cable Code Identification
CLG835H

Color English Abbreviation Color English Abbreviation

Violet VIOLET VT Orange ORANGE OR
White WHITE WH Light blue LIGHT BLUE LTBU
Red/green RED/GREEN RD/GN Yellow/blue YELLOW/BLUE YL/BU
Remarks: The code composed of 2 colors indicates double-color wire
For example: "RD/GN" shows red-green wire.

Wire specifications

Allowable current and voltage drop of AV wire, and approximate performances of AVS, AVSS, and QVR
shall be executed uniformly according to the following table.

Ambient temperature 30°C(86°F) 40°C(104°F) 50°C(122°F) 60°C(140°F) 70°C(158°F)

Allowable current/
A mV/m A mV/m A mV/m A mV/m A mV/m
voltage drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
8 74 213 66 190 57 164 47 135 33 95
Nominal 15 103 176 92 157 30 137 65 111 46 79
sectional
area(mm2) 20 135 148 121 133 105 116 85 94 60 66
30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 60 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37

Circuit type and color abbreviation code

For general corresponding rules between circuit type and wire color, see the following table.

Circuit type Color abbreviation codes

Power line OR, RD
Signal line WH
Earthing BK, GY
Communication line RD/GN, YU/BU
1-10
Coating Materials January 24, 2017
CLG835H

Coating Materials

Name Specification Main features and purposes

1277 Thread locker seal- ● Features: anaerobic and fast air drying
1277
ants ● Purposes: used for parts not frequently removed
1243 Thread locking seal-
1243 Used for removable parts (speed sensor in general)
ant
● Features: rust protection for a long time
Long-term anti-rust agent LONG#2 light yellow ● Purposes: used for mounting face of pump, sensor,
hydraulic fitting, etc
Efficient cleaning agent ● Features: strong ability of cleaning
1755
1755 ● Purposes: used for pump and motor
● Feature: it has features of high-temperature resistance, self-
lubrication and medium resistance and is used for medium
Anaerobic pipe thread
1567 (sealing oil, air, vapor, water) pipeline cone/taper thread
sealant
● Purposes: used for water temperature sensor and oil
pressure sensor
Cleaning agent for electro-
HD-10 Used for cleaning oil pipe connectors, etc.
mechanical equipment
Diesel engine sealant 1515 Used for mounting face of diesel engine flange
Polyurethane sealant 1924 Used for waterproof of start motor and assembling clearance
Mobilux EP None Used for rust protection of rear cover hinge

Paint standard:

There are two main kinds of colors that applied to 835H:

Yellow: matte (50%) RAL1006 yellow
Grey: matte (40%) RAL7021 grey
The standard of paint quality is as follows (for more information, see QJ/LG 08.44-2013):

S/N Items Indicator Testing method Remarks

Paint film shall be uniform Refer to the require-
Paint film
color, and no blistering, crack, ments at all levels of
1 appear- Visual check
wrinkle, under screen, rust, surface for details of
ance
damage, dirt and so on allowable defects
For details, see the
requirements at all lev-
Meet the minimum require-
Paint film els of surface. For
2 ments of paint film gloss at all Visual/gloss meter
gloss matte paint, refer to
levels of surface
the special require-
ments
Meet the minimum require- For details, please see
Paint film
3 ments of paint film thickness at Thickness gauge of paint film the requirements at all
thickness
all levels of surface levels of surface
 1-11
January 24, 2017 Coating Materials
CLG835H

S/N Items Indicator Testing method Remarks

Use single cutting edge or scriber to
perform the cross cut on the paint film Approval standard: No
with five horizontal and vertical lines. the whole piece of grid
Adhesion
Good adhesion and no peeling The distance between the scribing lines film drops. (Little film
4 of paint
in detection of paint film is 1 mm~1.5 mm and the depth can drop around the scrib-
film
reach the steel plate substrate. Then ing lines can be allow-
stick the transparent adhesive tape and able.)
compact, then tear off the tape
For details, please see
Color dif- Meet color difference require-
5 Visual check/Color difference meter the requirements at all
ference ments at all levels of surface
levels of surface
There is no paint contamina-
6 Shield tion, mechanical impurity, rust Visual check
and dirts
The decal should be correct,
7 Decal complete, decorous, firm, Visual check
smooth and no popping
1-12
Weight Table January 24, 2017
CLG835H

Weight Table
The following table indicates the reference value of the weight of each component. When using the lifting
equipment , please refer to the following table to select the sling.

Component Weight (kg)

Engine 571kg\ 1259 lb
Radiator 285 kg \ 628 lb
Fuel tank 122 kg\ 269 lb
Front axle assembly 788 kg\ 1738 lb
Rear axle assembly 779 kg\ 1718 lb
Tire rim 295 kg\ 650 lb
Drive shaft 83 kg\ 183 lb
Gearbox & torque converter assembly (oil bearing) 510 kg\ 1125 lb
Cab 685 kg\ 1510 lb
Seats 29 kg\ 64 lb
Engine hood as 210 kg\ 463 lb
Left rear fender 27 kg\ 60 lb
Right rear fender 30 kg\ 66 lb
Air conditioner 100 kg\ 221 lb
Steering pump 34 kg\ 75 lb
Control valve 45 kg\ 99 lb
Fan drive motor 12 kg\ 26 lb
Hydraulic oil tank 130 kg\ 287 lb
Boom cylinder assembly (single) 122 kg\ 269 lb
Bucket tilting cylinder assembly 124 kg\ 283 lb
Secondary steering pump 20 kg \ 44 lb
Ride control accumulator 41 kg\ 90 lb
Rocker arm 138 kg\ 304 lb
Boom 662 kg\ 1460 lb
Front frame 942 kg\ 2077 lb
Rear frame 882 kg\ 1945 lb
Battery box-lh 71 kg\ 157 lb
Battery box-rh 71 kg\ 157 lb
Counterweight 152 kg\ 335 lb
Work implement 880 kg\ 1940 lb
Linkage 34 kg\ 75 lb
Quick coupler frame 267 kg\ 589 lb
Quick Coupler Bucket 734 kg\ 1618 lb
Tooth 190 kg\ 419 lb
Movable blade(*6) 15 kg\ 33 lb
Battery(*2) 18 kg\ 40 lb
 1-13
January 24, 2017 Unit Conversion Table
CLG835H

Unit Conversion Table

The Manual uses ISO International System of Units, and ISO international units are converted into Brit-
ish units as shown in following figure:

Parameters Metric unit British unit Multiple

mm In 0.03937
Length
mm ft 0.003281
L US gal 0.2642
Capacity L US qt 1.057
m³ Yd3 1.308
Weight kg lb 2.205
N kgf 0.10197
Intensity
N lbf 0.2248
Nm kgf·m 0.10197
Torque
Nm lbf·ft 0.7375
MPa 3 10.197
kgf/cm
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C ×1.8+32
km/h mph 0.6214
Speed
min-1 rpm 1.0
L/min US gpm 0.2642
Flow
mL/rev cc/rev 1.0
1-14
Standard Torque Table January 24, 2017
CLG835H

Standard Torque Table

TORQUE SPECIFICATIONS – METRIC HARDWARE

Use the following torques when specifications are not given.

These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or
when lubricated with engine oil, These values do not apply if graphite or Moly disulfide grease or oil is
used.

Grade 8.8 Bolts , Nuts , and Studs

Size N.m \ lbf·ft
M6 7.7±1.1 N.m \ 5.67±0.81 lbf·ft
M8 19±2.9 N.m \ 14.01±2.13 lbf·ft
M10 72±6 N.m \ 53±4 lbf·ft
M12 120±10 N.m \ 89±7 lbf·ft
M14 195±15 N.m \ 144±11 lbf·ft
M16 305±25 N.m \ 225±18 lbf·ft
M18 415±35 N.m \ 306±26 lbf·ft
M20 600±50 N.m \ 443±37 lbf·ft
M22 800±70 N.m \ 590±52 lbf·ft
M24 1020±100 N.m \ 752±74 lbf·ft
M27 1500±100 N.m \ 1106±77 lbf·ft
M30 1850±150 N.m \ 1364±111 lbf·ft
M33 2900±400 N.m \ 2139±295 lbf·ft
M36 3100±250 N.m \ 2286±184 lbf·ft

Grade 10.9 /12.9 Bolts , Nuts , and Studs

Size N.m
M10 72±6 N.m\ 53±4 lbf·ft
M12 120±10 N.m\ 89±7 lbf·ft
M14 195±15 N.m\ 144±11 lbf·ft
M16 305±25 N.m\ 225±18 lbf·ft
M18 415±35 N.m\ 306±26 lbf·ft
M20 600±50 N.m\ 443±37 lbf·ft
M22 800±70 N.m\ 590±52 lbf·ft
M24 1020±100 N.m\ 752±74 lbf·ft
M27 1500±100 N.m\ 1106±77 lbf·ft
M30 1850±150 N.m\ 1364±111 lbf·ft
M33 2900±400 N.m\ 2139±295 lbf·ft
M36 3100±250 N.m\ 2286±184 lbf·ft
 1-15
January 24, 2017 Standard Torque Table
CLG835H

Tightening torque of 24° cone O-ring sealed hose connector

Hose inner diame- Tightening torque

Series Thread size
ter mm N.m kgf.m
M12×1.5 5 16±1 1.6±0.1
M14×1.5 6.3 16±1 1.6±0.1
M16×1.5 8 26±2 2.7±0.2
M18×1.5 10 37±2 3.8±0.2
M22×1.5 12.5 47±2 4.8±0.2
Light-type
M26×1.5 16 89±4 9.1 ±0.4
M30×2 19 116±5 11.8±0.5
M36×2 25 137±6 14.0±0.6
M45×2 31.5 226±11 23.1±1.1
M52×2 38 347±16 35.4±1.6
M14×1.5 5 26±2 2.7±0.2
M16×1.5 6.3 42±2 4.3±0.2
M18×1.5 6.3 53±2 5.4±0.2
M20×1.5 8 63±3 6.4±0.3
M22×1.5 10 79±4 8.1 ±0.4
Heavy type
M24×1.5 12.5 84±4 8.6±0.4
M30×2 16 126±6 12.9±0.6
M36×2 19 179±8 18.3±0.8
M42×2 25 263±12 26.8±1.2
M52×2 31.5 368±17 37.6±1.7

Tightening torque of flange-type sealed hose connector bolt

Bolt performance Tightening torque

Series Bolt
level N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
8.8
M12 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
Light-type
M8 33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
10.9
M12 136±6 12.8±0.6
M16 310±15 31.6±1.5
1-16
Standard Torque Table January 24, 2017
CLG835H

Bolt performance Tightening torque

Series Bolt
level N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
M12 8.8 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
M20 420±20 42.8±2.0
Heavy type
M8 33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
M12 10.9 136±6 12.8±0.6
M16 310±15 31.6±1.5
M20 577±27 58.9±2.8

Tightening torque of thread angle type sealed hose connector

Material of fasten-
Carbon steel, alloy steel Aluminum product
ings
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 3.0±0.2
G3/8 73.5±4.5 7.5±0,46 49±3 5.0±0.3
G1/2 110±10 11.2±1.0 55±5 5.6±0.5
G3/4 165±15 16.8±1.5 74±4 7.5±0.4
G1 225±25 23.0±2.55 / /
G1-1/4 275±25 28.0±2.55 / /
G1-1/2 285±15 29.1±1.5 / /
 1-17
January 24, 2017 Oils use specifications
CLG835H

Connector tightening torque

Tightening torque
Thread size
N.m kgf.m
M12 24±2 2.4±0.2
M14 30±2 3.1±0.2
M16 30±2 3.1±0.2
M18 30±2 3.1±0.2

Oils use specifications

Fluids and lubricants for CLG835H-T4F

Category Name Capacity Application parts Remarks

≥-10°C(14°F) ★ SAE 15W/40 CJ-4 12L\
Engine oil Diesel engine
≤-10°C(14°F) SAE 5W/40 CJ-4 3 US gal

Engine ≥-10°C(14°F) ★ 10# Ultra low sulfur diesel 190L\

Diesel engine
fuel ≤-10°C(14°F) 35# Ultra low sulfur diesel 50 US gal
19L\
Adblue ★ RD-11 Diesel engine def tank
5 US gal
-15~40°C(5~104°F) ★ HM-46 Anti-wear hydraulic oil
Hydraulic 120L\ Work hydraulic system,
oil -25~40°C(- HV-46 low-temperature anti- 32 US gal steering hydraulic system
13~104°F) wear hydraulic oil

Torque ★ SAE 15W-40 Mobil Delvac

≥-10°C(14°F) 40L\ Torque converter and
converter 1300
11 US gal power shift gearbox
oil ≤-10°C(14°F) S4 TXM 10W-30
★ SAE 80W-90/LS Heavy-load
≥-10°C(14°F)
wheel gear oil 34L\ Front and rear axle bevel LiuGong
Gear oil
75W-90/LS Heavy-load wheel 9 US gal gear and wheel reducer bridge
≤-10°C(14°F)
gear oil
2.5Kg\
Refrigerant ★ R134a Air conditioner
5.5 lb
★ 2# Molybdenum disulfide lith- Roller bearing, slide bear-
Manual lubrication
ium grease ing, pin shaft of work
implement, pin shaft of
0# Composite lithium base
≤-10°C(14°F) 2L\ steering cylinder, pin shaft
Grease grease
1 US gal of vehicle frame, swing
frame of rear axle, spline
2# Composite lithium base
Central lubrication of drive shaft, cardan joint,
grease
and water pump shaft
22L\
Coolant ★ Shell anti-freezing solution
6 US gal
★ refers to the standard configuration
1-18
Oils use specifications January 24, 2017
CLG835H

NOTE 1 : DO NOT use an alternate oil in the axle , the transmission box ,the engine . the parts could be
damaged as a result of using an alternate oil.
NOTE 2: SEE your dealer for winter fuel requirements in your area , if the temperature of fuel below the
cloud point , will cause the engine lose power or not start.
NOTE 3: Low sulfur fuel should be used. the wrong fuel used will cause the engine damaged as a result.

Specifications for acceptable Diesel Fuel

Perkins Specification for Distillate Diesel Fuler

Property Units Requirements
Aromatics %Volume 35% maximum “ISO”3837
Ash %Weight 0.01% maximum “ISO”6245
Carbon Residue
%Weight 0.35% maximum “ISO”4262
on 10% Bottoms
Cetane Number _ 40 minimum “ISO”5165
The cloud point must not exceed the lowest
Cloud Point °C “ISO”3015
expected ambient temperature.
Copper
_ No. 3 maximum “ISO”2160
Strip Corrosion
Density at 15°C
(59°F) Kg/m3 801 minimum and 876 maximum “ISO”3675 “ISO”12185

10% at 282°C (539.6°F) maximum

Distillation °C “ISO”3405
90% at 360°C (680°F) maximum
Flash point °C Legal limit “ISO”2719
Minimum of 80% reflectance after aging for 180
Thermal Stability No equivalent test
minutes at 150°C (302°F)
6°C (42.8°F)minimum below ambient tempera-
Pour Point °C “ISO”3016
ture
Sulfur % mass 0.0015 “ISO”20846 “ISO”20884
Kinematic Viscos- The viscosity of the fuel that is delivered to the
mm2/s(cSt) “ISO”3405
ity fuel injection pump.”1.4 minimum/4.5 maximum”
Water and sedi-
%weight 0.1% maximum “ISO”
ment
Water %weight 0.1% maximum No equivalent test
Sediment %weight 0.05% maximum “ISO”3735
Gums and Resins mg/100ml 10 mg per 100 ml maximum “ISO”6246
Lubricity cor-
rected wear scar
mm 0.52 maximum “ISO”12156-1
diameter at 60°C
(140°F)
 1-19
January 24, 2017 Oils use specifications
CLG835H

MAINTENANCE SCHEDULE

FREQUENCY IN HOURS

SERVICE

LUBRICATE
INITIAL

REPLACE
CHANGE

ADJUST
SERVICE

CHECK

CLEAN

DRAIN
SERVICE POINTS
INTERVAL

Radiator Coolant Level ★

Tires ★
Hydraulic Filter ★
As Required
Air Cleaner ★ ★
Alternator , AC ,Drive Belt ★
Fire Extinguisher ★
Every 10 Hours Check Engine Oil Level 10
Check Engine Coolant Level 50
Check Transmission Oil Level 50
Every 50 Hours Check Hydraulic Oil Level 50
Grease Bucket Mounting Fittings 50
Bleed Fuel Filter of Condensation 50
Change Engine Oil and Filters 100
Replace Fuel Filters 100
First 100 Hours Change Hydraulic Filter 100
Change Transmission Oil and Filter 100
Change Oil in Axles 100
Grease Front Drive Shaft Support Bear-
100
ing
Grease Steering Cylinder Pivots (4 Fit-
Every 100 100
tings)
Hours
Grease Lift & Tilt Cylinder Pivots (6 Fit-
100
tings)
Grease Articulation Fittings 100
Check Cab Fresh Air Filter 250 ★
Check AC Return Air Filter 250 ★
Every 250 Check Radiator Coolant Level 250
Hours Check Tire Pressure & Wheel Torque 250
Check Drive Belts 250
Check Air Filter 250
Check Axle Oil Level 500
Check Battery Volt and Nuts Torque 500
Every 500
Change Engine Oil and Filter 500
Hours
Replace Fuel Water Separator 500
Replace Fuel Filter 500
1-20
Oils use specifications January 24, 2017
CLG835H

FREQUENCY IN HOURS

SERVICE

LUBRICATE
INITIAL

REPLACE
CHANGE

ADJUST
SERVICE

CHECK

CLEAN

DRAIN
SERVICE POINTS
INTERVAL

Replace Hydraulic Oil Filter 500 1000

Replace Pilot Hydraulic Oil Filter 500 1000
Change Front & Rear Axle Oil 1000
Every 1000 Replace Cab Fresh Air Filter 1000
Hours Replace AC Return Air Filter 1000
Change Transmission Oil and Filter 100 1000
Check Accumulator Nitrogen Press 500 1000
Clean Fuel Tank 100 1000
Every 2000 Change Hydraulic Oil & Filter 2000
Hours Change Coolant 2000
Note: ★ means service as required.
 1-21
January 24, 2017 Technical Specification of the Machine
CLG835H

Technical Specification of the Machine

P11000006

Application

This loader is a kind of engineering machinery

mainly used for loading & unloading loose mate-
rials. It is mainly used for loading, unloading, Do not operate machine in conditions with
bulldozing and traction operation etc. at mine rollover or falling object risk.
areas, ports and docks, capital construction, road
repair and steel & iron enterprises etc. It is a kind
of multi-purpose and high efficiency engineering
machinery.
Preventive measures for operation,
This loader is a kind of general-purpose engi- maintenance and safety rules outlined on this
neering machinery and is not suitable for the manual are only suitable for the stipulated
flammable, explosive, dusty and air poisonous applications of the machine. Do not use the
environments. machine beyond the stipulated application
scope, Guangxi LiuGong Machinery Co., Ltd
Requirements of Work Environments
will not bear any safety liability, and these
1. Altitude: ≤ 3000 m safety liabilities will be born by users. Under
any cases, do not use the forbidden
2. Environmental temperature: -15°C~40°C operation outlined in this manual.
(The cold starting Aid device is not available)
3. Water Depth: ≤ 630 mm
1-22
Technical Specification of the Machine January 24, 2017
CLG835H

Main Components

4 3
2
1

8
7 11
12
9 10 13
14 15

FRONT
19 RIGHT

16

18 17

LEFT
REAR

1. Bucket 6. Cab 11. Front frame 16. Engine hood

2. Rocker arm 7. Rear fender 12. Front fender 17. Rear combination lights
3. Bucket cylinder 8. Counterweight 13. Boom cylinder 18. Ladder
4. Front combination lights 9. Rear wheel 14. Front wheel 19. Rear work lights
5. Front work lights 10. Hydraulic oil tank 15. Boom
 1-23
January 24, 2017 Technical Specification of the Machine
CLG835H

Performance Parameters
All rated lift capacities are based on the criteria of the machine being leveled on a hard and flat 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.
The following table lists the specifications in standard collocation, please refer to the appendix of this
section for the specification change parts of the other special collocations (such as larger bucket, longer
boom, and side dump bucket).
Exterior Drawing

H
C
A
B

P
E

F D
G
L
1-24
Technical Specification of the Machine January 24, 2017
CLG835H

Machine Specifications
CLG835H T4f
NO. Item Unit
Quick coupler Pin On
1 Rated load weight kg (lb) 3000 (6615) 3000 (6615)
2 Rated power kW 97.9 97.9
3 Operating mass kg (lb) 11200 (24696) 10800 (23814)
4 Rated bucket capacity m3 1.9 1.9
5 Dumping height mm (In) 2700 (106) 2800 (110)
6 Max. breakout force (bucket tilting) kN (lbf) 85 (19108) 90.1 (20254)
7 Tipping load (aligning) kg (lb) 7700 (16979) 9452 (20842)
8 Tipping load (full steering) kg (lb) 6600 (14553) 7369 (16249)
9 Boom lifting time (full load) s 5.5 5.5
10 Total time s 9.7 9.7
11 Max. traveling speed km/h(mph) 38.6 (23.9) 38.6 (23.9)
12 Max. gradeability ° 28 28
13 Min. turning radius (outside of front wheel) mm (In) 4920 (194) 4920 (194)
Overall Dimensions
Parameters below are for Z-bar or 8-bar machine Z-bar Z-bar
1 A: Height to hinge pin, fully raised mm (In) 3720 (146) 3720 (146)
2 B: Dumping height, fully raised mm (In) 2700 (106) 2800 (110)
3 C: Dumping reach, fully raised mm (In) 1150 (45) 1076 (42)
4 D: Max. digging depth mm (In) 100 (4) 80(3)
5 E: Min. ground clearance (at articulation joint) mm (In) 325 (13) 325 (13)
F: Distance from centre of rotation to the centre of the front
6 mm (In) 1435 (56) 1435 (56)
wheels
7 G: Wheel base mm (In) 2870 (113) 2870 (113)
8 H: Overall height (top of cab) mm (In) 3200 (126) 3200 (126)
9 J: Tread width mm (In) 1855 (73) 1855 (73)
10 K: Overall width (outside of wheel) mm (In) 2450 (96) 2450 (96)
11 L: Over length (bucket on ground) mm (In) 7265 (286) 7115 (280)
12 M: Max. steering angle ° 38 38
13 W: Overall width (outside of bucket) mm (In) 2530 (100) 2530 (100)
14 R1: Turning radius (outside of bucket) mm (In) 5650 (222) 5050 (199)
15 R2: Turning radius (center of rear wheel) mm (In) 4622.5 (182) 4622.5 (182)
16 P: Departure angle ° 28 28
17 S1: Bucket tilt back angle (on ground) ° 45 45
18 S2: Bucket tilt back angle (in transport position) ° 48 48
19 S3: Bucket tilt back angle (in highest position) ° 60 60
20 S4: Dumping angle (in highest position) ° 45 45
21 T: Bucket articulation height (in transport position) mm (In) 450 (18) 450 (18)
 1-25
January 24, 2017 Technical Specification of the Machine
CLG835H

Main Components Specifications

Engine
1 Manufacturer / Perkins
2 Model / 1204F-E44TA
3 Type / Electronic fuel injection
4 Displacement L (US gal) 4.4 (1.16)
5 Rated power KW (hp) 97.9 (131.3)
6 Emission level / Tier 4f
Number of cylinders and
7 / Straight-four cylinders
arrangement
8 Intake type / Turbocharged & inter-cooling
9 Rated speed r/min 2200
10 Max. rotating speed (no-load) r/min 2376
11 Min. rotating speed (no-load) r/min 800
12 Rotating speed at max. torque r/min 1400
13 Max. torque N.m (lbf·ft) 530 (391)
14 Start motor V-Kw 24V-5.5 KW
15 Alternator V-A 24V- 70A
Power train system
1 Torque converter Type Single turbine, three members
2 Manufacturer ZF
3 Model 4WG158A
4 Type Fixed shaft type, power shift
Transmission Four forward gears and three reverse
5 Number of gears
gears
Operating pressure of shift oil pump
6 1.6~1.8MPa (232~261psi)
(gear pump)
7 Manufacturer LiuGong
8 Model LiuGong 3T wet-type axle
9 Type Wet-type alxe
Drive axle
10 Max. traction force 100kN (22480lbf)
11 Front & rear axle reduction ratio 20.2656
12 Rear axle swing angle 12°
13 Wheels Tire model 17.5-25 PR16/TL L-3
14 F1/ R1 7.1/ 7.1km/h (4.4/ 4.4mph)
15 F2/ R2 12.3/ 12.3km/h (7.6/ 7.6mph)
Traveling speed
16 F3/ R3 25.1/ 25.1km/h (15.6/ 15.6mph)
17 F4 38.6km/h (23.9/ 23.9mph)
Work hydraulic system
1 Work pump Type Piston pump
2 Work pump displacement ml/r (cc/rev) 100 (100)
1-26
Technical Specification of the Machine January 24, 2017
CLG835H

Main Components Specifications

3 System pressure Mpa (psi) 19 (2755)
4 Control valve / Three spools
5 System flow L/min (US gpm) 210 (55.48)
6 Lifting time (full load) s 5.5
7 Dumping time s 1.5
8 Float lowering time s 3.5
9 Total time s 9.7
Steering hydraulic system
1 Steering angle ° 38
2 Steering pump Type Piston pump
3 Steering pump displacement ml/r (cc/rev) Share with work pump
4 Steering system pressure Mpa (psi) 19 (2755)
5 Steering system flow L/min (US gpm) 210 (55.48)
6 Secondary steering pump Type Gear pump
Secondary steering pump
7 ml/r (cc/rev) 10 (10)
displacement
Secondary steering system
8 Mpa (psi) 16 (2320)
pressure
Secondary steering system
9 L/min (US gpm) 22-25l/min (5.8-6.6gpm) @52bar
flow
Brake hydraulic system
1 Service brake Type Full hydraulic wet type brake
2 Brake pump Type Gear pump
3 Brake pressure Mpa (psi) 6 (870)
Nitrogen pre-charge pressure
4 Mpa (psi) 5.5 (797.5)
of service brake accumulator
5 Parking brake Type Drum type parking brake
6 Parking brake control mode / Hydraulic control
Nitrogen pre-charge pressure
7 Mpa (psi) 9.2 (1334)
of parking brake accumulator
Air conditioner system
1 Type / Cooling & heating A/C
2 Heating capacity W 5800
3 Cooling capacity W 5000
4 Refrigerant Model R134a
Electrical system
1 System voltage / DC 24V

Refill capacities
1 Fuel tank L (US gal) 190 (50.2)
2 Engine oil L (US gal) 12 (3.17)
3 Cooling system L (US gal) 22 (5.8)
 1-27
January 24, 2017 Technical Specification of the Machine
CLG835H

Main Components Specifications

4 Transmission oil L (US gal) 40 (10.57)
5 Drive axle oil L (US gal) 34 (8.98)
6 Hydraulic oil L (US gal) 120 (31.7)
7 AdBlue L (US gal) 19 (5.02)
Other specifications
1 Cooling pump type / Gear pump
2 Cooling pump displacement ml/r (cc/rev) 27 (27)
3 Cooling pump flow L/min (US gpm) 59.4 (15.7)
4 Cooling motor displacement ml/r (cc/rev) 35 (35)
5 Cooling motor flow L/min (US gpm) 77 (20)
Nitrogen pre-charge pressure
6 of pilot oil supply valve Mpa (psi) 0.6 (87)
accumulator
Nitrogen pre-charge pressure
7 Mpa (psi) 2.5 (362.5)
of ride control accumulator
Note:
1. Continuing improvement and advancement are made to LiuGong products. All the specifications are the latest product
information obtainable at the time of publication. LiuGong will reserve the right to make change without notice.
2. The above parameters are the theoretical values, the tolerance ranges during testing are provided by LiuGong
standard.
1-28
Machine Inspection Table January 24, 2017
CLG835H

Machine Inspection Table

Inspec-
S/N Inspection method and acceptance criteria
tion item
Complete machine information: visual check the complete machine number for compliance with
1
description of model
Fastening bolt: visual check whether the left and right mounting bolts of front axle are tightened
2
firmly in place; visually check whether the left and right front rim bolts are firmly tightened
Fastening bolt: visual check the mounting bolts between front drive shaft and front axle, output
3
flange of transmission and middle bearing fastened;
Fastening bolt: visual check whether the emergency braking flexible shaft is connected reliably;
4
brake cylinder for oil leakage and connected reliably;
5 Fastening bolt: visual check whether mounting bolts of upper and lower hinge are tightened
Fastening bolt: visual check the left and right mounting bolts of rear axle are tightened; visually
6
check the left and right rear rim bolts are firmly tightened

Inspection 7 Water level: anti-freeze level shall be over the middle line in the level window of expansion tank
before test Oil: pull out the oil dipstick and the engine oil level shall be between the MIN and MAX marks of
8
run the dipstick, and the oil is not in white
Hydraulic oil: lay flat the bucket, lower the boom to the minimum at idling, and visual check the
9 oil level of the hydraulic oil tank is within the green scale and the oil is not in white 5 min after the
engine stalls
Transmission fluid: when the engine is idling and the transmission fluid temperature is not more
than 40 ℃ (104 ℉ ), check that the level shall be between cold fluid MAX and MIN marks. Then,
place the shift lever at four gear and depress the brake, then the accelerator to run the transmis-
10 sion for 5~8min resulting in the transmission fluid temperature reaching 100~110℃(212~230℉).
Release the accelerator and place the shift lever at neutral gear, then check that the level is
between hot oil MAX and MIN marks when the transmission fluid reaches a temperature more
than 80 ℃ (176 ℉ ).
Air-tightness: visual check each hydraulic line, cylinder, transmission, axle, oil tank, radiator, die-
11
sel engine for no leakage during inspection
1 Open and close the left and right doors of cab, and no seizing or abnormal sound should occur.
2 Shake the interior of the cab by hand and no looseness should occur
Turn on/off the dome light, radio, front and rear sunshade, cigarette lighter, and they should
3
function normally
Inflatable seat (option): the height and front & rear adjustment distance of the seat is obvious;
adjustment angle of left and right backrest armrest is obvious; move upward the handle at the
4
front of suspension, the suspension rises, otherwise goes down. There is no abnormal sound
and parts interference during air-filled detection.
Climbing up
Turning on the electric lock: turn on the front floodlight, work light, alarm light, parking light by
the cab 5
order and get off the vehicle to check if they function normally
Starting the complete machine: operate the engine speed adjustment switch and visual check
6
the corresponding change to the speed of the tachometer on the instrument panel.
Starting the complete machine: operate the switch of LCD to switch the voltage and timing dis-
7
play
8 Visual check: timer displays and record the time
Steering wheel: it can be adjusted front and rear, upper and down normally; no looseness after
9
locking. Lift the steering wheel upwards by hand and no axial runout occurs (≤3mm);
 1-29
January 24, 2017 Machine Inspection Table
CLG835H

Inspec-
S/N Inspection method and acceptance criteria
tion item
Horn: press the horn button on the lever of the horn button/control lever on the combination
Climbing up
10 lever horn button/steering wheel and listen, no abnormal sound and failure to the horn should
the cab
occur
The air volume switch, temperature setting switch, defrost setting switch, air mode switch, auto
mode switch on the A/C panel functions normally and is indicated correspondingly on the LCD;
1
the temperature, air volume, direction at the air outlet is the same with setting value on the
Air condition- panel.
ing system Self-diagnosis of A/C: press the "OFF" switch on the LCD panel, and the temperature setting
and air volume icon on the display disappears; press the up/down regulation button " " and " " on
2
the temperature setting switch "TEMP" simultaneously for more than 3 seconds. If "E-" appears
on the LCD, it indicates no failure, while "E1" appears, it indicates failures
Starting the complete machine: it starts normally, and listen to the engine and air filter, no abnor-
1 mal sound is heard, and it turns off normally without delay; observe the engine under the diesel
engine idling and top speed, and it shall not stall
Starting the complete machine: adjust the complete machine operating idle speed to a level
2
more than 950rpm and the engine does not stall with the bucket lifted
Starting the complete machine: visual check that no trouble code appears on the LCD of instru-
3 ment panel, and no indicating identification, alarm and flashing appears on the instrument panel
or normally on.
Rearview instrument system (option): when placing the shift lever at reverse, the rearview
4
instrument activates automatically and the image shall be clear
Control lever: there is no seizing and interference with other parts when operating the FNR han-
5
dle boom to rise, drop, take back and dump the bucket
Pilot shutoff function: the pilot shutoff lever is at OFF position, operate the pilot lever and the
6 work implement shall not act; the pilot shutoff lever is not installed reversely and has no interfer-
ence with housing;
Detection of bucket automatic reset: the bucket is unloaded, lift the boom to the highest position
to make the bucket under discharging state and then take back the bucket and it should stop
Driving test moving automatically and then control lever returns back to neutral position when the bucket
7
comes near to the switch and bucket limitation magnet. Then lower the boom to place the
bucket on the ground, at this time, check the bucket and it should be horizontal to the ground;
and the engine is at full throttle during this process
Detection of boom automatic reset: boom limitation: lift the boom and it should stop rising when
8 it reaches the setting highest position; the control lever returns back to neutral position automat-
ically. The engine is at full throttle during this process
Work implement limitation: visual check that the bucket limit block contacts with boom and
rocker arm limit block when the boom is lifted to the highest position for discharging; take back
9 the bucket when the boom descends to a position that its front pin is about 500mm(19.7In) away
from ground, visual check that boom limit block contacts after taking back the bucket and the
clearance between boom and bucket is more than 5mm(0.197In)
Inspection of work implement running: lift the boom during which no abnormal sound shall
10 occur; no twisting to the bucket during taking and holding back the bucket when the boom is
lifted to the highest position and lowest position;
Floating function and inner leakage detection: when jacking up the bucket backward, visual
check that the boom does not drop quickly; when the bucket is jacked up, push the control lever
11
to the boom lowering, floating position, and the control lever shall close, visually check that the
boom shall be floating and lowering
1-30
Machine Inspection Table January 24, 2017
CLG835H

Inspec-
S/N Inspection method and acceptance criteria
tion item
Ride control (option): park the machine on the level ground, disconnect the ride control system
12 button, jack up the shovel head; after 5 seconds, connect the ride control system button, and the
boom shall perform automatic lowering operation.
Visual check and listening: when turning to the maximum left and right steering angle, the limit
block contacts and no abnormal sound shall occur; visually check that there is no interference
13 between the armrest of cab and front frame, front and rear frame when turning to the maximum
left and right steering angle; there is no interference and pulling between hydraulic line&electri-
cal circuit and other sharp edges
W/steering cushion: turn the complete machine to the limit position, and the steering cushion is
14
compressed (8-12) mm
Secondary steering (option): turn on the electric lock without starting, the secondary steering
15 indicator on the instrument panel comes on when the secondary steering switch is pressed, and
the steering can be normally performed
Gear inspection: Manual 1) Place the manual/auto shift rocker switch to "Manual" 2) Start the
16 complete machine and idle; 3) Release the parking brake; 4) Operate the shift lever and all the
gears shall be available freely;
Gear inspection: Semi-automatic shift 1) Place the manual/auto shift rocker switch at neutral
position; 2) Start the complete machine and idle; 3) Release the parking brake; 4) Operate the
shift lever, and place it at F1 position, and the gear to complete machine transmission shall be
F1 5) Operate the shift lever, and place it at F2 position, and the gear to complete machine
transmission shall be F2; 6) Operate the shift lever, and place it at F3 position, and the gear to
complete machine transmission shall still be F2, depress the accelerator gradually to the maxi-
17
mum and hold it, increase the speed of complete machine, and when it reaches a certain value,
Driving test the gear shall automatically shift up to F3; 7) Keep the opening of throttle, and continuously
increase the vehicle speed and operate the shift lever and place it at F4, and when the speed
reaches a certain value, the gear shall automatically shift up to F4 from F3; (the corresponding
gear is displayed on the gear display during the above operation; and the corresponding speed
is displayed on the LCD of instrument panel)
Gear inspection: Full-automatic shift 1) Place the manual/auto shift rocker switch at "Auto" posi-
tion; 2) Start the complete machine; 3) Release the parking brake; 4) Operate the shift lever, and
place it at F3 position, depress the accelerator gradually to the maximum and hold it, when
speed reaches a certain value, the gear shall automatically shift up to F3 from F2; 5) Keep the
18
opening of throttle, and continuously increase the vehicle speed and operate the shift lever and
place it at F4, and when the speed reaches a certain value, the gear shall automatically shift up
to F4 from F3; (the corresponding gear is displayed on the gear display during the above opera-
tion; and the corresponding speed is displayed on the LCD of instrument panel)
KD function test: Place the shift lever at 2 with low speed, test the key KD on the control lever
19
and FNR respectively, press the key KD and the gear is switched to I
FNR lever test: place the control lever at N2 firstly. And then push the key of FNR lever to N. The
FNR function is activated after the enable key of the FNR lever is pressed. When the FNR func-
20
tion is activated, the FNR lever can be used to perform F(forward)\N(neutral)\R(reverse) and KD
function operation
Power shutoff function 1) place the power shutoff function selection switch at enable state; 2)
release the parking brake; 3) operate the shift lever and place it at F1 or F2 and drive the vehi-
cle; 4) depress the service brake pedal and when it reaches a certain level, the gear shall shift
21
down to neutral; and the power shutoff indicator on the instrument panel comes on; 5) release
the brake pedal, and the gear shall return back to F1 or F2; 6) the power shutoff fails when the
shift lever is placed at F3 or F4.
 1-31
January 24, 2017 Machine Inspection Table
CLG835H

Inspec-
S/N Inspection method and acceptance criteria
tion item
Backup alarm: when the shift lever is placed at reverse, the reverse alarm begins to perform
22
buzzing alarm immediately.
Brake system: Drive the vehicle for 10 laps, during which depress the brake pedal and the com-
23 plete machine is braked, two times per lap; no seizing shall be felt when depressing the acceler-
ator and brake pedal during driving
Fault alarm inspection: observe that no axle oil pressure, oil pressure, service brake, emergency
brake, transmission fluid pressure, hydraulic oil temperature alarm indicator on instrument panel
24
indicates alarm during driving; visual check that torque converter oil temperature, engine water
and oil temperature is displayed at green area;
Steering during driving: no seizing and heavy, floating is felt when turning to the left and right
25
during driving
Power train system inspection: listen to the diesel engine operation for abnormal sound; front
26 and rear axle for abnormal sound; gearbox & torque converter assembly for abnormal sound
during driving
Emergency brake: apply hand brake after climbing 15% of slope (for hand brake with lever, it
27 needs to pull the hand brake latch for 2/3 travel), and then release the brake valve, the complete
Driving test vehicle shall stay for 5 seconds and remain stationary
Pressure maintaining of hydraulic system: extend and retract all oil cylinders to the maximum
with control lever remained open at each end of travel to obtain safety valve pressure, which is
28
remained for about 5 seconds, continuously check it for 120 times with interval more than 10
seconds
Fan's positive and negative rotation (option): the engine is idling, press the fan's positive and
negative rotation switching switch for less than 60 seconds, and then fan can be switched to
29
negative rotation with indicator on; press the switch again for less than 60 seconds and the fan
is switched to positive rotation with the indicator off, no abnormal sound occurs during switching
Detection of rear axle swing angle: reverse the complete vehicle with single wheel on the slope
of vehicle inspection slot, visual check that the tire has no interference with frame, fender, rear
30
cover (with clearance more than 20 mm) pipe on axle has no interference with diesel engine
after stopping the vehicle
Centralized lubrication line: 1) fastened to pin lubrication pipe joints without oil leakage; 2) cen-
tralized lubricator time is correctly set; 3) oil pipe is not bent and twisted; 4) oil pipe runs
31
smoothly without interference with proper length and beautiful appearance; there is no pulling
interference during turning and operation of work implement
1-32
Machine Inspection Table January 24, 2017
CLG835H

Inspec-
S/N Inspection method and acceptance criteria
tion item
Visual check: gap of lapped surface at hinge between boom and frame, oil cylinder, rocker and
1
tie rod light is ≤1mm
Touch: there is no oil leakage at big cavity and small cavity pipe and joint of left and right boom
2 oil cylinder pipeline; visual check that there is no oil leakage at big cavity and small cavity pipe
and joint of bucket tilting cylinder pipeline
Touch: there is no oil leakage at left and right front axle clamp; no oil leakage at front axle input
3
flange; no oil leakage at axle housing and brake line joint on axle
4 Touch: ride control accumulator is installed firmly with the joint free of oil leakage
Touch: there is no oil leakage at transmission front output flange, transmission filler mounting
5
face, shift control valve, level window, level mouth, breather and brake cylinder
Touch: there is no oil leakage at steering gear and joint, pressure regulating valve, flow amplify-
ing valve, unload valve, combination valve, electric proportioning valve, steering pump, priority
6
valve, pilot valve, charge valve, mounting face of working pump and pipe joint; there is no water
leakage at heater pipe and water return pipe joints
Touch: there is no oil leakage at safety valve and oil inlet and return pipe joints to the boom,
bucket tilting, control valve, pilot hose joint on the control valve; visually check that there is no
7
interference between oil inlet and return pipe of control valve, pilot control pipe and other sharp
Static check edges, moving parts
Touch: there is no oil leakage at left and right steering oil cylinder pipe and joint; visually check
8 that there is no interference between steering and brake pipe and other sharp edges, moving
parts
Touch: there is no oil leakage at accumulator in transmission and brake pipe joint, pilot accumu-
9 lator, transmission oil filter and its joint, charge valve and its joint and hydraulic rising mecha-
nism
Touch: there is no oil leakage at bottom of hydraulic oil tank, flange, plug, level window, oil inlet
10
and return pipe joint and flange face
Touch: there is no oil leakage at diesel fuel tank and outlet pipe joint, diesel fuel tank body and
11
flange, plug
Visual check: the left and right semi-circles fender and rear fender is matched flush without
12
shaking
Visual check: rear cover with lifting mechanism is raised smoothly during which there is no inter-
13 ference with other parts; there is no interference between lifting jack and frame, radiator baffle;
there is no oil leakage at lifting cylinder joint
Visual check: rear cover is symmetrical at left and right sides; bottom of rear cover is attached
14
with counterweight, rear frame, left and right plate
 1-33
January 24, 2017 Machine Inspection Table
CLG835H

Inspec-
S/N Inspection method and acceptance criteria
tion item
Visual check: there is no interference between hydraulic oil tank and cab; there is no interfer-
15
ence between left and right hydraulic oil tank guard, foot pedal and driver
Visual check: diesel engine mounting bolt is fastened and there is no oil leakage at parts on left
side and oil pan; there is no interference between diesel engine oil pan and sub frame, rear
16
frame beam; no interference between diesel engine torque converter assembly oil return pipe
joint and intermediate plate of frame
Visual check+touch: there is no water leakage at upper and lower water pipe, cool and warm
17 water pipe and water valve; there is no oil leakage at pipe joints of filter, high pressure oil pump,
flywheel housing cover;
Visual check: there is no interference between brake line at left side of engine, filter and sharp
edges (harness is far away from high temperature area and not interfered with fuel pipe); there
18
is no interference between filters and sharp edges and other parts, and the hoses are not
twisted;
Visual check: urea heating pipe, cool water pipe, diesel particle filter water pipe runs smoothly
19
without interference and is far away from high temperature area.
20 Visual check: arrow of solenoid water valve shall face the urea tank.
Visual check: harness at upper side of diesel particle filter is far away from high temperature
21
area.
Static check Visual check: A/C pipe runs smoothly and is not interfered with other parts, diesel engine high
22
temperature area and the exposed A/C aluminium pipe is not interfered with other parts.
Visual check: the pulley belt is not twisted and peeled off; and the A/C compressor pulley is in
23
the same horizontal plane with diesel engine pulley;
Visual check: clearance between engine fan and shroud is ≥10mm, fan guard ≥15mm; the pul-
24
ley is not interfered with fan guard
Visual check + touch: there is no water and oil leakage at radiator assembly and its radiator pipe
25
joint;
Visual check+touch: there is no oil leakage at rear axle input flange, axle housing and plug, pipe
26
on axle, left and right clamp, breather; axle brake hose joint is not interfered with oil pan;
Visual check+touch: there is no oil leakage at radiator pipe at right side of engine, fuel pipe,
27 brake pipe, filter; there is no interference between filters and sharp edges and other parts, and
the hoses are not twisted
28 Visual check +touch: there is no oil leakage at radiator pipe reversing valve, fan pump joint;
Inspection of quick coupler: lower the bucket to the ground, shut it off and close the pilot shutoff
valve to OFF position. Turn the spool lever to COUPLER, start the machine, open the pilot shut-
29 off valve to OPEN. Operate the multi-functional pilot lever, and check the quick coupler frame
movable pin for free extending and retracting. Turn the engine off, close the pilot shutoff valve to
OFF position, and turn the spool lever to Aux position.
1-34
Machine Inspection Table January 24, 2017
CLG835H
 2-1
January 24, 2017 Power System
CLG835H

Power System
Basic Information ............................................................................................................2-3
Safety .....................................................................................................................................................2-3
Overview-components and position .......................................................................................................2-5
System technical parameters.................................................................................................................2-9
Universal tool, tooling list .....................................................................................................................2-10

Structure Function Principle ........................................................................................2-11

Engine system .....................................................................................................................................2-11
Overview ..........................................................................................................................................2-11
Diesel engine ...................................................................................................................................2-12
Intake and exhaust system ..................................................................................................................2-25
Intake and exhaust assembly...........................................................................................................2-25
Air filter .............................................................................................................................................2-28
Diesel Particle Filter System ................................................................................................................2-30
DEF pipeline assembly ........................................................................................................................2-31
DEF tank ..........................................................................................................................................2-33
DEF pump ........................................................................................................................................2-36
Cooling system ....................................................................................................................................2-38
Overview ..........................................................................................................................................2-38
Radiator group .................................................................................................................................2-43
Fan ...................................................................................................................................................2-45
Refilling and replacement of coolant ................................................................................................2-45
Fuel System .........................................................................................................................................2-46
Fuel Tank Assembly.........................................................................................................................2-46
Fuel Lines.........................................................................................................................................2-47

Removal and Installation ..............................................................................................2-49

Removal and installation of diesel engine............................................................................................2-49
Removal and installation of air filter .....................................................................................................2-64
Disassembly and assembly of air filter.................................................................................................2-67
Removal and installation of DPF (Diesel Particle Filter) ......................................................................2-71
Removal and installation of DEF pump................................................................................................2-75
Disassembly and assembly of DEF tank..............................................................................................2-79
Removal and installation of DEF(diesel exhaust fluid) pump...............................................................2-86
Disassembly and assembly of DEF pump ...........................................................................................2-88
2-2
Power System January 24, 2017
CLG877H

Removal and installation of radiator.....................................................................................................2-91

Disassembly and assembly of radiator ..............................................................................................2-100
Removal and installation of fan ..........................................................................................................2-106
Removal and installation of fuel tank .................................................................................................2-111
Removal and installation of fuel radiator ............................................................................................2-115

Fault Diagnosis and Troubleshooting .......................................................................2-118

Precautions for fault diagnosis ...........................................................................................................2-118
Common fault code and troubleshooting ...........................................................................................2-118
 2-3
January 24, 2017 Basic Information
CLG835H Safety

Basic Information Preventing Burns

After running for some time, parts of the machine

Safety will be hot,such as, engine, DPF (Diesel
Particulate Filter) and inter-cooler steel pipe,
those parts which are cooled down later shall be
Compressed Air inspected or repaired.
Compressed air may cause personal injury.
When using the compressed air for cleaning,
wear the mask, protection suits and shoes. The
maximum pressure of the compressed air for
cleaning should be lower than 25psi (0.2MPa).

Safe Disposal of Waste Fluids

P11000148
● Improper treatment of waste engine oil,
waste diesel and waste DEF is harmful to
environment and ecosystem. Treatment shall Coolant
conform with the local laws and regulations.
At working temperature, the coolant of the
● It is mandatory and necessary to collect the engine is at high temperature and has pressure,
liquid with containers spattered during the the radiator and all the pipes connected to the
inspection, maintenance, test, adjustment radiator contain hot water or vapor, if you touch
and repair of machine. Proper container shall them, serious burn would occur.
be prepared well before opening any fluid
cavity or disassembling the parts containing ● When checking the coolant level, the engine
liquid. Use proper container when draining shall be shut off and the filler cap shall be
liquid. cooled to the extent that it can be opened by
bare hands. Slowly loosen the filler cap of
● Do not use the food or drink containers cooling system to release the pressure.
because they may be drunk by others by
mistake. ● Coolant contains alkali which may causing
injury and do not let it contact your skin, eyes
and mouth.

P19M00059 P11000147

Fire & Explosion Prevention

● All fuels, such as most of lubricants and

some cooling agent are flammables.
2-4
Basic Information January 24, 2017
Safety CLG835H

● Fuel leaking onto the hot surface or electrical

elements may cause fire.
● Do not smoke when refilling or within refiling
area, and in the place storing flammables.

P11000157

● Store the fuel, lubricant into containers with

relevant marks to avoid use by non-working
personnel.
● Put the cleaning cloth or other combustible
materials with oil soaked into protective
container, and set it at a safe place.
● Do not perform welding or flame cutting onto
the pipe containing flammable liquid. Before
welding or cutting, it shall be shall be cleaned
completely with flammable liquid.
● Accumulated flammable materials such as
fuel, lubricant or other scattered materials on
the machine shall be cleaned up.
● Diethyl ether (Warning: Do not use diethyl
ether to start the engine)
● Any approach which attempts to start the
engine by use of diethyl ether may cause
serious damage to engine or casualties.

P11000158
 2-5
January 24, 2017 Basic Information
CLG835H Overview-components and position

Overview-components and position

Components and position

Power system has the function of converting chemical energy of fuel into mechanical energy to be sup-
plied to the machine. Power system includes engine system, radiator system and fuel tank assembly.
Among them, the engine mounting consists of engine, and the radiator mounting consists of cooler com-
ponents.
Module structure figure of power system

Engine mounting assembly

(Include the engine)

Intake and
exhaust assembly

Engine system Fuel lines

Filling system

DEF pipeline assembly

Radiator mounting assembly

(Include radiator group)
Power system Cooling system

Radiator pipe

Oil drain device

Fuel tank assembly

P18P00006
2-6
Basic Information January 24, 2017
Overview-components and position CLG835H

Position figure of power system in the machine

1
2

P18P00007

1. Engine system 2. Cooling system 3. Fuel tank assembly

 2-7
January 24, 2017 Basic Information
CLG835H Overview-components and position

Components of power system

6
2

3
4
P18P00008

1. Diesel particle filter DOC 3. DEF pump 5. Radiator mounting assembly

2. Diesel engine 4. DEF tank 6. Oil-water separator
2-8
Basic Information January 24, 2017
Overview-components and position CLG835H

Components of power system

12

7 11

10

P18P00009

7. Air filter 9. Oil drain device 11.Diesel particle filter SCR

8. Fuel fine filter 10.Solenoid water valve 12.Exhaust pipe
 2-9
January 24, 2017 Basic Information
CLG835H System technical parameters

System technical parameters

Model Perkins 1204F-E44AT

Type In line-four cylinders, four-stroke, turbocharged
Emission EPA Tier4 Final
*Rated power 97.9kW/2200r/min(133.144PS/2200rpm)
Engine *Maximum idling speed 2376±50rpm
*Minimum idling speed 800±50rpm
Engine oil level 7.7L (2.03434USgal)
Clockwise ( viewed from the fan end to flywheel
Direction of rotation
housing end)
Diameter of 880mm(34.6456In), 12 pieces of
Fan
blades, air suction type
Cooling system
Opening temperature: 82°C(179.6°F)
Thermostat
Fully open temperature: 94°C(201.2°F)
Engine oil system Oil filter Full flow type and replaceable (filter can rotate)
Preheating system Preheating method Grid heater
Core type Plate-fin type
Water radiator 870mm X 454mm X 120mm
Core size (height × width × thickness)
(34.2519In X 17.87398In X 4.7244In)
Core type Plate-fin type
Hydraulic oil radiator 870mm X 166mm X 120mm
Core size (height × width × thickness)
(34.2519In X 6.53542In X 4.7244In)
Core type Plate-fin type
Torque converter oil radiator 870mm X 264mm X 120mm
Core size (height × width × thickness)
(34.2519InX 10.39368In X 4.7244In)
Core type Plate-fin type
Air-air intercooler 870mm X 178mm X 120mm
Core size (height × width × thickness)
(34.2519In X 7.00786In X 4.7244In)

Notes: Data marked with * is based on engine with fuel system and water pump under intake resistance
of 380 mm H2O (3.72 kPa) and exhaust resistance of 160.5 mm Hg (21 kPa) not including alternator,
fan, optional configurations and drive components.
2-10
Basic Information January 24, 2017
Universal tool, tooling list CLG835H

Universal tool, tooling list Precautions on removal and installation:

1. Assembly and disassembly must be carried

Name Specification out when engine is cool. In general, open
engine hood after engine is shut down, and
7#, 8#,10#, 11#, 12#, 13#, 16#,
Open-end wrench
18#, 19#, 20#, 22#, 24#, 30# wait for 15 minutes before the engine is
cooled down.
Ratchet wrench, 10#, 11#, 12#,
Ratchet wrench,
socket
13#, 16#, 18#, 19#, 20#, 22#, 24# 2. Measurement equipment and tools such as
and 30# socket torque wrench, etc. shall have compliance
120±6N.m(12±0.6kgf.m), certificates issued by metrological depart-
Torque wrench
1020±6N.m(102±0.6kgf.m) ment;
Traveling crane More than 2t (4410Ib)
3. Because many other related components on
Wire rope with Weight load over 840Kg the complete machine are concerned during
hooks (1852.2Kg) the removal and installation of each compo-
Steel ruler Steel ruler nent, removed components (especially stan-
Straight screw- dard parts) shall be reasonably placed to
driver avoid wrong installation, neglected installa-
Cross screwdriver T25 tion, part missing, etc. during reassembly.
Lifting eye 4. If the removal and installation of other com-
Plastic sealing ponents on the complete machine are con-
membrane cerned in the removal and installation of each
Waste oil tank component, tools are referred to the tool list
Remarks:
for the removal and installation of other com-
ponents and not listed in the tool list of this
component;
5. If the expected effect can be reached in the
ways of using open-end wrench, blower gun
and socket as well as ratchet wrench and
socket to remove and install, anyone can be
chosen.
 2-11
January 24, 2017 Structure Function Principle
CLG835H Engine system

Structure Function Principle

Engine system

Overview

Components and position

The diesel engine mounting assembly is composed of diesel engine, bracket and shock absorber.

1
3

2
P18P00009

1. Diesel engine 2. Bracket 3. Shock absorber

Working principle description

Engine mounting as has the function of realizing effective installation of engine.

The working principle of engine as is as follows: engine is fixed on complete machine via engine mount-
ing composed of mounting support and shock absorber, engine has excellent working environment
through shock isolating action of shock absorber, vibration of engine transferred to complete machine is
reduced, and riding comfort is improved.
Generally, requirements for the engine assembly are as following.
1. Active and static loads can be supported under all working conditions, and engine assembly has dis-
placements in all directions within acceptable range and does not interfere with other parts on chas-
sis. Meanwhile, before repairing the engine, there are no damaged parts.
2. Vibration generated by engine can be sufficiently isolated from being transferred to frame and cab,
and cab operating comfort and service life of complete machine components are improved.
2-12
Structure Function Principle January 24, 2017
Engine system CLG835H

3. Impact generated by uneven roads can be effectively isolated from being transferred to engine
through engine mounting, and influence of road impact on engine is reduced.

Diesel engine

Technical parameters

Model Perkins 1204F-E44TA

Number of cylinder 4
Cylinder diameter 105 mm (0.344505ft)
Stroke 127 mm (0.416687ft)
Displacement 1.16248USgal
Suction mode Turbocharged inter-cooled
*Rated power 97.9kW/2200r/min (133.144PS/2200rpm)
*Maximum idling speed 2376±50rpm
*Minimum idling speed 800±50rpm
 2-13
January 24, 2017 Structure Function Principle
CLG835H Engine system

Part Structure and Principle Introduction

External view of Perkins engine 1204F-E44TA

3
1 2 4

13

12 6

11

10
7

9
8 P18P00010

1. Front lifting eye 6. Pnmiog/trarferfuel pump 11.Oil sampling vafve

2. Crankcase breather 7. In line fuel fitier 12.High-pressure fuel pump
3. Secondary fuel filter 8. Oil level gauge (dipstick) 13.Oil filler
4. Primary fuel fitter 9. Oil drain plug
5. Electronic Control Module 10.Oil filter
2-14
Structure Function Principle January 24, 2017
Engine system CLG835H

14

15

16

17
19

18

P18P00012

14.Air intake 16.Water pump 18.Tensioner

15.Coolant outlet 17.Coolant intake 19.Belt
 2-15
January 24, 2017 Structure Function Principle
CLG835H Engine system

21
20 22
23

32
24
31

30

25

26
29
27
28 P18P00012

20.Back pressure valve 25.Starter solenoid 30.Flywheel housing

21.Htgh-pressure turtoocharger 26.Starting motor 31.NOx reduction cooler
22.Low-pressure turbocharger 27.Starter relay 32.Rear lifting eye
23.Alternator 28.Oil dram tap
24.Refrigerant compressor 29.Flywheel
2-16
Structure Function Principle January 24, 2017
Engine system CLG835H

The diesel engine is generally composed of two major mechanisms and four systems:

 Engine body
and cylinder head

Crank rod
connection mechanism

Air distribution mechanism

Diesel engine Cooling system

Lubrication system

Fuel system

Auxiliary system
P18P00014

Engine body
Basic body of engine and cylinder
head

It is the frame of engine, and

composed of cylinder block, Engine body
crankshaft case and oil pan.

P18P00014
 2-17
January 24, 2017 Structure Function Principle
CLG835H Engine system

It is located at top of cylinder

block, and used for sealing the
cylinder head, and forms a com-
bustion chamber together with
cylinder and piston. It is usually Cylinder head
installed with nozzle, air intake/
exhaust valve, intake/exhaust
pipe and rocker arm shaft
assembly.

P18P00016

Machine body and work compo-

nent, which is composed of pis-
ton group, connecting rod Crank rod con-
group, crankshaft flywheel nection mecha-
group, and used for converting nism
the chemical energy of fuel into
mechanical energy for output.

P18P00017
2-18
Structure Function Principle January 24, 2017
Engine system CLG835H

3 It is composed of piston, piston

ring and piston pin.
Piston: piston head is a part of Piston group
combustion chamber, with the
shape of dome head, flat head,
4 crown head

1. Gas ring 3. Piston

2. Oil ring 4. Piston pin P18P00018

It is composed of connecting
rod, connecting rod bolt and
connecting rod bearing. The
connecting rod is used for con- Connecting rod
verting the reciprocating motion group
of piston into the rotation motion
of crankshaft, and transferring
the force of piston to crankshaft.

P18P00019
 2-19
January 24, 2017 Structure Function Principle
CLG835H Engine system

It is composed of crankshaft, fly- Crankshaft fly-

wheel and torsion damper wheel group

P18P00020

5
≊䰶ᇚ㖟
1

It is composed of valve group

2
京ᵼ and valve train, and mainly used
for controlling the intake/
exhaust process of engine and Air distribution
ensuring that the fresh air is mechanism
filled into the cylinder timely and
3京ḧ making the exhaust gas out of
࠮䖤 ≊䰶 the cylinder in time.
4
6

1. Bucket lever 4. Cam

2. Push rod 5. Air valve chamber cover
3. Ejector pole 6. Air valve

P18P00021
2-20
Structure Function Principle January 24, 2017
Engine system CLG835H

It is composed of valve, valve

guide, valve seat ring, valve
Valve group
2 spring, valve rotating mecha-
4 nism

1. Valve guide pipe 3. Valve spring

2. Valve 4. Valve seat ring
P18P00022

2
1. Bucket lever
2. Push rod It is composed of camshaft, tap-
3. Ejector pole pet, push rod, rocker arm, timing Valve train
4.Cam shaft gear

4
P18P00023

Guarantee working under suit-

able temperature. It is com-
Cooling system
posed of water pump,
thermostat and water channel
 2-21
January 24, 2017 Structure Function Principle
CLG835H Engine system

It is used for increasing the

pressure of cooling water to
accelerate the cycle of cooling
Water pump
water in the cooling system to
enhance the heat radiating abil-
ity

P18P00024

It is used for controlling the cool-

ing water to pass major cycle or
minor cycle depending on the
Thermostat
cooling water temperature to
make the engine operate under
the proper temperature

P18P00025

It is built into the machine body

to allow the cooling water flow
Water channel
over each component to be
cooled

4 Components:
Oil pan, oil pump, oil radiator, oil
5 filter

1 6
Function:
Lubrication sys-
2 It is used for transferring the tem
proper amount of lubricant to
3 the system where the part to be
1. Coarse filter 4. Main oil gallery lubricated locates and its attach-
2. Fine filter 5. Engine oil pump ment to ensure the normal oper-
3. Engine oil pan 6. Secondary filter
ation of engine
P18P00026
2-22
Structure Function Principle January 24, 2017
Engine system CLG835H

It is composed of fuel coarse fil-

ter (oil-water separator),fuel
delivery pump,fuel fine filter,fuel
injection pump,injector,fuel pipe Fuel system
and combustion chamber,and
used for supplying fuel to
engine.

It is used for filtering the larger

Fuel coarse fil-
particles of impurity and
ter (oil-water
installed at the front of fuel inlet
separator)
line (fuel delivery pump)

P18P00027

Start and generate power, etc. Auxiliary system

The starter motor is energized

and rotates to drive the crank-
shaft of engine to rotate and Starting system
allow it transmitted to a state of
running itself from static state.

P18P00028
 2-23
January 24, 2017 Structure Function Principle
CLG835H Engine system

P18P00029

It is used for charging the bat-

tery when the engine operates
to ensure that the battery can Alternator
provide high enough voltage
during the engine cranking

P18P00030

It pushes the turbo to drive the

vane rotating at high speed by
using the high speed of exhaust
to increase intake pressure and Turbocharger
improve intake quantity (intake
density), and finally improve
engine power and economy.

P18P00031
2-24
Structure Function Principle January 24, 2017
Intake and exhaust system CLG835H

Intake and exhaust system

Intake and exhaust assembly

Components and position

Intake and exhaust assembly consists of air pre-filter, air filter, diesel oxidation catalyst (DOC), selective
catalytic reducer (SCR) and exhaust pipe.

1
4

P18P00032

1. Air filter 3. Selective catalytic reducer (SCR)

2. Exhaust pipe 4. Diesel oxidation catalyst (DOC)

Description of principle diagram and working principle

The functions of the intake and exhaust assembly are:

1. Supply clean and dry air with proper temperature for engine to burn so as to minimize engine wear
and optimize engine performance;
2. Keep all exhaust gases safely away from engine and discharge them into atmosphere quietly while
optimizing engine performance.
 2-25
January 24, 2017 Structure Function Principle
CLG835H Intake and exhaust system

Working principle of the intake and exhaust assembly: air is taken in through air pre-filter. There are
rotating blades inside the air pre-filter, which can discharge big dust in intake air from the bottom of air
pre-filter. Intake air reaches air filter, filter element removes small dust and moisture to obtain clean and
dry air to be sent to turbocharger, the turbocharger is driven by engine exhaust to pressurize intake air
and increase intake quantity, and sufficient combustion of fuel can be ensured. Air coming out of turbo-
charger goes through air-air intercooler in cooling system and electric heater of engine itself to obtain
proper temperature and then enters engine block to burn. Exhaust gas generated after combustion
reaches turbocharger via exhaust manifold, drives turbocharger to pressurize intake air and is then dis-
charged to DPF (Diesel Particle Filter). When exhaust gas gets to diesel particle filter DOC, particulates
will be oxidized to CO2. Then enters into decomposition reactor tube (DRT). Urea solution injected to
DRT from the outside will break down to form ammonia gas and mingle with exhaust gas. When gas
mixture including exhaust gas and ammonia gas enters into diesel particle filter SCR, under the reaction
of catalyzer, nitride oxides will be broken down into nitrogen and water. Finally, exhaust gas pollutants
content injected into the atmosphere will be greatly reduced, conforming with Euro IV emission require-
ment.

Air intake path figure of engine:

2 
Cold gas 

3
Hot gas

P18P00033

1. Air pre-filter 2. Air filter 3. Turbocharger

2-26
Structure Function Principle January 24, 2017
Intake and exhaust system CLG835H

Exhaust path figure of engine:

 Cold gas 

Hot gas 

1
P18P00034

1. Turbocharger 2. Diesel oxidation catalyst DOC 3. Selective catalytic reducer SCR

 2-27
January 24, 2017 Structure Function Principle
CLG835H Intake and exhaust system

Air filter

Technical parameters

P18P00035
2-28
Structure Function Principle January 24, 2017
Intake and exhaust system CLG835H

Part Structure and Principle Introduction

The air filter is composed of housing, main filter,safety filter and end cover. Air filter ensures clean and
dry air to enter engine through main filter element and safety filter element. When engine operates, air
enters air filter through pre-filter, and is filtered by main filter element and is then secondarily filtered by
safety filter element,as shown in figure below:

4
1
2 3
P18P00036

1. Shell 2. Safety filter element

1. Main filter element 3. Cover

Dirty air gets

into pre-filter part

Clean air gets

into engine

Air flow with dust

P18P00037

Air filter blocked alert of this machine is the electronic induction type. When the filter works for a period of
time, much dust is accumulated on filter element, and air resistance through filter is increased. When
circulating air resistance is above 6.2KPa (0.0632214kgf/cm³), air filter blockage sensor installed
between air filter and turbocharger will transmit signal to air filter alert indicator on instrument panel.
When the indicator goes on, air filter shall be maintained.
 2-29
January 24, 2017 Structure Function Principle
CLG835H Diesel Particle Filter System

Diesel Particle Filter System

Part Structure and Principle Introduction

The main function of DPF (Diesel Particle Filter) is to reduce the harmful substance of engine exhaust in
order to conform with emission standard. Particulates and NOx emission of the model conform with the
emission standard of Tier 4Final/Euro Stage IV.

Exhaust

P18P00038

1. DOC 2. DEF nozzle 3. SCR

Terminology:

DOC: Diesel Oxidation Catalyst

SCR: Selective Catalytic Reduction
Diesel particle filter of the model adopts DOC+SCR routine. When exhaust passes DOC, under the
function of catalyzer, hydrocarbon HC is oxidized to CO2 and water. When exhaust passes SCR, nitride
oxides NOx is reduced to nitrogen and water.
The reaction in the DOC:
HC (Hydrocarbon Compounds ) + O2 → H2O + CO2
The reaction in the SCR:
NOx(nitrogen oxides) + NH3(ammonia)+ O2 → (catalytic reaction) → N2 + H2O.
2-30
Structure Function Principle January 24, 2017
DEF pipeline assembly CLG835H

DEF pipeline assembly

Components and position

DEF pipe-line assembly includes DEF tank, DEF pump, DEF pipe-line and water way.

4
1

P18P00039

1. DEF tank 3. DEF pipe-line

2. DEF pump 4. Water way
 2-31
January 24, 2017 Structure Function Principle
CLG835H DEF pipeline assembly

Description of principle diagram and working principle

The function of DEF pipe-line is to provide appropriate amounts of DEF for DPF (Diesel Particle Filter)
system in order to reduce nitride oxides content of exhaust. DEF is pumped to DEF pump from DEF tank
via outlet pipe and then transported to injector via pressure pipe. Excess urea returns urea pump from
the return pipe.

DEF flows out of tank

DEF flows back to tank

DEF flows back to nozzle

1
P18P00040

1. DEF tank 3. DEF liquid return pipe 5. DEF pressure pipe

2. DEF outlet pipe 4. DEF pump 6. Nozzle
2-32
Structure Function Principle January 24, 2017
DEF pipeline assembly CLG835H

Water way is used to transfer engine coolant to DEF tank and heat the DEF solution avoiding the crystal-
lization. When urea temperature is less than -8°C(17.6°F), the solenoid water valve of water way opens,
and engine coolant enters into urea tank to prevent urea solution from freeze, however, when urea tem-
perature exceeds 5°C(41°F), the solenoid water valve of water way closes to prevent urea solution from
precipitation out because of being excessively heated.

1
Water effluent from engine

Engine returning water

P18P00041

1. DEF nozzle 3. Engine returning water inlet 5. DEF tank

2. Engine water outlet 4. Solenoid water valve

DEF tank

Technical parameters

USABLE VOLUME 19.3L

DEUTSCH DT04-4P
PIN #1: CAN LOW
ELECTRICAL CONNECTOR: PIN #2: CAN HIGH
PIN #3: GROUND
PIN #4: POWER
 2-33
January 24, 2017 Structure Function Principle
CLG835H DEF pipeline assembly

Part Structure and Principle Introduction

The function of DEF tank is to store DEF solution and provide DEF for DPF (Diesel Particle Filter) during
the machine operates. DEF tank consists of shell, multi-functional head unit and cover. There are three
sensors in the multi-functional head unit: temperature sensor, liquid level sensor and quality sensor.
Temperature sensor detects DEF solution temperature and transports signal to ECM, when DEF temper-
ature is less than -8°C, the solenoid water valve is opened, and engine coolant enters into def tank to
prevent DEF solution from freezing, however, when DEF temperature exceeds 5°C, the solenoid water
valve is closed to block coolant entering and prevent DEF solution from being excessively heated. Fuel
level sensor detects the surplus of DEF solution and transports signal to ECM, if DEF fuel lever is less
than alarm value, the situation will trigger low fuel lever alarm and remind the operator of adding DEF.
Mass sensor detects DEF mass, if user wrong adds other oils or water,or the concentration of DEF solu-
tion is unqualified, these situations will lead to alarm and remind the operator of adding DEF.

Multifunction DEF Header Unit

1
4
Fill Cap

2Tank Fill Port Adapter

5

P18P00042
1. Multifunction DEF Header Unit 3. Drain Plug 5. Fill Port Adapter
2. Tank 4. Fill Cap
2-34
Structure Function Principle January 24, 2017
DEF pipeline assembly CLG835H

Multi-functional head unit

6
Electrical connection
flying lead - 375 mm long

4
2
7

5
8

1
3

P18P00043

1. DEF level and temp sensor assembly 4. DEF outlet 7. DEF inlet
2. DEF tank heating tube (engine coolant flow 5. Coolant inlet 8. Coolant outlet
internally) 6. Electrical connection flying lead - 375mm
3. DEF suction filter on pick up long
 2-35
January 24, 2017 Structure Function Principle
CLG835H DEF pipeline assembly

DEF pump

Part Structure and Principle Introduction

Urea pump will pump urea solution from urea tank, and the urea solution is transported to the nozzle of
diesel particle filter after filtering.

1 Cap for serviceable

DCU 11 filter on top of unit
2

Mounting 10
Mounting Tab
Tab

9
Vent

Harness
PEU Harness 8 Restraint
3 Connectror

DEF flows into DEF pump

Mounting
Tab 4 DEF flows toward nozzle
Mounting Tab
7

DEF Outlet to injector DEF inlet from Tank

6
5
P18P00044

1. DCU 5. DEF Outlet to injector 9. Vent

2. Mounting Tab 6. DEF inlet from Tank 10.Mounting Tab
3. PEU Harness Connectror 7. Mounting Tab 11.Cap for serviceable filter on top of unit
4. Mounting Tab 8. Harness Restraint
2-36
Structure Function Principle January 24, 2017
DEF pipeline assembly CLG835H

P18P00045

1. Protection shield 2. Strainer assembly 3. Housing

 2-37
January 24, 2017 Structure Function Principle
CLG835H Cooling system

Cooling system

Overview

Components and position

The radiator system is composed of radiator mounting, radiator pipe and oil drain device.

3
1
P18P00046

1. Radiator mounting 2. Radiator pipe 3. Oil drain device

2-38
Structure Function Principle January 24, 2017
Cooling system CLG835H

Description of principle diagram and working principle

Cooling system comprises a radiator and corresponding connecting lines, where the radiator is com-
posed of a water radiator, an air-air intercooler, a hydraulic oil radiator and a torque converter oil radiator.
Its function is to radiate heat produced by each part (or system) into the air along with cooling air in order
to ensure each part works properly in appropriate temperature range.
As shown below, diesel engine cooling system mainly comprises a radiator (water tank), a water pump, a
fan, a thermostat, an engine oil cooler, water intake and outtake pipes, etc.

3 2 1 10
9

5 6
6 7
4

P18P00047

1. Water outlet pipe assembly 5. Fan 9. Heating valve

2. Small circulation 6. Water pump 10.Water temperature sensor
3. Thermostat 7. Engine oil radiator
4. Radiator 8. Water drain valve
 2-39
January 24, 2017 Structure Function Principle
CLG835H Cooling system

Cooling system of this machine adopts hydraulic to drive fan and adopts suction mode to cool. The
system adopts forced closed circulating water cooling system. Working principle of system is as follows:
water outlet at lower part of cooler is connected with water inlet of engine oil cooler via water hose, water
outlet of engine oil cooler is connected with water pump via water hose, water pump pumps coolant into
cylinder block water passage, coolant firstly cools cylinder through water jacket inside cylinder block,
then flows up to cool cylinder head, and is collected by water outlet header pipe to reach thermostat.
When coolant temperature is lower than 84°C(183.2°F), thermostat is closed, and all coolant is
bypassed to water pump inlet. At the moment, coolant is only circulating between cylinder block and
cylinder head, so that warm-up can be quickly realized. When coolant temperature is above
82°C(179.6°F), thermostat starts to be opened, part of coolant flows to water inlet at upper part of cooler
and enters radiator to be cooled by cooling fan. When coolant temperature is above 95°C(203°F),
thermostat is totally opened, bypass hole is closed, and all coolant is cooled by radiator. The coolant
flowing direction at the moment is shown in the chart.

Engine water circulation

P18P00048

1. Engine 2. Water radiator

2-40
Structure Function Principle January 24, 2017
Cooling system CLG835H

Air-air intercooler radiator

Air-air intercooler has the main function of cooling high-temperature high-pressure gas across
turbocharger and reducing temperature of air entering engine combustion chamber to increase air
density. Its working principle is shown in Fig. below. After air is pressurized by turbocharger, temperature
rises up sharply, pressure is increased, air flows into air-air intercooler from left air pipe and passes
across core of air-air intercooler, external cooling air flows by outside the core to bring away heat of air
inside intercooler so as to reduce its temperature to be lower than 80°C(176 °F), and then, the air flows
into engine intake manifold and cylinder from right air pipe of air-air intercooler.

4
1

2
9
8
P18P00049

1. Booster air inlet 4. Air-air intercooler radiator 7. Cylinder

2. Booster air outlet 5. Pressurized hot air 8. Exhaust gas
3. Pressurized cold air 6. Intake branch pipe 9. Muffler
 2-41
January 24, 2017 Structure Function Principle
CLG835H Cooling system

The air-air inter cooler radiating system of the vehicle arranged as the drawing below.

P18P00050

1. Air-air intercooler 2. Turbocharger

Hydraulic oil radiator

Hydraulic oil radiator has the main function of radiating heat generated by hydraulic oil during the work-
ing of hydraulic system to avoid temperature of hydraulic oil line from being too high.
2-42
Structure Function Principle January 24, 2017
Cooling system CLG835H

Torque converter oil radiator

Torque converter oil radiator has the main function of radiating heat generated by torque converter oil
during the working of transmission and torque converter to avoid temperature of torque converter and
transmission from being too high and ensure normal working of machine.

P18P00051

Radiator group
Technical parameters
Core type Plate-fin type
Water radiator 870mm X 454mm X 120mm
Core size (height × width × thickness)
(34.2519In X 17.87398In X 4.7244In)
Core type Plate-fin type
Hydraulic oil radiator 870mm X 166mm X 120mm
Core size (height × width × thickness)
(34.2519In X 6.53542In X 4.7244In)
Core type Plate-fin type
Torque converter oil radiator 870mm X 264mm X 120mm
Core size (height × width × thickness)
(34.2519InX 10.39368In X 4.7244In)
Core type Plate-fin type
Air-air intercooler 870mm X 178mm X 120mm
Core size (height × width × thickness)
(34.2519In X 7.00786In X 4.7244In)
 2-43
January 24, 2017 Structure Function Principle
CLG835H Cooling system

Part Structure

The radiator assembly is composed of air-air intercooler, water radiator, hydraulic oil radiator and torque
converter oil radiator.

2
3

P18P00052

1. Water radiator 3. Air-air intercooler

2. Hydraulic oil radiator 4. Torque converter oil radiator
2-44
Structure Function Principle January 24, 2017
Cooling system CLG835H

Fan 6. Slowly open auxiliary tank cover (wait until

engine coolant temperature drops to be
Technical parameters below 50°C\122°F), slowly add coolant until
coolant level is within 1 cm higher than well-
Number of
Diameter Mode head bottom, and remain stable within ten
vane minutes.
880mm\ Induced
Fan 12
34.6456In draft

Refilling and replacement of coolant

1. Completely mix water and anti-freeze in

advance according to selected cooling pro-
portion.
2. Park machine on flat ground, apply parking P18P00054
brake and shut down engine.
3. Turn on the power switch (-); insert the key
Base of the wellhead
into the start switch and turn to 1st gear
clockwise to power on the machine, pull the
change-over switch of air conditioning sys-
tem to heating position.
4. Open engine hood, and turn the manual
valve on the water inlet pipe of engine to ON
position (at which, valve handle is consistent P18P00055
with line route).
7. Tighten auxiliary tank cover, start engine,
firstly operate it for 5 minutes at low idle
speed, then operate it for 5 minutes at high
idle speed, and increase coolant temperature
to be above 85°C(185°F).
8. Check coolant level through inspection win-
dow once again, and after engine coolant
temperature drops to be below 50°C(122°F),
continue to refill coolant until level is within 1
P18P00053 cm higher than wellhead bottom as neces-
sary.
5. (Only operate this step in replacing coolant.)
Put a container with the capacity of about 35 9. Close the engine hood.
L at rear left side of machine, connect one
hose into water drain valve of drain hose,
unscrew auxiliary tank cover, loosen water
drain valve so that coolant flows into the con-
Do not only use the water as coolant
tainer, and tighten water drain valve after
draining coolant. When filling coolant, air in engine cooling
system pipe shall be discharged,
Do not refill coolant into hot engine to avoid
possible damages to engine body. Wait until
engine temperature is below 50°C(122°F).
 2-45
January 24, 2017 Structure Function Principle
CLG835H Fuel System

Fuel System

Fuel Tank Assembly

Technical parameters

Effective volume 193L (50.9906USgal)

Part Structure and Principle Introduction

The fuel tank assembly is mainly composed of fuel tank, filler pipe, breather pipe, fuel tank cover.

P18P00056
2-46
Structure Function Principle January 24, 2017
Fuel System CLG835H

Fuel Lines

Overview-components and position

The fuel line is composed of fuel hose, fuel filter and fuel radiator.

P18P00057

1. Fuel radiator 3. Fuel hose

2. Oil-water separator 4. Fuel pump
 2-47
January 24, 2017 Structure Function Principle
CLG835H Fuel System

Description of principle diagram and working principle

6 3

P18P00058

1. Fuel tank 3. Oil transfer pump 5. Oil-water separator

2. Fuel filter 4. High-pressure fuel pump 6. Fuel radiator

Fuel system acts to provide engine with clean and sufficient fuel, which thus ensures proper operation of
engine. Its working principle is shown above: when engine works, oil transfer pump sucks fuel from fuel
tank, then oil-water separator eliminates water from fuel, next fuel filter eliminates Impurities from fuel,
and finally fuel enters high pressure fuel pump. The fuel is pressurized by the high pressure fuel pump
and filled into high pressure common rail. Then, the fuel in the common rail enters into injector, while the
spare fuel returns back to the outlet of high pressure fuel pump. The injector is controlled by ECM. The
diesel fuel is injected into combustion chamber, while the spare fuel returns back to the outlet of high
pressure fuel pump and then back to fuel tank after cooled.

Fuel radiator

The fuel radiator is used for cooling the hot fuel that returns back from engine fuel pump to avoid the hot
fuel directly flowing back to the fuel tank and heating the fuel in it.
2-48
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Removal and Installation

Removal and installation of diesel engine

Removal

Figures Contents Tools

1. Turn off the negative elec-
trode switch, and hang on a
"No operating" warning
board.

P18P00059
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P18P00060
 2-49
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

1. Remove the engine hood
top cover according to
removal and installation
requirements and steps of
engine hood.
2. Remove air filter according
to the removal steps of air fil-
ter and seal every port with
plastic seal membrane as
required.
3. Remove diesel particle filter
and connecting pipe accord-
ing to the removal steps of
diesel particle filter and seal
every port with plastic seal
membrane as required. Plastic sealing
membrane
4. Drain the cooled water in the
engine to oil collection dish Oil collecting
for unified disposal. basin
5. Remove electrical connector
and wiring on engine
according to removal and
installation requirements
and steps of electrical sys-
tem.
6. Remove A/C compressor, A/
C pipe and warm air hose
from the engine according to
removal and installation
requirements and steps of
air conditioning system, and
seal every ports with plastic
sealing membrane as
required.
2-50
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Figures Contents Tools

7. Unscrew the fuel pipe joint
screw connected to the die-
sel engine fuel pump with
wrench. Remove the screw,
seal gasket and keep them
in a plastic bag. Mask the Tool:
fuel pipe joint with sealing Open-end
membrane. wrench 19#
Plastic sealing
bag
Plastic sealing
membrane

P18P00061

8. Unscrew the intercooler pipe

fixing clamp and bracket.
Unscrew the clamps at both
ends of intercooler pipe,
Tool:
unplug the pipe and seal
every port with plastic seal Open-end
membrane. wrench 12#, 16#
Plastic sealing
membrane

P18P00062

9. Unscrew the clamp at the

connection of intake pipe
and engine, unplug the
intake pipe. Unscrew the Tool:
connecting clamp between
intake pipe and intake hose, Open-end
take off the intake pipe. Seal wrench 8#
every port with plastic seal- Plastic sealing
ing membrane. membrane

P18P00063
 2-51
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

10. Unscrew the clamp at the
connection of water inlet
pipe, outlet pipe and engine,
unplug the water inlet pipe,
outlet pipe and seal every
port with plastic seal mem- Tool:
brane. Open-end
wrench 8#
Plastic sealing
membrane

P18P00064

11. Unscrew the clamp at the

connection of water inlet
pipe and engine, unplug the
water inlet pipe and seal
every port with plastic seal
membrane.
Tool:
Open-end
wrench 7#
Plastic sealing
membrane

P18P00065
2-52
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Figures Contents Tools

12. Unscrew the 4 bolts on the
heat insulation bracket, and
tilt it to the radiator direction
by an angle to avoid interfer-
ence when lifting the engine.

P18P00066
13. Slowly operate traveling
2 crane, hang lifting eye on
1
engine with hook on wire
rope, and tauten wire rope
without lifting engine.

Tool:
Traveling crane
Wire rope with
hooks

1. Lifting eye
2. Lifting eye P18P00067
 2-53
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

14. Remove captive bolts on
connecting surface of
engine and torque con-
verter & engine flywheel
according to removal and
installation requirements
and steps of transmission &
torque converter assembly.

P18P00068

15. Hold fixing nut of engine with

an open-end wrench, and
remove captive bolt of
engine from under engine
mounting support with a
blower gun, a rod and a
socket. And take down the
upper shock absorber and
its cover from the engine
Tool:
mounting support.
Open-end
wrench 30#

P18P00069
2-54
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Figures Contents Tools

16. Operate wire rope on travel-
Lifting hole ing crane for lifting hook to
pass hook through lifting
hole at pulley side of engine,
and lift engine as slowly as
possible. It is recommended
that lifting height is not more
than 5 mm.
Traveling crane
Wire rope with
hooks

P18P00070

17. Take out the shock absorber

and cover under the mount-
ing support of the engine.

P18P00071
 2-55
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

18. Slowly operate traveling
crane and hold both sides of
engine in order to ensure
that engine is slowly and
steadily lifted out of com-
plete machine and will not
collide with other parts of
complete machine.

1 2

1. Holding position
2. Holding position
P18P00072

19. Loosen captive bolt of

engine mounting support
with an open-end wrench
and take it out, then take
down engine mounting sup-
port.
Tool:
Open-end
wrench 16#

P18P00073
2-56
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Installation

Figures Contents Tools

1. Install engine mounting sup-
port on engine with captive
bolt for engine mounting
support, and pre-tighten
captive bolt with an open-
end wrench. Tool:
2. Tighten mounting base cap-
Open-end
tive bolt of engine with a wrench 16#,
torque wrench to torque of
120±50N.m (12±5kgf.m). torque wrench
120±6N.m(12±0.
6kgf.m)

P18P00074

3. Place shock absorber and

cover at upper and lower
sides of engine mounting
support respectively, and
adjust shock absorber so
that it is installed into hole of
mounting support.

P18P00075
 2-57
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

4. Operate the traveling crane
Lifting hole and put down the engine as
slow as possible to match
the engine surface and
gearbox & torque converter
assembly surface, and align
the holes.

P18P00076

5. Install and tighten the bolts

and hard washer of the
torque converter housing &
the engine housing. Tighten-
ing torque: 72±6Nm
(7.2±0.6kgf.m). Tool:
16# socket,
pneumatic
impact wrench,
open-end 16#
fixed torque
spanner

P18P00077
2-58
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Figures Contents Tools

6. Crank the engine flywheel
case to make the torque
converter align with mount-
Tool:
ing threaded hole on the
engine flywheel, screw and 16# Socket,
tighten the fastening bolts
pneumatic
and washer for attaching the
impact wrench,
torque converter to the
open-end 16#
engine flywheel by hand
fixed torque
with a torque of 60±5Nm
spanner
(6±0.5kgf.m).
P18P00078

7. Assemble shock absorber,

cap and engine mounting Tool:
support together by passing
engine fasteners such as Open-end
captive bolt and nut through wrench 16#
them.
8. Hold nut with an open-end
wrench, and pre-tighten cap-
1020±6N.m
tive bolt of engine from
(102±0.6 kgf.m)
under engine mounting sup-
torque wrench
port with a blower gun, a rod
and a socket.
9. Re-tighten captive bolt of
transmission with a torque
wrench according to
P18P00079
removal and installation
requirements and steps of
transmission.
10. Tighten captive bolt of
engine with a torque wrench
to torque of 1020±6N.m
(102±0.6 kgf.m) .
 2-59
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

11. Push the heat-insulation
bracket to installation posi-
tion and tighten the 4 anchor
bolts.

Tool:

P18P00080

12. Insert the water inlet pipe

into hot water inlet of engine,
then clamp it with a clamp.

Tool:
Open-end
wrench 7#

P18P00081
2-60
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Figures Contents Tools

13. Insert the water outlet pipe
into water outlet of engine,
the water inlet pipe into
water inlet of engine, then
clamp it with a clamp.

Tool:
Open-end
wrench 8#

P18P00082

14. Insert the intake pipe into air

inlet of engine, then clamp it
with a clamp. Insert the
intake pipe into intake hose
and clamp it with a clamp.
Tool:
Open-end
wrench 8#

P18P00083

15. Insert the intercooler pipe

into silicone hose on the
engine and radiator and
clamp it with a clamp. Fix
the intercooler pipe bracket
on the intake/exhaust Tool:
bracket and pre-tighten it Open-end
with bolts. Fix the intercooler wrench 12#, 16#
pipe on the bracket with U-
clamp and tighten it with a
nut. Tighten the intercooler
pipe bracket mounting bolt.
P18P00084
 2-61
January 24, 2017 Removal and Installation
CLG835H Removal and installation of diesel engine

Figures Contents Tools

16. Fix the diesel joint on the
engine fuel pump with screw
and seal gasket. The pipe
connected to the oil-water
separator is fuel inlet pipe
and is connected to the fuel
inlet of fuel pump with only
the inlet marked "in" . Tool:
Open-end
wrench 19#

P18P00085

17. Install the A/C compressor,

A/C pipe and warm air water
pipe to the engine according
to the installation require-
ments and steps of air con-
ditioning system.
18. Install the electrical connec-
tor and circuit to the engine
according to the removal
and installation require-
ments and steps of electrical
system described.
19. Install the diesel particle fil-
ter and connecting pipe
according to the installation
steps of diesel particle filter
described.
2-62
Removal and Installation January 24, 2017
Removal and installation of diesel engine CLG835H

Figures Contents Tools

20. Install the air filter according
to the installation steps of air
filter described.
21. Install the engine hood
according to installation
steps of engine hood.
22. Open the engine hood and
fill the anti-freeze.
23. Close the engine hood and
take off the warning board
"No operating".
 2-63
January 24, 2017 Removal and Installation
CLG835H Removal and installation of air filter

Removal and installation of air filter

Removal

Figures Contents Tools

1. Put out the harness connec-
tor on the air filter, and seal
every ports with plastic seal-
ing membrane as required.

Tool:

P18P00086

2. Loosen the clamp connect-

ing air filter and intake pipe
with wrench, and remove
the clamp. Pull out the
intake pipe and seal the
ports with plastic membrane.
Tool:
Open-end
wrench 8#

P18P00087
2-64
Removal and Installation January 24, 2017
Removal and installation of air filter CLG835H

Figures Contents Tools

3. Loosen the bolts of the air fil-
ter mounting plate with
wrench, then remove the air
filter with mounting plate.

Tool:
Open-end
wrench 13#

P18P00088

4. Remove captive bolts of air

filter with open-end wrench,
and remove air filter.
Remove the blocking indica-
tor of air filter from the air fil-
ter.
Tool:
Open-end
wrench 10#

P18P00089
 2-65
January 24, 2017 Removal and Installation
CLG835H Removal and installation of air filter

Installation

Figures Contents Tools

1. Fix the air filter on the
mounting plate with bolts.

Tool:
Open-end
wrench 10#

P18P00090

2. Install the air filter with the

mounting plate on the heat
insulation bracket.

Tool:
Open-end
wrench 13#

P18P00091

3. Install the intake pipe in the

both ends of air filter, and
hold them with clamps.

Tool:
Open-end
wrench 8#

P18P00092
2-66
Removal and Installation January 24, 2017
Disassembly and assembly of air filter CLG835H

Figures Contents Tools

4. Install the blocking indicator
of air filter on the air filter,
and press the indicator end
face to reset it.

Tool:

P18P00093

5. Check the inner of connec-

tors on the air filter and indi- Tool:
cator for water or sand. If
any, clean them up. Plug the Open-end
harness connector on the wrench 10#
two connectors.

Disassembly and assembly of air filter

Disassembly

Figures Contents Tools

1. Open the lock buckle, and
remove the end cover on the
air filter;

It needs no other
tooling or tools in
the disassembly
process.

P18P00094
 2-67
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of air filter

Figures Contents Tools

2. Take out the main filter ele-
ment along the direction of
housing. It can be taken out
directly by hand, and then
take out the main filter ele-
ment by sequence.

P18P00095

3. Take out the safety filter ele-

ment along the direction of
housing. Use the handle on
the surface of safety filter
element to pull the filter ele-
ment towards the housing
center, and remove it.

P18P00096

Check

Check the main and safety filter element before installation. Visually check the sealing surface for cut,
tear or indentation. If there is any visible damage, do not install them.
2-68
Removal and Installation January 24, 2017
Disassembly and assembly of air filter CLG835H

Assembly

Figures Contents Tools

1. Use the handle of safety fil-
ter element to make the filter
element slide into the outlet
side at an oblique angle and
push it to the position, until
the filter element is already
firm and flat in the housing. It needs no other
tooling or tools in
the assembly
process.

P18P00097

2. Insert the main filter ele-

ment. Push downward the
filter element at 5°angle,
until it hit the end of housing.

P18P00098
3. Install cover of air filter and
tighten the lock buckle. If
uncovered, remove the
cover and re-check the filter
element position. If the
installation of filter element
is incorrect, it will be difficult
to install the cover.

P18P00099
 2-69
January 24, 2017 Removal and Installation
CLG835H Removal and installation of DPF (Diesel Particle Filter)

Removal and installation of DPF (Diesel Particle Filter)

Removal

Figures Contents Tools

1. Turn off the negative elec-
trode switch, and hang on a
"No operating" warning
board.

P18P00100
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P18P00060

2. Remove the mounting bolt

of the exhaust pipe, and
take off the exhaust pipe.

Tool:
Open-end
wrench 13#

P18P00102

3. Remove the engine hood

and top cover according to
removal and installation
requirements and steps of
engine hood.
2-70
Removal and Installation January 24, 2017
Removal and installation of DPF (Diesel Particle Filter) CLG835H

Figures Contents Tools

4. Remove the DEF(diesel
exhaust fluid) pipe joint and
electrical connector on the
DOC.

P18P00103

5. Unplug the exhaust pipe and

SCR electric connector,
Remove the U-clamp and
clamp, take off the exhaust
pipe.
Tool:
Open-end
wrench 11#

P18P00104

6. Loose the clamp of DOC &

bellow, and unscrew the
captive bolts of brackets.
Tool:
Open-end
wrench 11#
Open-end
wrench 18#

P18P00105
 2-71
January 24, 2017 Removal and Installation
CLG835H Removal and installation of DPF (Diesel Particle Filter)

Figures Contents Tools

7. Unscrew the captive bolts on
one side bracket of SCR and
lower the diesel particle fil- Tool:
ter. Take care of the clamp Open-end
and seal gasket, and mask wrench 18#
each port with plastic seal
Traveling crane
membrane.
Wire rope with
hooks
Plastic sealing
membrane
P18P00106

Installation

Figures Contents Tools

1. Lift the diesel particle filter,
put it to installing position,
Tool:
install the bracket bolts and
pre-tighten the clamp. Open-end
wrench 11#
Open-end
wrench 18#
Traveling crane
Wire rope with
hooks
P18P00107

2. Adjust the diesel particle fil-

ter position, and tighten the
clamp.

P18P00108
2-72
Removal and Installation January 24, 2017
Removal and installation of DPF (Diesel Particle Filter) CLG835H

Figures Contents Tools

3. Insert the exhaust pipe into
SCR outlet port, tighten the
clamp and U-clamp, and
insert the electric connector.

Tool: Open-end
wrench 11#

P18P00109

4. Connect the DEF pipe, and

insert the electric connector.

P18P00110

5. Install the engine hood and

top cover according to
removal and installation
requirements and steps of
engine hood.
6. Fix the exhaust pipe to the
engine top cover.

Tool:
Open-end
wrench 13#

P18P00102
 2-73
January 24, 2017 Removal and Installation
CLG835H Removal and installation of DEF pump

Removal and installation of DEF pump

Removal

Figures Contents Tools

1. Stop the vehicle, and turn off
the negative electrode
switch, and hang on a "No
operating" warning board
when the urea pump stops
operating.

P18P00112
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P18P00060

2. Open the engine hood, and

remove the protection plate
from the fuel tank.

Tool:
Open-end
wrench 13#

P18P00114
2-74
Removal and Installation January 24, 2017
Removal and installation of DEF pump CLG835H

Figures Contents Tools

3. Unscrew the clamp of urea
pipe with straight screw-
driver, and then pull out the
pipe from the urea tank.
Seal every port with plastic Tool:
sealing membrane as Straight screw-
required. driver
Plastic sealing
membrane

P18P00115

4. Remove the 4 captive bolts

from the DEF bracket, and
take out the DEF tank from
the counterweight bottom.

Tool:
Open-end
wrench 13#

P18P00116

5. Unscrew the mounting strap

bolt of the DEF tank and the
tank can be taken out.

Tool:
Open-end
wrench 10#

P18P00117
 2-75
January 24, 2017 Removal and Installation
CLG835H Removal and installation of DEF pump

Installation

Figures Contents Tools

1. Put the DEF tank into the
bracket, get the strap
through the tank body and
tighten the strap bolt.
Tool:
Open-end
wrench 10#

P18P00117

2. Put the DEF tank into install-

ing position from the coun-
terweight bottom and tighten
the 4 captive bolts

Tool:

P18P00116

3. Insert the quick joint of urea

pipe to the joint of urea tank.
It is not in place until a
sound is heard. The two
joints is different in specifica-
tion, and can not be inserted
if inversely connected.

Tool:

P18P00120
2-76
Removal and Installation January 24, 2017
Removal and installation of DEF pump CLG835H

Figures Contents Tools

4. Connect the water pipe to
the water pipe joint of urea
tank, and clamp it with
clamp. The pipe connected
to solenoid water valve is
inlet pipe, which is con-
nected to the water inlet on Tool:
the urea tank with arrow
indicated. Straight screw-
driver

P18P00121

5. Insert the urea filler to the

urea tank and clamp it with a
clamp.

Tool:
Straight screw-
driver

P18P00122

6. Insert the DEF(diesel

exhaust fluid) tank joint to
the vehicle wiring harness.

P18P00123
 2-77
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of DEF tank

Figures Contents Tools

7. Put on the fuel tank protec-
tion plate and tighten with
bolts.

Tool:
Open-end
wrench 13#

P18P00124

Disassembly and assembly of DEF tank

Disassembly

Figures Contents Tools

1. Unscrew the retention
screws that secure the
Retaining Ring to the reser-
T25 Driver voir.

tool:
T25 Torx Driver

Retention
Screws

P18P00125
2-78
Removal and Installation January 24, 2017
Disassembly and assembly of DEF tank CLG835H

Figures Contents Tools

P18P00126

2. Using a flathead screw-

driver, gently pry around
where the head unit is con-
nected to the reservoir while
simultaneously pulling on
the top of the unit. Continue
until DEF mounting base is
free from reservoir. tool:
DO NOT pull on the wires or
flathead screw-
fittings.
driver

P18P00127
 2-79
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of DEF tank

Figures Contents Tools

3. Pull the DEF head unit out
until the bottom of the
header is at the bottom of
the tank bore.

P18P00128

P18P00129
2-80
Removal and Installation January 24, 2017
Disassembly and assembly of DEF tank CLG835H

Figures Contents Tools

4. Angle the heel of Tri-function
sensor foot upward and
rotate the header until the
bottom of the header is posi-
tioned inside the tank bore.
When the bottom of the
header is in the tank bore,
fold the filter downward
towards the interior of the
tank. Continue to carefully
remove the header out of
the tank bore until com-
pletely freed. 
P18P00130
DO NOT pull directly out as
this might damage the DEF
head and bore seal.

P18P00131
 2-81
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of DEF tank

Check

Check the surface of filter element, and clean it if has sundries. If the filter element is found with cracks
or big hole, replace it with new one.

Assembly

Figures Contents Tools

1. Apply a thin layer of O-ring
lubrication to the Bore seal
O-ring.

P18P00132

2. Fold the Filter element in

half towards the bottom of
the Tri-Function Sensor. Tilt
the header to an approxi-
mate 45° angle, with respect
to the top of the tank. With
the heel of the Tri-Function
Sensor foot angled upward,
place the filter edge and the
toe of the Tri-Function Sen-
sor into the tank bore. Grad-
P18P00133
ually work the bottom
portion of the DEF head into
the Bore opening until com-
pletely inserted in the tank.
DO NOT push the MFHU
directly into the tank as this
could damage the unit.
2-82
Removal and Installation January 24, 2017
Disassembly and assembly of DEF tank CLG835H

Figures Contents Tools

P18P00134

P18P00135

3. Position the DEF head unit

in the desired orientation
and press on the top of the
blue mounting base until it is
completely seated in the
tank bore. 
DO NOT press directly on
the fittings.

P18P00136
 2-83
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of DEF tank

Figures Contents Tools

4. Position the retaining ring on
Head unit and install the
retention screws using the
T25 Torxwrench. Recom-
mended torque on screws is
20 - 30 in-lbs (2.26 – 3.38 N
m).

P18P00137

Tool:
T25 Torx wrench

P18P00138
2-84
Removal and Installation January 24, 2017
Removal and installation of DEF(diesel exhaust fluid) pump CLG835H

Removal and installation of DEF(diesel exhaust fluid) pump

Removal

Figures Contents Tools

1. Write 1, 2, 3 on the stickers
respectively and stick them
on the three DEF pipes from
left to right. Pull out the urea
pipe, harness connector Tool:
from the urea pump. Seal
every port with plastic seal- Plastic sealing
ing membrane. membrane
Sticker

P18P00139

2. Unscrew the urea pump

mounting bolt from the
bracket. Then remove the
urea pump.

Tool:
Wrench 13#

P18P00140
 2-85
January 24, 2017 Removal and Installation
CLG835H Removal and installation of DEF(diesel exhaust fluid) pump

Installation

Figures Contents Tools

1. Fix the urea pump on the
bracket and tighten it with
bolts. The recommended
tightening torque is 15.2 –
22.8 N·m.
Tool:
Wrench 13#

P18P00141

2. Insert the three urea pipes to

the urea pump by the order
1, 2, 3 from left to right until
a sound is heard. Insert the
urea pipe joint to the position
of urea pump joint.

P18P00142
2-86
Removal and Installation January 24, 2017
Disassembly and assembly of DEF pump CLG835H

Disassembly and assembly of DEF pump

Disassembly

Figures Contents Tools

1. Unscrew the filter element
cover by hand.

P18P00143

2. Take out the filter element

assembly upward and verti-
1 cally.
2

1.Filter element cover 3.Housing

2.Filter element
P18P00144
 2-87
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of DEF pump

Check

Figures Contents Tools

1. Check the filter element
cover for cracks or hole.
1 These cracks or holes may
cause urea leakage.
2 Check the thread of filter
element cover for damage,
and if does, replace it with a
new one.
Check the thread of urea
3 pump body. If the thread is
damaged, replace the com-
plete urea pump.

1.Filter element cover 2. Filter element 3. Housing

P18P00145

2. Clean the filter element

cover with warm water and
1 soft gauze.

1.Filter element cover 2. Filter element 3. Housing

P18P00146
2-88
Removal and Installation January 24, 2017
Disassembly and assembly of DEF pump CLG835H

Assembly

Figures Contents Tools

1. Install the filter element
assembly into the DEF
pump housing with filter ele-
1 ment assembly tightening
torque 14N.M(124lbin), and
2
then tighten the protective
cover.

Tool:
3
Open-end
wrench 27#

1.Filter element cover 3. Housing

2 Filter element P18P00147

2. Turn on the negative (-)

switch and start the engine,
check the urea pump for
leakage. If there is leakage,
please refer to the above
steps of disassembly and
inspection.
 2-89
January 24, 2017 Removal and Installation
CLG835H Removal and installation of radiator

Removal and installation of radiator

Removal

Graph Contents Tools

1. Turn off the negative elec-
trode switch, and hang on a
"No operating" warning
board.

P18P00148
G
IN
N
AR
W

er ot
op o n

e
at
d
r:
te
ra
pe
O

e:
at
D

P18P00060

2. Remove the engine hood

and top cover according to
removal and installation
requirements and steps of
engine hood.
3. Unscrew the drain connector
to drain the engine cooling
water.

Tool:
Open-end
wrench 36#
Water tank

P18P00150
2-90
Removal and Installation January 24, 2017
Removal and installation of radiator CLG835H

Graph Contents Tools

4. Unscrew the hydraulic oil
drain connector to drain the
hydraulic oil in the radiator.

Tool:
Open-end
wrench 36#
Oil tank

P18P00151

5. Unscrew the torque con-

verter oil drain connector to
drain the torque converter oil
in the radiator.
Tool:
Open-end
wrench 36#
Oil tank

P18P00152

6. Unscrew the clamp of inter-

cooler pipe, unplug the sili-
cone hose at radiator side
and seal every port with
plastic seal membrane. Tool:
Open-end
wrench 12#
Plastic sealing
membrane

P18P00153
 2-91
January 24, 2017 Removal and Installation
CLG835H Removal and installation of radiator

Graph Contents Tools

7. Unscrew the water pipe
clamp and pull out the water
pipe from the radiator. Seal
every port with plastic seal-
ing membrane.

Tool:
Open-end
wrench 8#
Plastic sealing
membrane

P18P00154

8. Remove the oil inlet/return

pipes of the torque converter
oil radiator & drain pipe joint,
unplug the temperature sen-
sor connector and seal each
port with plastic seal mem-
brane.

Tool:
P18P00155 Outer hexagon
wrench 8#
Plastic sealing
membrane

P18P00156
2-92
Removal and Installation January 24, 2017
Removal and installation of radiator CLG835H

Graph Contents Tools

9. Remove the oil inlet/return
pipe joints of the hydraulic
oil radiator and drain pipe
joint, unplug the temperature
Tool:
sensor connector and seal
each port with plastic seal Open-end
membrane. wrench
Plastic sealing
membrane

P18P00157

10. Remove the oil inlet/return

pipe connectors of the fuel
radiator and seal each port
with plastic seal membrane.

Tool:
Open-end
wrench
Plastic sealing
membrane

P18P00158

11. Remove the condensing

agent inlet/outlet connec-
tors of the A/C radiator, and
seal each port with plastic
Tool:
seal membrane.
Open-end
wrench
Plastic sealing
membrane

P18P00159
 2-93
January 24, 2017 Removal and Installation
CLG835H Removal and installation of radiator

Graph Contents Tools

12. Remove the oil inlet/outlet/
return pipe connectors of
cooling motor and seal each
port with plastic seal mem-
Tool:
brane.
Open-end
wrench
Plastic sealing
membrane

P18P00160

13. Slowly operate traveling

crane, hang lifting eyes with
wire rope, and tauten wire
rope but not lift yet.

Tool:
Traveling crane
Wire rope

P18P00161

14. Remove 4 anchor captive

bolts from the radiator
assembly.

Tool:
Open-end
wrench 24#
Traveling crane

P18P00162
2-94
Removal and Installation January 24, 2017
Removal and installation of radiator CLG835H

Graph Contents Tools

15. Uplift the traveling crane, lift
out the radiator assembly
slowly and put it on flat
ground.

Tool:
Traveling crane

P18P00163

Installation

Graph Contents Tools

1. Uplift the traveling crane, lift
the radiator assembly to
installing position.

Tool:
Traveling crane
Wire rope

P18P00164

2. Tighten the radiator mount-

ing bolts with the tightening
torque 305 ± 25N.m.

Tool:
Open-end
wrench 24#

P18P00165
 2-95
January 24, 2017 Removal and Installation
CLG835H Removal and installation of radiator

Graph Contents Tools

3. Loose the wire rope

Tool:

P18P00166

4. Install the oil inlet/outlet/

return pipe connectors of
cooling motor

Tool:
Open-end
wrench

P18P00167

5. Install the condensing agent

inlet/outlet connectors of the
A/C radiator.

Tool:
Open-end
wrench

P18P00168
2-96
Removal and Installation January 24, 2017
Removal and installation of radiator CLG835H

Graph Contents Tools

6. Install the oil inlet/outlet con-
nectors of fuel radiator.

Tool:
Open-end
wrench

P18P00169

7. Install the oil inlet/return

pipes of the hydraulic oil
radiator & drain pipe joint,
insert the temperature sen-
sor connector.
Tool:
Open-end
wrench

P18P00170
 2-97
January 24, 2017 Removal and Installation
CLG835H Removal and installation of radiator

Graph Contents Tools

8. Install the oil inlet/return
pipes of the torque converter
oil radiator & drain pipe joint,
insert the temperature sen-
sor connector.

P18P00171 Tool:
Open-end
wrench

P18P00172

9. Insert the water inlet/ outlet

pipes into the water radiator
about 50mm, and then
clamp the water pipe with
clamp.

Tool:
Open-end
wrench 8#

P18P00173
2-98
Removal and Installation January 24, 2017
Removal and installation of radiator CLG835H

Graph Contents Tools

10. Connect the intercooler pipe
and air-air intercooler with
silicone hose and then
clamp it with a clamp.

Tool:
Open-end
wrench 12#

P18P00174

11. Tighten the radiator water

draining switch, torque con-
verter oil draining switch and
hydraulic oil draining switch.

Tool:

P18P00175

12. Replenish the coolant,

hydraulic oil and torque con-
verter oil as required.
13. Install the engine hood and
top cover according to
removal and installation
requirements and steps of
engine hood.
 2-99
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of radiator

Disassembly and assembly of radiator

Disassembly

Graph Contents Tools

1. Unscrew the 4 fixing bolts on
the upper connecting plate,
remove the bolts and con-
necting plate.

Tool:
Open-end
wrench 16#

P18P00176

2. Unscrew 4 captive bolts (do

not remove) of lower con-
necting plate, so that left and
right supports and lower
connecting plate can rotate
relatively.

Tool:
Open-end
wrench 18#

P18P00177
2-100
Removal and Installation January 24, 2017
Disassembly and assembly of radiator CLG835H

Graph Contents Tools

3. Push the radiator to right by
1 3 4 the order 4321 with the aid
2
of straight screwdriver, suc-
cessively take out torque
converter oil radiator, air-air
intercooler, water radiator
and hydraulic oil cooler and
collect sponge and shock
absorber. Tool:
CAUTION: Hold radiator Straight
assembly by someone or screwdriver
use corresponding stabilizing
equipment to prevent radiator
components from tilting when
above 1, 2 and 3 operations
are carried out.
1. Hydraulic oil cooler 3. Air-air intercooler
2. Water radiator 4. Torque converter oil cooler
P18P00178

Check

Check the radiator passage wall for cracks, and if does, it is necessary to perform the repair welding and
replace the radiator.
Check the radiator fin, and if the fin is bent for a large area and blocks the passage, it is necessary to flat
the fin by the wind direction or replace the radiator.
Check the radiator passage for blocking by debris or impurities, and if does, it is necessary to blow it
clean with compressed air. Please notice that the direction of compressed air shall be inverse with that of
air which passed through the radiator during normal operation of the machine.
 2-101
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of radiator

Assembly

Graph Contents Tools

1. Connect the left and right
supports to the lower con-
necting plate with bolts, but
not tighten the bolts, so that
left and right supports and
lower connecting plate can
rotate relatively, and place
the sponge on the lower
backing plate.

P18P00179

2. Put the shock cushions to

the lower plate holes and
insert the radiator to the
lower plate holes rightly.
Perform the same assembly
method for the other radia-
tors.

P18P00180
2-102
Removal and Installation January 24, 2017
Disassembly and assembly of radiator CLG835H

Graph Contents Tools

3. Put the shock cushion on
top of radiator to the radiator
and put the sponge.

Tool:
Open-end
wrench 16#

P18P00181

4. Install the upper plate and

tighten the 4 captive bolts of
the upper and lower con-
necting plates.
CAUTION: The radiator
assembly shall be held
by someone or using
corresponding stabilizing Tool:
equipment to prevent radiator
Open-end
assembly from tilting when
wrench 18#
above 1, 2, 3, 4 operations are
carried out.

P18P00182
 2-103
January 24, 2017 Removal and Installation
CLG835H Removal and installation of fan

Removal and installation of fan

Removal

Graph Contents Tools

1. Turn off the negative elec-
trode switch, and hang on a
"No operating" warning
board.

P18P00183
G
IN
N
AR
W

er ot
op o n

e
at
d
r:
te
ra
pe
O

e:
at
D

P18P00060

2. Open engine hood

2-104
Removal and Installation January 24, 2017
Removal and installation of fan CLG835H

Graph Contents Tools

3. Unscrew the mounting bolt
of shield and remove the
shield.

Tools
Open-end
wrench 16#

P18P00185

4. Unscrew the mounting bolt

of fan, catch the root of fan
vane and shake slightly to
make the fan separate from
the flange plate and then
remove the fan.

Tools
Open-end
wrench 10#

P18P00186
 2-105
January 24, 2017 Removal and Installation
CLG835H Removal and installation of fan

Installation

Graph Contents Tools

1. Install the fan to the flange
with the inner side (concave
side) of arc surface of fan
facing the rear of complete
machine.

P18P00187

Exterior (convex)
x)
IInterior (concave)

P18P00188
2-106
Removal and Installation January 24, 2017
Removal and installation of fan CLG835H

Graph Contents Tools

2. Fix the fan on the flange with
bolts.

Tools
Open-end
wrench 10#

P18P00189

3. Measure clearances
between fan and shroud and
it should be more than
10mm(0.3937In).

Tools
Steel ruler

1. Clearance between fan and shroud >10mm

P18P00190
 2-107
January 24, 2017 Removal and Installation
CLG835H Removal and installation of fan

Graph Contents Tools

4. Install the shield to the
shroud and tighten it with
bolts.

Tools
Open-end
wrench 16#

P18P00191

5. Measure clearances
between fan and shield and
1 it should be more than
20mm (0.7874In).
2

>20mm
Tools
Steel ruler

1. Edge of the fan

2. Shield inner side

P18P00192

Check

Check the fan vane for damage or scratches, the connection of fan vane and fan & hub for cracks, and if
the fan is damaged, it is necessary to replace it with a new one with the same part number.
2-108
Removal and Installation January 24, 2017
Removal and installation of fuel tank CLG835H

Removal and installation of fuel tank

Removal

Graph Contents Tools

1. Drainage of diesel fuel:
Clean drain hole of fuel tank,
place a clean oil container
under the fuel tank, and
unscrew drain plug. After
fuel is drained, fix drain plug
back to fuel tank. Drained Tool:
fuel should be strictly sealed 24# socket,
for preservation to prevent socket wrench,
pollution to fuel. oil tank

P18P00193

2. Removal of pipe clamp:

Remove all of hydraulic pipe Tool:
or electric harness bolts, Open-end
remove clamps, and loose wrench 16#, 18#
the pipes and harness.
3. Remove the fuel lines of
suction and return port:
After fuel is drained, remove
screw of fuel hose at fuel
tank end, take down fuel
hose of that end, and fix the Tool:
screw back to fuel return
Open-end
hole. Block the fuel hose
wrench 19#
with clean plastic bag.

P18P00196
 2-109
January 24, 2017 Removal and Installation
CLG835H Removal and installation of fuel tank

Graph Contents Tools

4. Removal of fuel sensor wire
harness:
Remove the harness con-
nector of fuel tank sensor.

P18P00197

5. Removal of fuel tank:

Remove the 4 mounting
bolts and nuts from the fuel
tanks.
Caution: Fuel tank is
connected to frame
through bolts and nuts in four
mounting points. After mount- Tool:
ing bolts are loosened, fuel
tank will separate from frame. Open-end
Before removal, use a reliable wrench 30#,
tool (e.g., forklift) with suffi- Carrier tool or
cient bearing capacity to sup- tooling
port fuel tank.
Before step 5, make sure
steps 2~4 have been done;
otherwise, corresponding
parts will be damaged, and
even a safety accident will
P18P00198 occur.
2-110
Removal and Installation January 24, 2017
Removal and installation of fuel tank CLG835H

Graph Contents Tools

P18P00199

P18P00200
 2-111
January 24, 2017 Removal and Installation
CLG835H Removal and installation of fuel tank

Installation

Graph Contents Tools

1. Install the cushion to the four
brackets of diesel fuel tank.

P18P00201

2. Transfer the diesel fuel tank

to the position under the rear
frame with carrier tool to
align the hole of diesel fuel
tank with the diesel fuel tank
mounting hole on the rear
frame. Fix the diesel fuel
tank on the rear frame with
bolts, hard washer, locknut Tool:
with the tightening torque of Open-end
fuel tank mounting bolt of wrench 30#,
600 ± 50N•m (60 ±
5kgf.m). Carrier tool or
tooling

P18P00202

3. Connect the fuel level sen-

sor harness connector to the
complete machine harness.

P18P00203
2-112
Removal and Installation January 24, 2017
Removal and installation of fuel tank CLG835H

Graph Contents Tools

4. Install the fuel pipe to the
flange of the diesel fuel tank
with screw, seal gasket.

Tool:
Open-end
wrench 19#

P18P00204

5. Fix all of the hydraulic pipe

or electric harness with Tool:
clamps to corresponding Open-end
positions, tighten and finish wrench 16#, 18#
the fixing.
6. Refill the fuel.

Cleaning

Remove the flange cover of washing port on the front end of fuel tank, use clean fuel to wash the inner
oil tank surface. Unscrew drain plug at bottom of fuel tank to drain fuel (use a proper container to collect
fuel). Rinse it by fuel repeatedly until the drained fuel is clean. Put drain plug back onto the floor of fuel
tank.
 2-113
January 24, 2017 Removal and Installation
CLG835H Removal and installation of fuel tank

Removal and installation of fuel radiator

Removal

Figures Contents Tools

1. Unscrew the fuel pipe joint
screw connected to the fuel
radiator with wrench.
Remove the screw, seal Tool:
gasket and keep them in a
plastic bag. Mask the fuel Open-end
pipe joint with sealing mem- wrench 19#
brane. Plastic sealing
bag
Plastic sealing
membrane

P18P00207

2. Unscrew the mounting bolt

of fuel radiator with wrench
and remove the fuel radiator.

Tool:
Open-end
wrench 16#

P18P00208
2-114
Removal and Installation January 24, 2017
Removal and installation of fuel tank CLG835H

Installation

Figures Contents Tools

1. Install the fuel radiator on
the support and tighten it
with bolts.

Tool:
Open-end
wrench 16#

P18P00209

2. Install the fuel pipe joint on

the fuel radiator with screw,
and please notice that the
joint shall be added with seal
gasket at both sides.

Tool:
Open-end
wrench 19#

P18P00210

Check

1. Check the fuel radiator, and if the radiator fin is blocked with dirt, please clean it with compressed air.
2. Check the fuel radiator, and if the fuel pipe is found damage, replace it with a new one.

Test Requirements

1. When the fuel radiator is installed, start the machine to allow it run for several minutes, observe the
radiator for leakage.
2. If the leakage occurred at joint, there is a possibility that the screw is not tightened or the seal gasket
is damaged, and it is necessary to tighten the screw or replace the seal gasket. If the leakage
occurred at radiator itself, there is a possibility that the fuel line is damaged and it is necessary to
replace the radiator with a new one.
 2-115
January 24, 2017 Fault Diagnosis and Troubleshooting
CLG835H Precautions for fault diagnosis

Fault Diagnosis and Trouble-

shooting

Precautions for fault diagnosis

Park the machine on the flat ground, check

whether the locking pin, cushion block and park-
ing brake are fixed firmly.
When two or more workers are operating, follow
the agreed signal strictly, and any unauthorized
people are not allowed to get close.
If the radiator cover is removed when the engine
is still hot, the hot coolant may spray out which
will cause scald. Therefore, start the fault diagno-
sis when the engine is cooled.
Specially notice that do not touch any hot compo-
nents or do not be jammed by any rotating com-
ponents.
When disconnecting the wire, be sure to discon-
nect the negative pole (-) of the battery first.
Be sure to release the inner pressure when
removing the plug or cover where the oil pres-
sure, water pressure or air pressure may exist.
When installing the measuring device, make
sure that it is connected correctly.

Common fault code and trouble-

shooting

For common fault codes and troubleshooting,

refer to Troubleshooting Manual of Perkins
Engine1204F-E44TA&1204F-E44TTA.
2-116
Fault Diagnosis and Troubleshooting January 24, 2017
Common fault code and troubleshooting CLG835H
 3-1
January 24, 2017 Power Train System
CLG835H

Power Train System

Basic Information ............................................................................................................3-3
Safety .....................................................................................................................................................3-3
System composition and position ..........................................................................................................3-4
System technical parameters.................................................................................................................3-5
System schematic diagram and working principle description...............................................................3-6
Overview of transmission fluid ...............................................................................................................3-7
Maintenance and replacement of gearbox and drive axle oil.................................................................3-8
Universal tool, tooling list .....................................................................................................................3-10
Special tool, tooling list ........................................................................................................................3-10

Structure Function Principle ........................................................................................3-11

Torque Converter - Gearbox System ...................................................................................................3-11
Drive axle system.................................................................................................................................3-17
Drive Shaft System ..............................................................................................................................3-19
Tire&rim system ...................................................................................................................................3-21

Testing and adjustment ................................................................................................3-25

Torque Converter - Gearbox System ...................................................................................................3-25
Drive axle system.................................................................................................................................3-25

Removal and Installation ..............................................................................................3-26

Removal and installation of torque converter-gearbox system ............................................................3-26
Disassembly and assembly of torque converter-gearbox assembly ....................................................3-38
Removal and installation of drive shaft system ....................................................................................3-39
Removal and installation of front axle assembly ..................................................................................3-44
Removal and installation of rear axle assembly...................................................................................3-47
Disassembly and assembly of the drive axle .......................................................................................3-60

Fault Diagnosis and Troubleshooting Methods .........................................................3-61

Testing and adjustment ................................................................................................3-63
Power Train Test..................................................................................................................................3-63
3-2
Power Train System January 24, 2017
CLG835H
 3-3
January 24, 2017 Basic Information
CLG835H Safety

Basic Information

Safety This word means existing potential danger,

and if no avoidance, it may cause slight or
Many accidents in operation, maintenance, medium personal injury.
repair and other aspects are caused by fail to "Caution" is also used for reminding the
observe the basic safety rules and precautions. If safety attentions of unsafe operation possi-
the case of potential risk is fully aware in bly causing personal injury. "Danger" repre-
advance, these accidents usually can be sents the worst dangerous conditions. Safety
avoided. The operators must pay attention to sign of "danger" or "warning" is an attach-
these potential risks, and be trained for relevant ment set at the specific dangerous location.
skills before properly and safely operating, General precautions are listed on the safety
maintaining and repairing the machine. sign of "Caution".
● Any improper operation, maintenance and In addition, please carefully follow the "Cautions"
repair methods may lead to hazardous condi- listed in this Manual, otherwise, it may result in
tion, cause personal injury and even death. great damage to the machine. We are unable to
● Be sure to read and understand the relevant enumerate all the possible risks (including
security measures and precautions before potential dangers), and the warnings in the
operating, maintaining and repairing the Manual and product do not cover all the risks and
machine. dangers. If the tools, operation procedures,
methods or techniques are not specially
● Please strictly obey the safety warning infor- recommended by our company, it is necessary to
mation listed in this Manual and on the ensure the personal safety of every one, and
machine during operating, maintaining and protect the machine against any damage.
repairing the machine, otherwise heavy casu-
alties will occur. The contents herein are provided based on the
status of the machine at the time when the
Safety warning information in the Manual is Manual was written, whereas, all products are
indicated by the following symbols updating, and this machine is no exception. Any
modification will influence the operation,
maintenance and repair of the machine,
therefore, please contact the LiuGong dealers for
This word means existing potential danger, latest and most comprehensive service
and if no avoidance, it may cause death or information before operating, maintaining and
serious personal injury. repairing the machine.

This word means danger will occurred imme-

diately, and if no avoidance, it may cause
death or serious personal injury.
3-4
Basic Information January 24, 2017
System composition and position CLG835H

System composition and position

The power train system is a critical part of a loader, like a heart, and it is located at portion between the
engine and tire, as shown in red in the figure below. It mainly consists of three majority components:
gearbox, drive shaft and drive axle.
Fig 3-1 Schematic diagram of position for wheel loader

P18T00001

System technical parameters

Main technical parameters for the power train system of this machine are listed in Table 3-1.
Table 3-1: Main technical parameter table for power train system

System components Items Parameters Remarks

Model ZF 4WG158
Type Fixed shaft type
Gear box
Full-auto electro hydraulic
Control mode
control
Torque converter Type Single-turbo, three-element
Spiral gear level-I reduction,
Drive mode
Drive axle wheel planetary gear reduction
Brake mode Wet brake
 3-5
January 24, 2017 Basic Information
CLG835H System schematic diagram and working principle description

Table 3-1: Main technical parameter table for power train system

System components Items Parameters Remarks

Tubeless bias tire or tubed bias
Tire structure Radial tire
tire is optional
Tire Specification 17.5R25 two star L3
Level \
Type of tread L-3 Ordinary block
Rim Specification 25-14.00/1.5

System schematic diagram and working principle description

The torque converter -gearbox assembly equipped in this machine is ZF 4WG158 full auto type, and the
drive axle is 30 wet axle, whose structure diagram are shown as below:
Figure 3-2 Diagram for gear box assembly composition

1 2 3 4 3

14

13 6

12
7
11
8
10

9 P18T00002

1. Coupling device 8. Output plate

2. Torque converter housing 9. Nameplate
3. Lifting eye 10.Output flange
4. Control harness interface 11.Speed sensor
5. Electro-hydraulic shift control valve 12.Oil outlet of torque converter
6. Suction tube 13.Torque converter outlet oil temperature sensor
7. Brake 14.Cover
3-6
Basic Information January 24, 2017
System schematic diagram and working principle description CLG835H

Fig 3-3 Structure diagram for drive axle assembly

Axle housing bevel gear of the wheel reduction half shaft

P18T00003

As shown in the above figure, the engine is coupled with the torque converter of the torque converter-
gear box assembly, a part of engine power is used to drive the torque converter to work and another part
is used to drive the hydraulic pump so as to provide power for the hydraulic system.
When the engine works together with torque converter, the engine output power is input into the gear
box via the torque converter. Under the control of its electro-hydraulic shift control valve, the gear box
can output power and speed at different positions with gear shafts and clutches.
The power output from the gear box is transmitted to the main drive of drive axle via a drive shaft, and
then transmitted to wheel reducer by left and right axle shafts via main drive differential, and further to
tire rim assembly by decelerating and increasing torsion, thus finally to drive the loader to travel and
work.
 3-7
January 24, 2017 Basic Information
CLG835H System schematic diagram and working principle description

Overview of transmission fluid

The oil product used for wheel loader is divided into four categories, i.e. the lubricant, grease, brake fluid
and fuel, each of which can play a different role in the use of loader.
The lubricant, used in the loader, has two effects , one is to lubricate the parts and reduce the pressure,
so as to prolong the service life of parts; the other is to dissipate the heat of parts produced by friction, so
as to make the parts work normally. The lubricant is composed of various petroleum-based additives.
The wheel loader use a kind of lubricant which has four classes , i.e, diesel oil, gear oil, hydraulic drive
shaft and hydraulic fluid. The applications of the lubricant used in the power train system of this machine
are shown in the table below:
Table 3-2 Table of lubricant application

Cate- Ambient temperature Recommended

Application parts
gory -40 -30 -20 -10 0 10 20 30 40 50 brand

Mobil Delvac Super 1300 ZF torque converter &

engine oil transmission assembly
Torque
(-15°C~+50°C)\ uses SAE 15-40 in gen-
converter
(-5°F~122°F) eral areas and in hot
- gearbox
Mobil ATF 220 desert areas; and uses
assembly
(-35°C~+50°C)\ Mobil ATF220 in arctic
(-31°F~122°F) areas.
Mobil gear oil 80W-90/LS
with additives
LiuGong axle uses SAE
(-15°C~+50°C)\
80W-90/LS in general
(-5°F~122°F);
and hot areas, and Mobil
Mobil gear oil 424
424 with additives and
(-40°C~+50°C) \
Gear oil Shell SPIAX S6 AXME
(-40°F~122°F)with addi-
75W-90/LS in arctic
tives
areas.
Shell SPIAX S6 AXME
LS means the additives
75W-90/LS
are inclusive
(-40°C~+50°C)\
(-5°F~122°F)
3-8
Basic Information January 24, 2017
Maintenance and replacement of gearbox and drive axle oil CLG835H

Maintenance and replacement of 2) After the Oil sump tank of the gear box com-
pletely gets empty, wipe clean the mating
gearbox and drive axle oil surface on drain plug and gearbox housing
that contacting with O ring of the oil drain
The oil product added to the torque converter - plug. After the O-ring of the oil drain plug is
gearbox assembly must be consistent with oil list replaced, reassemble and tighten it.
TE-ML 03 recommended by ZF, the oil level shall 3) Add the oil in accordance with the oil list TE-
be checked once a week by the following ML 03 as recommended by ZF;
methods:
4) Check the oil level by the method as speci-
1) Park the machine on level ground; fied for transmission.
2) Place the gear box gear in the neutral posi- The fine oil filter is also replaced every time the
tion; oil change is done for the gear box. The oil filter
3) Torque converter - gearbox oil is at 80- may be installed by the following method:
95°C\176°F~203°F; 1) Apply a small amount of the gear box oil on
4) The engine is idling 800rpm); the oil seal of oil filter;
5) Observe the oil level gauge of gearbox and 2) The oil filter is screwed in until the oil seal of
it shall be in the "HOT" zone; oil filter contacts the filter head, tighten it 1/3
to 1/2 turn by hand.
After the torque converter and gearbox assembly
co-work for the first 100h, the oil shall be The oil product added in the drive axle must be
replaced every 1000h or at least once a year. Oil in accordance with the oil list of 85W-90 heavy-
can be replaced by the methods as below: load wheel gear oil (GL-5) recommended by
LiuGong. The oil level of LiuGong axle may be
1) Unscrew the drain plug on the torque con-
checked by the following methods:
verter - gearbox assembly to drain the oil.
Figure 3-5 Wheel drain plug and oil level check
plug

The waste oil shall be collected in a container

during oil drainage, in order to avoid environ-
mental contamination;
The oil shall be fully cooled before oil drain-
age, in order to avoid personal injury due to
hot oil splashing onto the body.
Figure 3-4 Gearbox drain plug

P18T00005

P18T00004
P18T00004
 3-9
January 24, 2017 Basic Information
CLG835H Universal tool, tooling list

1) Wheel reducer: place the axle according to the installation position, and turn the hub to keep the oil
level in a horizontal position, fill oil from left and right hubs respectively until the oil overflows the oil
level plug; park the reducer for ten minutes after the drive axle running, and then check the oil level,
and add enough lubricating oil.
Figure 3-6 Bevel gear refuel plug and oil level check plug
Bevel gear refuel plug and oil level check plug

P18T00006

2) Axle housing: the oil is added into axle housing until it overflows from the oil filler.
The axle oil shall be replaced at the first 500h, after that once every 1000h, or at least once a year.

Universal tool, tooling list

For the universal tools, tooling list, please see the torque converter-gear box system, drive axle system
and drive shaft system.

Special tool, tooling list

For the special tool, tooling list, please see "ZF Box Overhaul Manual" for details.
3-10
Structure Function Principle January 24, 2017
Torque Converter - Gearbox System CLG835H

Structure Function Principle Figure 3-8 Structural schematic diagram of

torque converter - gear box assembly
Clutch
Torque Converter - Gearbox Forward KV Clutch K1

System Converter

Input Pump
The torque converter -gearbox system equipped 1. Power Take -OFF
in this machine is ZF 4WG158 full auto type,
which mainly consists of a three-element, single- Clutch K2

turbo torque converter, mechanical gear box with

four forward gears, three reverse gears and Clutch K3
Clutch Reverse KR
electro hydraulic shift control system, as shown
Clutch K4
below: Parking Brake

Figure 3-7 External view of torque converter - LAYSHAFT

gear box assembly Output Output
KV - Gerar Rear Axle Front Axle

Idler Gear
Speedometer Drive
Oil Sump
K4 - Gerar P18T00008

P18T00007
 3-11
January 24, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

System technical parameters

The technical parameters of ZF 4WG158 torque converter - gear box assembly in this machine are listed
in Table 3-3.
Table 3-3 Technical parameter table of torque converter - gear box assembly

Remar
Component Items Parameters
ks
Model ZF 4WG158
Type Fixed shaft type
Gears Four forward gears, three reverse gears
Gearbox
Torque converter-gear box assembly
430\ 948.15
Quality (oil not included) /kg\lb
Type of emergence parking brake Shoe brake
Type Single-turbo, three-element
Circulation circle diameter of torque con-
340\ 13.39
verter/mm\In
Torque converter
Inlet pressure of torque converter/MPa\ psi 0.85\ 123.25
Outlet pressure of torque converter/MPa\
0.50\ 72.5
psi
System voltage/V 24
Shift control
Shift control mode Auto electro hydraulic power shift
system
System working pressure/MPa\ psi 1.6+0.2\ 232+29

System schematic diagram and working principle description

The torque converter of this system is a three-element with single-turbo structure, and the diagram for its
structure and working principle is as follows:
Figure 3-9 Structure diagram for torque converter

Turbine wheel
Pump wheel

From the engin

P18T00009
3-12
Structure Function Principle January 24, 2017
Torque Converter - Gearbox System CLG835H

Figure 3-10Schematic diagram for torque converter hydraulic

Hydraulic torque converter

Outlet constant
pressure valve of
torque converter

Inlet constant refined

pressure valve filtration
of torque converter
Radiator

Front pump

Transmission Engine Rough

—shaft lubrication filtration
Tank P18T00010

We can see from structure diagram for torque converter, a three-element, single-turbo torque converter
mainly consists of pump wheel, guide wheel and a turbine. As the pump wheel of torque converter is
directly coupled with and driven by the engine, the hydrodynamic drive oil between pump wheel and tur-
bine forms complex flow under rotation of pump wheel. The mechanical energy is converted into kinetic
energy of oil fluid. The fluid flow with kinetic energy strikes against the turbine at a high speed. The tur-
bine absorbs its kinetic energy and restores it to mechanical energy for gearbox. The guide wheel is sta-
tionary. When the fluid flow(which is from the turbine and has some kinetic energy) passes through the
curved blade of the guide wheel, the torque formed by the impact force and counterforce produced on
the blade acts on the engine base, and equivalent to the sum of increased torque of turbine from coun-
terforce and reduced torque of pump wheel from impact force. It is possible that the output torque of tur-
bine is greater than input torque of pump wheel, based on which, the torque converter is variable.
The working oil of torque converter is imported into the torque converter through the coarse and fine fil-
ters from the oil tank by the variable pump. There is a constant pressure valve (safety valve) set at the
inlet of torque converter, whose main role is to avoid excessive pressure in the torque converter to dam-
age the parts. There is another constant pressure valve (back pressure valve) at the outlet of torque con-
verter, whose main role is to ensure the torque converter is full of working oil in order to avoid cavitation
appeared during operation and impact on the performance of torque converter.
 3-13
January 24, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

An electro-hydraulic shift control valve is installed on the gear box assembly, see figure 3 -11 and 3-12
for structure composition and operating hydraulic pressure schematic diagram.
Figure 3-11 Diagram for structure and composition of electro-hydraulic shift control valve

CABLE HARNESS X HOSE LINE FROM

M4 TO REVERSING VALVE

CONTROL PRESSURE
SHIFT VALVE 4
VALVE

REVERSING VALVE
HOSE LINE FROM
M4 TO REVERSING VALVE
REDUCING VALVE

2-STAGE
PRESSURE
CONTROL VALVE PRESSURE CONTROL VALVE

SHIFT VALVE 2
BLEEDER VALVE

RESET VALVE

SHIFT VALVE 1 SHIFT VALVE 5 SHIFT VALVE 3

P18T00011
Figure 3-12 Schematic diagram for hydraulic pressure of torque converter - gear box assembly
OIL CIRCULATION DIAGRAM 4 WG-200 WITH 2-STAGE PRESSURE CONTROL VALVE -VARIANT II -

TABLE -20 NEUTRAL

THE MARKED POSITIONS (e.g.53) CORRESPOND WITH
THE POSITIONS ON THE TABLE -15

DIAGRAM CODE “G”

4 SPEED -VERSION

LEGEND
CONTROL PRESSURE
CONTROL PRESSURE REDUCED
CONTROL PRESSURE MODULATED
CONVERTER INLET PRESSURE
CONVERTER EXIT PRESSURE
LUBRICATION
RETUAN FLOW INTO THE SUMP

P18T00012
3-14
Structure Function Principle January 24, 2017
Torque Converter - Gearbox System CLG835H

The electro-hydraulic shift control valve consists Figure 3-15 Drive line of forward gear 3
of solenoid valves M1, M2, M3, M4, M5, valve
stem and body. When the electro-hydraulic shift ࠰
OUT

control valve is operating, the fluid flow in the Torque

valve stem oil passage is controlled by the power converter
turbine
of solenoid valves, which finally control the
engagement and disengagement of clutch in the
gear box, thus to make the gear box achieve
Input shaft
different shifts. For the power transferring line
and gear engagement with the gear box in
different gears, please see the figure of the
power transferring line for each gear as the
following figure 3-13 to 3-19.
Figure 3-13 Drive line of forward gear 1
OUT
࠰
OUT
Output Output
shaft shaft
Torque
converter P18T00015
turbine
Figure 3-16 Drive line of forward gear 4
Input shaft
࠰
OUT

Torque
converter
turbine

Input shaft

OUT
Output Output
shaft shaft
P18T00013

Figure 3-14 Drive line of forward gear 2

OUT

Output Output
࠰
OUT
shaft shaft
Torque
converter P18T00016
turbine

Input shaft

࠰
OUT
Output Output
shaft shaft

P18T00014
 3-15
January 24, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

Figure 3-17 Drive line of reverse gear 1 Figure 3-19Drive line of reverse gear 3

OUT
OUT
Torque Torque
converter converter
turbine turbine

Input shaft
Input shaft

OUT
OUT
Output Output Output Output
shaft shaft shaft shaft

P18T00017 P18T00019

Figure 3-18 Drive line of reverse gear 2

OUT
Torque
converter
turbine

Input shaft

OUT
Output Output
shaft shaft
P18T00018
3-16
Structure Function Principle January 24, 2017
Drive axle system CLG835H

Drive axle system

Composition and position of drive axle system

The basic function of drive axle for wheel loader is to reduce the gear box input speed with main drive
and wheel reducer and increase the torsion, thus to meet the requirements of driving, operating speed
and traction of the base machine. And also, change the straight line motion to vertical-lateral motion via
main drive, so that the drive wheel can be driven to rotate to make the base machine drive along the
straight route. The differential helps balance the speeds of left and right tires to make sure the machine
can still drive when the driving resistances on both sides are different.
In addition to basic features of drive axle for wheel loader, it is also a load-bearing unit for complete
machine, a support device for road wheel and mounting & support device for service brake. The drive
axle system mainly consists of front axle, rear axle and brake lines. The swing axle also includes front,
rear swing brackets, support shaft and other parts.

System technical parameters

Major technical parameters for the drive axle system of this machine are listed in Table 3-4.

Table 3-4 Main technical parameter table for drive axle

System components Items Parameters Remarks

Spiral gear level-I reduction, wheel
Drive mode
planetary gear reduction
Front axle
Brake mode Built-in wet multi-plate type
Brake pressure /MPa\psi 1450
Spiral gear level-I reduction, wheel
Drive mode
planetary gear reduction
Rear axle
Brake mode Built-in wet multi-plate type
Brake pressure /MPa\psi 1450
 3-17
January 24, 2017 Structure Function Principle
CLG835H Drive axle system

System schematic diagram and working

principle description Figure 3-21 Diagram of the wheel reducer

The drive axle for wheel loader is classified into

two classes, i.e. front axle and rear axle, the
main difference between which is the spiral
directions of the spiral bevel gear pairs in the
main drive. The driving spiral bevel gear of front 1 2
axle is left-handed, and that of rear axle is right-
handed. The structure diagram for bevel gear
3
and wheel reducer of this machine is as shown in
figure 3-20 and 3-21.
4
Figure 3-20 Structure diagram of the bevel gear

5 4 5
2

3
P18T00021
1. Axle shaft 4. Hub
2. Planetary gear 5. Sun gear
3. Brake
1 The bevel gear structure is shown in Figure 3-21.
The bevel gear includes two parts, one is the
bevel gear composed of driving spiral bevel gear
and large size spiral bevel gear; the other is the
differential composed of cross axle and bevel
gear. The power is transmitted to the driving
spiral bevel gear by the gear box through drive
P18T00020
shaft, thus to drive the large size spiral bevel
1. Driving spiral bevel gear 4. Carrier gear with differential to rotate together. The half
2. Axle housing 5. Differential shaft gear of differential passes the power to left/
3. Driven spiral bevel gear
right half shaft which is connected with the
splines, and further to the wheel reducer. The
power is then transmitted to hub and finally to
drive the tire to rotate after further speed
reduction, increasing torsion through wheel
reducer.
3-18
Structure Function Principle January 24, 2017
Drive Shaft System CLG835H

Drive Shaft System

In the wheel loader, the drive shaft system is mainly used to deliver the power between the two con-
nected shafts, of which the relative position changes constantly during operation. Because of the special
transmission characteristics of universal joint, the drive shaft may connect two transmission parts with
nominal concentric axial line. However, an error may occur during installation and axial line deviates
from the original position when operating, the drive shaft is widely used in shoveling transportation
machine.

System composition and position

The drive shaft system of wheel loader is composed by the following two structural types in accordance
with its formal layout, the drive shaft system shown in Figure 3-25 consists of rear and front drive shafts,
the one shown in Figure 3-26 consists of rear, front, intermediate shafts and support assembly.
Figure 3-22 Drive shaft system

1
3

P18T00022
1. Front drive shaft 2. Torque converter-gear box assembly 3. Rear drive shaft

Figure 3-23 Drive shaft system

1 2 4

P18T00023

1. Front drive shaft&support assembly 3. Torque converter-gear box assembly

2. Intermediate drive shaft 4. Rear drive shaft
 3-19
January 24, 2017 Structure Function Principle
CLG835H Tire&rim system

System technical parameters

The technical parameters for the drive shaft system are listed in Table 3-5.

Table 3-5 Technical parameter table for drive shaft system

Parts name Input-end coupling type Output-end coupling type

Rear drive shaft 7C FLANGE 7C FLANGE
Intermediate drive shaft 180 round flange 150 round flange
Front drive shaft&support assembly 150 round flange 150 round flange

Tire&rim system

System composition and position

Tire & rim system are both components bearing weight of a complete machine and direct components
driving the complete machine to walk. Tires can be classified into bias tires with an inner tube, bias tires
without an inner tube, radical tires, solid tires, etc. in accordance with it structural layouts. They can also
be classified into block pattern tires, traction pattern tires, skidding tires, etc. according to pattern form.

System technical parameters

The technical parameters for the tire & rim system equipped in this machine are listed in Table 3-6.

Table 3-6 Technical parameters of tire&rim system

System compo-
Items Parameters Remarks
nents
Tubeless bias tire or tubed bias
Tire structure Radial tire
tire is optional
Specification 17.5R25 two star L3
Level \
Tire Type of tread L-3 Ordinary block
Front wheel:0.55-0.58\79.75-
84.10
Tire pressure (MPa)\(psi)
Rear wheel: 0.52-0.55\75.40-
79.75
Rim Specification 25-14.00/1.5
3-20
Structure Function Principle January 24, 2017
Tire&rim system CLG835H

Common failure modes of tire and reasons

Common failure mode of tire and reasons are as follows:

Typical pictures Failure mode Main reasons

1. Reasons for manufacture:
there is impurities, oil stains
or water in the tread rubber
or cord ply or not firmly com-
pressed when being
molded, or gasoline does
Delaminating of not fully volatilize.
crown 2. Reasons for usage: speed is
too fast (beyond specified
speed), and directive pattern
is traveling in reverse direc-
tion.
P18T00024

1. Reasons for manufacture:

there is impurities, oil stains
or water in sidewall rubber
or cord ply or not firmly com-
pressed, or gasoline does
not fully volatilize.
2. Traveling with insufficient air
Shoulder will intensify wear of tire
delamination shoulders and cause exces-
blasting sive heat, which will sepa-
rate sidewall rubber from
cord ply and cause an explo-
sion when problem gets
worse.

P18T00025
 3-21
January 24, 2017 Structure Function Principle
CLG835H Tire&rim system

Typical pictures Failure mode Main reasons

1. Reasons for manufacture:
there is impurities, oil stains
or water in sidewall rubber
or cord ply or not firmly com-
pressed when being molded
or gasoline does not fully
volatilize.
2. Traveling on uneven road
Delaminating of
with insufficient air or over-
sidewall
load or operating in severe
working conditions will
cause tire body to deform
badly and cause excessive
heat in partial sidewall so
that sidewall peels off or
explodes.
P18T00026

Major reasons: mixing of

extruded tread compound is
uneven, surfaces of semi-
Double skin finished product have impurities,
vulcanization mold has oil
stains, and isolating agent is
unevenly applied.

P18T00027
3-22
Structure Function Principle January 24, 2017
Tire&rim system CLG835H

Typical pictures Failure mode Main reasons

Major reasons: traveling with

too high pressure will cause
Wearing of
earthed area reduction of tire
crown
crown, local load increase and
wear intensification.

P18T00028

Major reasons: during traveling,

outer tube is scratched by
Trauma
pointed objects or is stabbed
evenly by pointed objects.

P18T00029

Major causes: the vehicle

speeds up when steering, the
tire side rubs the roadside
Side trauma obstacles; and installed tire is
stuck with hard objects; the
machinery is damaged during
transportation, installation.

P18T00030
 3-23
January 24, 2017 Testing and adjustment
CLG835H Power Train Test

Testing and adjustment

Power Train Test

Detection point layout of torque converter - gear box assembly as is shown in Figure 3-25, and names
and parameters of each detection point can be found in Table 3-7.
Figure 3-25 Measuring point layout

58

66
63

34
21
57 65

56
53

55 60 51
P18T00123

Table 3-7 Parameter list of the measuring point

S/N of the S/N of the

Name of the measuring Name of the Theoretical
measur- Theoretical value measuring
point measuring point value
ing point point
Input sensor of the gear
21 \ 55 Reverse gear clutch 1.6-1.8MPa
box
Output sensor of the
34 \ 58 Gear 3 clutch 1.6-1.8MPa
gear box
Inlet pressure of torque
51 Opening pressure: 0.85 56 Gear 1 Clutch 1.6-1.8MPa
converter
53 Forward gear clutch 1.6-1.8MPa\232-261psi 57 Gear 2 Clutch 1.6-1.8MPa
Pressure of shift control Outlet pressure of Opening
65 1.6-1.8MPa\232-261psi 63
system torque converter pressure: 0.5
60 Gear 4 Clutch 1.6-1.8MPa\232-261psi

Logical relations between gear states and working conditions of shift control valve solenoid valve can be
found in Table 3-8.
3-24
Testing and adjustment January 24, 2017
Torque Converter - Gearbox System CLG835H

Table 3-8 Logical relations between gear states and working conditions of shift control valve
solenoid valve

Electric condition of the solenoid valve

Sole-
noid Forward gear Reverse gear Neutral gear
valve
1 2 3 4 1 2 3 1 2 3 4
M1 ● ● ●
M2 ● ● ●
M3 ● ● ●
M4 ● ● ● ● ● ●
M5 ●
Clutch KV KV KV K4 KR KR KR
K3
Clutch K1 K2 K3 K3 K1 K2 K3

Remarks: ● means the solenoid valve is Drive axle system

energized;
Test Requirements: 1. Leakage check
Testing dynamic unbalance value Start up the machine, step on the service brake
After the drive shaft is repaired, a professional pedal for several times after the air pressure of
dynamic unbalance test must be performed. energy accumulator gets normal, observe
whether there is sign of leakage at the joint of
steel pipe of front axle brake and service brake
Torque Converter - Gearbox hose.
System 2. Exhaust
Figure 3-24 Rear axle ventilation plug
1. Leakage check
Start up the machine and operate it for several
minutes, observe whether there is sign of
leakage from the hose assembly coupled with
gear box assembly, if so, re-tighten it.
2. Test of gear box shift pressure
Power on the machine, now the oil pressure
warning light of gear box flashes on the
instrument panel, and after startup of machine, P18T00031
the warning light shall go out, if not, inspect the
oil level of gear box once again. 1) Loosen the exhaust plugs at both ends of
axle.
2) Start up the machine and step on the service
brake pedal until the oil overflows from the
exhaust plug.
3) Tighten the exhaust plug.
 3-25
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Removal and Installation

Removal and installation of torque converter-gearbox system

Removal of torque converter - gearbox system

Tools required
Reference picture Operation step
(Remarks)
1. Stop the machine on a level
ground, put the work imple-
ment, bucket levelly, and pull
up the emergency parking
brake lever.
2. Turn off the engine and
remove the key.
3. Remove the drain plug of
gear box assembly to drain
the oil.
Caution: The waste oil
shall be recovered in a
container during removal, in
order to avoid environmental
contamination. The removed 34# socket, 13#
hose is shielded to avoid con- socket,
tamination of parts. pneumatic
impact wrench
Danger: It is sure that the
P18T00032 hose pressure is fully
discharged and the oil is
cooled sufficiently before
removal of hose, in order to
avoid personal injury of hose
pressure and hot oil during
removal.
4. Remove the cab assembly
of machine, see section
“Removal and Installation of
Cab” for removal steps.
3-26
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
5. Remove the hose assembly
connecting the oil filter pipe
to the gear box assembly
with wrench.
Caution: The waste oil
shall be recovered in a 41# wrench
container during removal, in
order to avoid environmental
contamination.
P18T00033
The removed hose is shielded
to avoid contamination of
parts.
6. Remove the test line con-
nected to gear box assem-
bly and test hose.

18# Wrench

P18T00034

7. Remove the hose assembly

with a wrench.

41# Wrench

P18T00035
 3-27
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
8. Remove the clamping bolt
fixing the oil filler steel-pipe
with a wrench.

10# Wrench

P18T00036

9. Remove the coupling lock-

nut between rear drive shaft
and rear output flange of
gear box assembly.
Caution: The drive shaft
assembly is composed 18# Wrench
of slidable spline sleeve,
please take care to avoid per-
sonal injury caused by falling
P18T00037
of slide shaft fork during
removal.
10. Remove the coupling lock-
nut between intermediate
drive shaft and front output
flange of transmission
assembly.
21# Wrench

P18T00038
3-28
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
11. Remove the hose assembly
or the hose connected with
hydraulic pump from the
gearbox assembly, and refer
to removal of hydraulic sys-
tem for detailed procedures.

P18T00039

12. Remove the hose assembly

connected with brake sys-
tem from the emergency
parking brake chamber.

24# Wrench

P18T00040

13. Remove the bolts and

washer for attaching the
transmission mount to the
frame with an air gun.
46# wrench, 46#
socket,
pneumatic
impact wrench

P18T00041
 3-29
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
14. Pre-lift the gear box assem-
bly through the lugs with lift-
ing device.

Sling
(2 tons)

P18T00042

15. Remove the cover plate

from the transmission
assembly with a wrench.

13# Wrench

P18T00043

16. Remove the fastening bolts

used to attach the gear box
assembly to the engine fly-
wheel with a wrench.

16# Wrench

P18T00044
3-30
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
17. Remove the fastening bolts
used for attaching the gear
box assembly-torque con-
verter case to the engine
housing with an blower gun 16# socket,
and socket. pneumatic
impact wrench

P18T00045

18. Separate the transmission

assembly from the engine,
and secure the torque con-
verter case and core
through the bolt holes with
ropes and steel wires. Steel wire

P18T00046

19. Lift up the gear box assem-

bly from the machine
through the lugs with the
hoisting device and ropes
and place it in a safe area.

Sling
(2 tons)

P18T00047
 3-31
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Installation of torque converter-gear box system

Tools required
Reference picture Operation step
(Remarks)
1. Wipe clean the drain plug of
gear box, and then install it
in the threaded hole of gear 34# socket, 13#
box and tighten it with a socket,
torque of 600±70Nm\ pneumatic
442.5±51.6 lbf•ft. impact wrench,
open-end 34#
fixed torque
spanner
P18T00048

2. Secure the torque converter

to its housing through
threaded holes with the steel
wire or ropes.
Danger: The torque con-
verter can slide freely on
the guide wheel seat. When Steel wire
lifting up it, the torque con-
verter and its housing must
P18T00049
be secured firmly with the
steel wire or ropes, in order to
avoid personal injury due to
falling of torque converter.
3. Lift up the gear box assem-
bly onto the machine
through the lugs of gear box
assembly with the hoisting
device and ropes.

Sling
(2 tons)

P18T00050
3-32
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
4. Move gear box assembly to
fit it with engine flywheel
housing, and install the bolts
and hard washer used for 16# socket,
tightening the torque con- pneumatic
verter case to the engine impact wrench,
housing and then tighten open-end 16#
them. Tightening torque: fixed torque
72±6Nm\ 53.1±4.4 lbf•ft. spanner

P18T00051

5. Crank the engine flywheel

case to make the torque
converter align with mount-
ing threaded hole on the 16# socket,
engine flywheel, screw and pneumatic
tighten the fastening bolts impact wrench,
and washer for attaching the open-end 16#
torque converter to the fixed torque
engine flywheel by hand spanner
with a torque of 60±5Nm\
P18T00052 44.25±3.7 lbf•ft

6. Install the mounting hole

cover plate on the gear box.

13# Wrench

P18T00053
 3-33
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
7. Screw and tighten the bolts
and washer for fastening the
gear box mount to the frame 46# wrench, 46#
with the torque of socket,
2035±170Nm\ pneumatic
1500.8±125.38 lbf•ft. impact wrench,
open-end 46#
fixed torque
spanner
P18T00054

8. Attach the mounting end

flanges of drive shaft and
gear box to the rear output
flange of gear box, and
tighten the locknut to 18# wrench or
132±10Nm\ 97.35±7.38 open-end 18#
lbf•ft. fixed torque
spanner

P18T00055

9. Attach the intermediate drive

shaft to front output flange of
gear box and tighten the
locknut to 200±15Nm\
147.5±11.06 lbf•ft. 21# wrench or
open-end 21#
fixed torque
spanner

P18T00056
3-34
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
10. Install the oil filler steel-pipe
on the gear box and tighten
the set bolts with a torque of
26±3Nm\ 19.18±2.21 lbf•ft.
13# wrench or
open-end 13#
fixed torque
spanner

P18T00058

11. Install the hose referring to

the hydraulic installation and
hydraulic pump.

P18T00058

12. Install the hose assembly

used for attaching the oil fil-
ter pipe to the gear box, and
the tightening torque of hose
joint is 137±6Nm\ 41# wrench or
101.04±4.43 lbf•ft. open-end 41#
Caution: Two hose fixed torque
assemblies are spanner
respectively connected to the
P18T00059
inlet, outlet of fine oil filter in
directions as required,
avoiding installation error.
 3-35
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
13. Install the hose assembly
used for attaching the radia-
tor pipe to the gear box, and
the tightening torque of hose
joint is 137±6Nm\ 41# wrench or
101.04±4.43 lbf•ft. open-end 41#
fixed torque
spanner

P18T00060

14. Install the hose assembly

used for attaching the test
pipe to the gearbox, as
shown in the following figure
and table.
18# Wrench

P18T00061

Layout of test points of shift control valve

58

66
63

34
21
57 65 P18T00062

56
53

55 60 51

P18T00062
3-36
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
Logic diagram of test points and gear clutch

Theoretical S/N in the corre-

Decal marker Meanings
value sponding valve
PRESSURE OF IN FRONT Inlet pressure of torque Opening pres-
51
OF THE CONVERTER converter sure: 1.1 MPa
PRESSURE OF KV CLUTCH KV clutch pressure 1.6-1.8MPa 53
PRESSURE OF KR CLUTCH KR clutch pressure 1.6-1.8MPa 55
PRESSURE OF K1 CLUTCH K1 clutch pressure 1.6-1.8MPa 56
PRESSURE OF K2 CLUTCH K2 clutch pressure 1.6-1.8MPa 57
PRESSURE OF K3 CLUTCH K3 clutch pressure 1.6-1.8MPa 58
PRESSURE OF K4 CLUTCH K4 clutch pressure 1.6-1.8MPa 59

Mapping diagram of centralized measuring point

mounting plate and measuring point

P18T00063

15. Install the hose assembly

used for attaching emer-
gence parking brake cham-
ber to the brake system, the
tightening torque is 24# wrench or
37±2Nm\ 27.29±1.48 lbf•ft. open-end 24#
fixed torque
spanner

P18T00064
 3-37
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of torque converter-gearbox assembly

Tools required
Reference picture Operation step
(Remarks)
16. Fill the gear box by referring
to the Operation Manual of
this machine, and check the
oil level according to the
specified method.

Disassembly and assembly of torque converter-gearbox assembly

For disassembly and assembly of torque converter-gear box assembly in this machine, refer to "ZF Gear
Box Overhaul Manual".
3-38
Removal and Installation January 24, 2017
Removal and installation of drive shaft system CLG835H

Removal and installation of drive shaft system

Removal of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
1. Park the machine on a level
ground, turn off the engine,
and place the gear box han-
dle in neutral position, pull
up the emergency parking
brake lever and place the
wedges.
Caution: The drive shaft
assembly is composed
of slidable spline sleeve,
please take care to avoid per-
sonal injury caused by falling
of slide shaft fork during
removal.
2. Remove the connecting
locknut between the rear
drive shaft and rear axle
input flange with a wrench.

18# Wrench

P18T00065

3. Remove the connecting

locknut between rear drive
shaft and rear output flange
of gear box with a wrench,
and place the rear drive
shaft assembly in a safe 18# Wrench
area.

P18T00066
 3-39
January 24, 2017 Removal and Installation
CLG835H Removal and installation of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
4. Remove the connecting
locknut between intermedi-
ate drive shaft and front out-
put flange of gear box
assembly with a wrench.
21# Wrench

P18T00067

5. Remove tightening bolt and

nut between intermediate
drive shaft and front drive
shaft & bearing assembly,
and remove the intermediate
drive shaft from machine 18# Wrench
with a wrench.

P18T00068

6. Remove the bolts and

washer securely connecting
the front drive shaft and sup-
port assembly to middle
support plate with a wrench.
18# Wrench

P18T00069
3-40
Removal and Installation January 24, 2017
Removal and installation of drive shaft system CLG835H

Tools required
Reference picture Operation step
(Remarks)
7. Remove the bolts and nuts
securely connecting the
front drive shaft and support
assembly and front axle,
and remove front drive shaft
and support assembly from 18# Wrench
machine with a wrench.

P18T00070

8. Remove the tightening bolts

and washers of the support
plate and frame with a
blower gun or a wrench.
24# socket,
pneumatic
impact wrench
or 24# wrench

P18T00071

Installation of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
1. Wipe clean the surface,
install rear drive shaft and
rear axle input flange, and
align the the mounting
holes, then insert the tight- 18# wrench or
ening bolt and screw in the open-end 18#
nut and tighten it with a fixed torque
torque of spanner
132±10Nm\97.35±7.38 lbf•ft.

P18T00072
 3-41
January 24, 2017 Removal and Installation
CLG835H Removal and installation of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
2. Wipe clean the surface,
install the rear drive shaft
and rear output flange of the
gear box, and align the
mounting holes, screw in the
locknut and tighten it with a
torque of 132±10Nm\ 18# wrench or
97.35±7.38 lbf•ft. open-end 18#
fixed torque
Caution: When assem- spanner
P18T00073
bling, please make sure
to pay attention to the white
arrows on the identification of
drive shaft, both of which
must be aligned after assem-
bly!
3. Wipe clean the two mount-
ing surfaces of support
plates, and then pre-install it
onto the front frame. Set the
front drive shaft and support
assembly with middle sup-
port bearing on the front
frame middle support bear-
ing seat support plate.

P18T00074

4. Wipe clean the surface,

install the front drive shaft
and support assembly with
front axle input flange, and
align the mounting hole, 18# wrench or
screw in the locknut and open-end 18#
tighten it with a torque of fixed torque
132±10Nm\97.35±7.38 lbf•ft. spanner

P18T00075
3-42
Removal and Installation January 24, 2017
Removal and installation of drive shaft system CLG835H

Tools required
Reference picture Operation step
(Remarks)
5. Wipe clean the mounting
surfaces of front output
flange of gear box and inter-
mediate drive shaft flange,
and install the intermediate 21# wrench or
drive shaft to the front output open-end 21#
flange bolts of gear box, fixed torque
screw in the locknut and spanner
tighten it with a torque of
200±15Nm\ 147.5±11.06
P18T00076 lbf•ft.

6. Install the middle drive shaft,

front drive shaft and support
assembly, and align the
mounting holes. Insert the
tightening bolt and screw in
the locknut, and then tighten
them to 132±10Nm\ 18# wrench or
97.35±7.38 lbf•ft. open-end 18#
fixed torque
Caution: The intermedi- spanner
P18T00077
ate drive shaft middle
shaft fork must be aligned
with the fork which is coupled
with front axle on the front
drive shaft and support
assembly!
7. Adjust the front&rear,
left&right positions of inter-
mediate, front drive shafts
and support assembly to
make sure that the bolts Open-end 18#
between support plate and fixed torque
frame can be screwed in spanner or 18#
smoothly with torque of wrench
132±10Nm\ 97.35±7.38lbf•ft.

P18T00078
 3-43
January 24, 2017 Removal and Installation
CLG835H Removal and installation of front axle assembly

Tools required
Reference picture Operation step
(Remarks)
8. Install the tightening bolts
and washer of the middle
support bearing seat and
support plate, and tighten 24# socket, fixed
them to 22494±18.44 lbf•ft. torque blower
gun or open-end
24# fixed torque
spanner

P18T00079

Removal and installation of front axle assembly

Removal of front axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Stop the machine on a level
ground, put the work imple-
ment, bucket levelly, and pull
up the emergency parking
brake lever.
2. Turn off the engine, step on
the service brake pedal for Sling
several times, so as to
release the pressures of (12 tons)
energy accumulator and
axle brake pipe.
3. Lift up the machine with a
lifting device, and support it
up with a supporting device
with 4 tires off the ground
3-44
Removal and Installation January 24, 2017
Removal and installation of front axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
4. Pre-lift up the tires with a
hoist, remove the bolts and
nuts used for tightening the
rim and axle. Sling(2 tons)30#
socket,
5. Lift the tires away from pneumatic
machine and put them in a impact wrench
safe area. or open-end 30#
6. Repeat steps (4), (5), wrench
remove another tire installed
P18T00080 on the front axle.

7. Remove the hose assembly

connected to service brake
system and the front axle.
Caution: The waste oil
shall be recovered in a
container during removal, in
order to avoid environmental
contamination. The removed
hose is shielded to avoid con-
24# Wrench
P18T00081
tamination of parts.
Danger: It is sure that the
hose pressure is fully
discharged and the oil is
cooled sufficiently before
removal of hose, in order to
avoid personal injury of hose
pressure and hot oil during
removal.
8. Pre-lift the front axle assem-
bly with a sling.
9. Remove the bolts and nuts
for connecting the front axle
assembly to the front frame
with a blower gun. Sling(2 tons)40#
socket,
10. Put the axle assembly onto pneumatic
the ground slowly with a lift- impact wrench,
ing device. 40# wrench
P18T00082
11. Remove the axle assembly
from the bottom of machine
with a handling equipment,
and then put it on the appli-
ance for axle assembly.
 3-45
January 24, 2017 Removal and Installation
CLG835H Removal and installation of front axle assembly

Installation of front axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Take the front axle assembly
out of placed area with a
handling device, and posi-
tion it under its mounting Sling(2 tons) 46#
point. socket,
pneumatic
2. Lift up the front axle assem-
impact wrench,
bly with a hoist, and install it
open-end 46#
on the frame.
fixed torque
3. Install the tightening bolts spanner
P18T00083 and nuts and tighten them
with torque of 2035±170Nm\
1500.8±125.38 lbf•ft.
4. Install the front axle brake
pipe and service brake
hose. Tightening torque:
37±2Nm\ 27.29±1.48 lbf•ft.
Open-fixed 24#
fixed torque
spanner

P18T00084

5. Lift up the tire with a hoist

and install it onto the axle,
Sling
and then install the rim nut
and tighten it to 600±60Nm\ (2 tons)30#
442.5±44.25 lbf•ft. socket,
pneumatic
impact wrench,
open-end 30#
fixed torque
spanner
P18T00085

6. Lift the machine with a hoist,

remove the support device, Sling
and put the machine onto (12 tons)
the ground.
3-46
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Removal and installation of rear axle assembly

Removal of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Stop the machine on a level
ground, put the work imple-
ment, bucket levelly, and pull
up the emergency parking
brake lever.
2. Turn off the engine, step on
the service brake pedal for Sling
several times, so as to
release the pressures of (12 tons)
energy accumulator and
axle brake pipe.
3. Lift up the machine with a
lifting device, and support it
up with a supporting device
with 4 tires off the ground
4. Pre-lift up the tires with a
hoist, remove the bolts and
nuts used for tightening the Sling
rim and axle.
(2 tons)30#
5. Lift the tires away from socket,
machine and put them in a pneumatic
safe area. impact wrench
or open-end 30#
6. Repeat steps (4), (5),
wrench
remove another tire installed
P18T00086 on the rear axle.

7. Remove the the rear axle

and hose assembly
connected to service brake
system.

24# Wrench

P18T00087
 3-47
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
8. Remove the steel pipe
connected to the rear axle
and centralized lubricating
system.

Open-end 16#
wrench

P18T00088

9. Pre-lift the rear axle

assembly with a sling.
10. Remove the bolts and
locknuts for connecting the
rear axle assembly to the
rear frame. Sling (2 tons)
36# socket,
11. Put the axle assembly onto pneumatic
the ground slowly with a impact wrench,
lifting device. 36# wrench,
P18T00089
12. Remove the axle assembly
from the bottom of machine
with a handling equipment,
and then put it on the
appliance for axle assembly.
13. Place the axle assembly as
shown in the left figure to
make front swing frame
support shaft upward, and
rear swing frame support
shaft downward.

P18T00090
3-48
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
14. Remove the seal ring and
snap ring from the front
swing support rack with a
screwdriver.
Straight
screwdriver

P18T00091
15. Remove the front swing
support rack from axle
assembly with a lifting
device and place it in a safe
area. Sling
(2 tons)

P18T00092
16. Place the axle assembly as
shown in the left figure to
make the rear swing support
rack upward.

P18T00093

17. Remove the bolts, washers

with a wrench or an
pneumatic tool.

Open-end 18#
wrench

P18T00094
 3-49
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
18. Remove the cover.

Open-end 18#
wrench

P18T00095
19. Remove the thrust washer.

Straight
screwdriver

P18T00096

20. Remove the bolts and

washer tightening the
clamping plate.
Open-end 27#
wrench or 27#
socket,
pneumatic
impact wrench

P18T00097

21. Remove the clamping plate.

Straight
screwdriver

P18T00098
3-50
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
22. Remove the thrust washer.

Straight
screwdriver

P18T00099
23. Remove the rear swing
support rack with a lifting
device.

Sling
(2 tons)

P18T00100

24. Screw the M8 bolt in the

dowel and remove the
dowel.

Open-end 13#
wrench

P18T00101

25. Remove the bolts and wash-

ers tightening the support
shaft.
Open-end 21#
wrench or 21#
socket,
pneumatic
impact wrench

P18T00102
 3-51
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
26. Remove the support shaft
with a lifting device.

Sling
(2 tons)

P18T00103

Installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Lift up the axle assembly
and position it as shown in
the left figure onto a special
assembly device.

P18T00104

2. Wipe clean the mounting

face between the support
shaft and the axle case
connected to it with a clean
cloth, install the support
shaft onto the axle and align Copper bar
two dowel pins accurately,
strike it into the dowel pin
with a copper bar.

P18T00105
3-52
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
3. Apply thread lock sealant to
thread portions of bolts,
screw them into support
24# socket,
thread holes by 2-3 threads
pneumatic
by hand, and tighten them
impact wrench,
with an air gun. Tightening
open-end 24#
torque: 305±25Nm\
fixed torque
22494±18.44 lbf•ft.
spanner

P18T00106

4. Horizontally place rear

swing frame with the thread
hole end upward, and install
the bush into rear swing
support rack.

P18T00107

5. Turn over swing frame by

180°, install seal ring and
knock it to the end with
nylon hammer.

Nylon hammer

P18T00108

6. Turn over swing frame group

by 180°, evenly apply
molybdenum disulfide
lithium base grease to
bushing cone, and install
rear swing frame group into
spindle with lifting device.

P18T00109
 3-53
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
7. Install thrust washer and
pressing plate and align the
holes well.

P18T00110

8. Apply thread lock sealant to

thread portion of bolt, screw
bolts and hard washers into
the clamping plate thread 24# socket,
holes by 2-3 teeth by hand, pneumatic
and drive them in impact wrench,
symmetrically with open-end 24#
pneumatic impact wrench fixed torque
with the tightening torque of spanner
305±25Nm\ 224.94±18.44
P18T00111 lbf•ft.

9. Put a thrust washer and

cover and align the holes
well.

P18T00112

10. Apply thread lock sealant to

thread of bolts, screw bolts
and hard washers into cover
thread holes by 2-3 teeth by 21# socket,
hand, and drive them in pneumatic
symmetrically with impact wrench,
pneumatic impact wrench open-end 21#
with the tightening torque of fixed torque
195±15Nm\ 143.81±11.06 spanner
lbf•ft.
P18T00113
3-54
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
11. Horizontally place front
swing frame, and knock seal
ring into front swing frame
mounting hole to the end
with nylon hammer.
Nylon hammer
Caution: The seal ring lip
faces outward.
Seal
Sealring
ringliplip

P18T00114

12. Press the bushing into the

front swing frame to the bot-
tom
Caution: The small hole
of bushing must toward
the lug end of front swing
support.

P18T00115

13. Install the snap ring into the

groove with straight screw-
driver.

Straight
screwdriver

P18T00116

14. Knock seal ring into front

swing frame mounting slot to
the end with nylon hammer;
Caution:The seal ring lip
faces outward.

Seal
Sealring
ringliplip

P18T00117
 3-55
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
15. Evenly apply the molybde-
num disulfide lithium base
grease to bushing cone, and
then lift and install the front
swing support subassembly
onto the bearing seat of the
main transmission.
Sling
16. Place the axle assembly on
a transport device with a lift- (2 tons)
P18T00118
ing device, and right under
mounting point of rear axle.
17. Install the axle assembly
onto the rear frame with a
lifting device and align the
mounting holes.
18. Install the mounting bolts,
washers and nuts of the axle
assembly and tighten them
with an blower gun to 36# socket,
1122±90Nm\ 827.28±66.38 pneumatic
lbf•ft. impact wrench,
open-end 36#
fixed torque
spanner

P18T00119

19. Install the axle and hose

connecting the service brake
pipe and tighten it to
37±2Nm\ 27.29±1.48 lbf•ft.

Open-end 24#
wrench

P18T00120
3-56
Removal and Installation January 24, 2017
Disassembly and assembly of the drive axle CLG835H

Tools required
Reference picture Operation step
(Remarks)
20. Lift up the tire with a hoist
and install it onto the axle,
and then install the rim nut
and tighten it to 600±60Nm\ 30# socket,
442.5±44.25 lbf•ft. pneumatic
impact wrench
or open-end 30#
fixed torque
spanner

P18T00121

21. Install the steel pipe con-

necting the centralized lubri-
cating system and axle.

Open-end 16#
wrench

P18T00122

22. Lift the machine with a hoist,

remove the support device, Sling
and put the machine onto (12 tons)
the ground.

Disassembly and assembly of the drive axle

For disassembly and assembly of the drive axle in this machine, see "835H Drive Axle Service Manual"
for details.
 3-57
January 24, 2017 Fault Diagnosis and Troubleshooting Methods
CLG835H Disassembly and assembly of the drive axle

Fault Diagnosis and Troubleshooting Methods

Fault inspection and

Fault features Main reasons
troubleshooting
1. Start circuit of the base machine (such as 1. Check the circuit of the base machine.
power voltage, electric lock, startup relay
and startup motor) has faults.
2. The lever is not at the neutral position. 2. Shift the lever to neutral position.
The engine can not 3. The fuse to the control circuit on the base 3. Replace the fuse.
1
Activation machine is burnt.
4. Poor contact of handle plug or the handle 4. Organize the plugs.
is failed.
5. Poor contact of controller plug or the con- 5. Organize the plugs.
troller is failed.
1. Oil pressure gauge is failed. 1. Replace the oil pressure gauge
2. Insufficient tightening torque for bolt of 2. Tightening torque for M8-8.8 bolt of shift
Low shift pressure shift control valve. control valve is 26Nm.
2 at all gears 3. Spring of main pressure valve is broken. 3. Replace it.
Low pressure 4. Gear shift pump is worn 4. Replace the gear shift pump.
5. Fragments enter into shift control valve or 5. Replace the filter, and clean the control
valve is stuck valve.
1. O-ring in throttle plug is damaged 1. Replace the O-ring
Too short shifting
3 2. The tightening torque of pressure control 2. Tightening torque for M8-8.8 bolt of shift
time at all gears
valve bolts is out of specified range control valve is 26Nm.
Too long shifting 1. Throttle plug is blocked. 1. Clean and dredge.
4
time at all gears 2. Pressure control valve is stuck. 2. Wash and check.
1. Oil temp sensor is failed. 1. Replace the part.
2. Oil temperature gauge is failed. 2. Replace the part.
The oil tempera- 3. Insufficient oil level. 3. Check oil level following the correct
5 ture of the torque method.
converter is high 4. Air found in torque converter oil radiator. 4. Exhaust.
5. Oil line from torque converter to radiator is 5. Check oil pipe from radiator to gear box
poor. and radiator for blockage.
1. Poor cooling capability of radiator. 1. Check whether cooling capability is suffi-
cient, such as checking the degree of
tightness for engine fan belt and dirt
The oil tempera- attached to outer surface of radiator.
6 ture of the torque 2. Back pressure valve of torque converter 2. Be careful to check hose connector from
converter is high stuck. gear box to radiator. If hose connector
enters housing too deeply, pushes spool
of pressure valve and cause valve to stick,
oil line will be getting blocked.
3-58
Fault Diagnosis and Troubleshooting Methods January 24, 2017
Disassembly and assembly of the drive axle CLG835H

Fault inspection and

Fault features Main reasons
troubleshooting
1. Insufficient oil level. 1. Check oil level and add the oil by following
the right operation.
2. Elastic plate connecting engine and 2. Replace the elastic plate or replace the
torque converter is torn, or power connec- related damaged parts.
tion from torque converter to gear box
input gear has faults.
3. Circuit failure of the complete machine. 3. Check the power voltage for abnormal
Vehicle does not and the cable for damage.
7
move at any gear
4. Shift pressure is too low. 4. Refer to the troubleshooting above.
5. Solenoid valve is damaged. 5. Check if the rated current of solenoid
valve is 830 mA.
6. Shift lever is damaged. 6. Refer to the troubleshooting for lever.
Replace it.
7. Controller is damaged. 7. Refer to the fault inspection of controller.
Replace it
 3-1
January 24, 2017 Power Train System
CLG835H

Power Train System

Basic Information ............................................................................................................3-3
Safety .....................................................................................................................................................3-3
System composition and position ..........................................................................................................3-4
System technical parameters.................................................................................................................3-5
System schematic diagram and working principle description...............................................................3-6
Overview of transmission fluid ...............................................................................................................3-7
Maintenance and replacement of gearbox and drive axle oil.................................................................3-8
Universal tool, tooling list .....................................................................................................................3-10
Special tool, tooling list ........................................................................................................................3-10

Structure Function Principle ........................................................................................3-11

Torque Converter - Gearbox System ...................................................................................................3-11
Drive axle system.................................................................................................................................3-17
Drive Shaft System ..............................................................................................................................3-19
Tire&rim system ...................................................................................................................................3-21

Testing and adjustment ................................................................................................3-25

Torque Converter - Gearbox System ...................................................................................................3-25
Drive axle system.................................................................................................................................3-25

Removal and Installation ..............................................................................................3-26

Removal and installation of torque converter-gearbox system ............................................................3-26
Disassembly and assembly of torque converter-gearbox assembly ....................................................3-38
Removal and installation of drive shaft system ....................................................................................3-39
Removal and installation of front axle assembly ..................................................................................3-44
Removal and installation of rear axle assembly...................................................................................3-47
Disassembly and assembly of the drive axle .......................................................................................3-60

Fault Diagnosis and Troubleshooting Methods .........................................................3-61

Testing and adjustment ................................................................................................3-63
Power Train Test..................................................................................................................................3-63
3-2
Power Train System January 24, 2017
CLG835H
 3-3
January 24, 2017 Basic Information
CLG835H Safety

Basic Information

Safety This word means existing potential danger,

and if no avoidance, it may cause slight or
Many accidents in operation, maintenance, medium personal injury.
repair and other aspects are caused by fail to "Caution" is also used for reminding the
observe the basic safety rules and precautions. If safety attentions of unsafe operation possi-
the case of potential risk is fully aware in bly causing personal injury. "Danger" repre-
advance, these accidents usually can be sents the worst dangerous conditions. Safety
avoided. The operators must pay attention to sign of "danger" or "warning" is an attach-
these potential risks, and be trained for relevant ment set at the specific dangerous location.
skills before properly and safely operating, General precautions are listed on the safety
maintaining and repairing the machine. sign of "Caution".
● Any improper operation, maintenance and In addition, please carefully follow the "Cautions"
repair methods may lead to hazardous condi- listed in this Manual, otherwise, it may result in
tion, cause personal injury and even death. great damage to the machine. We are unable to
● Be sure to read and understand the relevant enumerate all the possible risks (including
security measures and precautions before potential dangers), and the warnings in the
operating, maintaining and repairing the Manual and product do not cover all the risks and
machine. dangers. If the tools, operation procedures,
methods or techniques are not specially
● Please strictly obey the safety warning infor- recommended by our company, it is necessary to
mation listed in this Manual and on the ensure the personal safety of every one, and
machine during operating, maintaining and protect the machine against any damage.
repairing the machine, otherwise heavy casu-
alties will occur. The contents herein are provided based on the
status of the machine at the time when the
Safety warning information in the Manual is Manual was written, whereas, all products are
indicated by the following symbols updating, and this machine is no exception. Any
modification will influence the operation,
maintenance and repair of the machine,
therefore, please contact the LiuGong dealers for
This word means existing potential danger, latest and most comprehensive service
and if no avoidance, it may cause death or information before operating, maintaining and
serious personal injury. repairing the machine.

This word means danger will occurred imme-

diately, and if no avoidance, it may cause
death or serious personal injury.
3-4
Basic Information January 24, 2017
System composition and position CLG835H

System composition and position

The power train system is a critical part of a loader, like a heart, and it is located at portion between the
engine and tire, as shown in red in the figure below. It mainly consists of three majority components:
gearbox, drive shaft and drive axle.
Fig 3-1 Schematic diagram of position for wheel loader

P18T00001

System technical parameters

Main technical parameters for the power train system of this machine are listed in Table 3-1.
Table 3-1: Main technical parameter table for power train system

System components Items Parameters Remarks

Model ZF 4WG158
Type Fixed shaft type
Gear box
Full-auto electro hydraulic
Control mode
control
Torque converter Type Single-turbo, three-element
Spiral gear level-I reduction,
Drive mode
Drive axle wheel planetary gear reduction
Brake mode Wet brake
 3-5
January 24, 2017 Basic Information
CLG835H System schematic diagram and working principle description

Table 3-1: Main technical parameter table for power train system

System components Items Parameters Remarks

Tubeless bias tire or tubed bias
Tire structure Radial tire
tire is optional
Tire Specification 17.5R25 two star L3
Level \
Type of tread L-3 Ordinary block
Rim Specification 25-14.00/1.5

System schematic diagram and working principle description

The torque converter -gearbox assembly equipped in this machine is ZF 4WG158 full auto type, and the
drive axle is 30 wet axle, whose structure diagram are shown as below:
Figure 3-2 Diagram for gear box assembly composition

1 2 3 4 3

14

13 6

12
7
11
8
10

9 P18T00002

1. Coupling device 8. Output plate

2. Torque converter housing 9. Nameplate
3. Lifting eye 10.Output flange
4. Control harness interface 11.Speed sensor
5. Electro-hydraulic shift control valve 12.Oil outlet of torque converter
6. Suction tube 13.Torque converter outlet oil temperature sensor
7. Brake 14.Cover
3-6
Basic Information January 24, 2017
System schematic diagram and working principle description CLG835H

Fig 3-3 Structure diagram for drive axle assembly

Axle housing bevel gear of the wheel reduction half shaft

P18T00003

As shown in the above figure, the engine is coupled with the torque converter of the torque converter-
gear box assembly, a part of engine power is used to drive the torque converter to work and another part
is used to drive the hydraulic pump so as to provide power for the hydraulic system.
When the engine works together with torque converter, the engine output power is input into the gear
box via the torque converter. Under the control of its electro-hydraulic shift control valve, the gear box
can output power and speed at different positions with gear shafts and clutches.
The power output from the gear box is transmitted to the main drive of drive axle via a drive shaft, and
then transmitted to wheel reducer by left and right axle shafts via main drive differential, and further to
tire rim assembly by decelerating and increasing torsion, thus finally to drive the loader to travel and
work.
 3-7
January 24, 2017 Basic Information
CLG835H System schematic diagram and working principle description

Overview of transmission fluid

The oil product used for wheel loader is divided into four categories, i.e. the lubricant, grease, brake fluid
and fuel, each of which can play a different role in the use of loader.
The lubricant, used in the loader, has two effects , one is to lubricate the parts and reduce the pressure,
so as to prolong the service life of parts; the other is to dissipate the heat of parts produced by friction, so
as to make the parts work normally. The lubricant is composed of various petroleum-based additives.
The wheel loader use a kind of lubricant which has four classes , i.e, diesel oil, gear oil, hydraulic drive
shaft and hydraulic fluid. The applications of the lubricant used in the power train system of this machine
are shown in the table below:
Table 3-2 Table of lubricant application

Cate- Ambient temperature Recommended

Application parts
gory -40 -30 -20 -10 0 10 20 30 40 50 brand

Mobil Delvac Super 1300 ZF torque converter &

engine oil transmission assembly
Torque
(-15°C~+50°C)\ uses SAE 15-40 in gen-
converter
(-5°F~122°F) eral areas and in hot
- gearbox
Mobil ATF 220 desert areas; and uses
assembly
(-35°C~+50°C)\ Mobil ATF220 in arctic
(-31°F~122°F) areas.
Mobil gear oil 80W-90/LS
with additives
LiuGong axle uses SAE
(-15°C~+50°C)\
80W-90/LS in general
(-5°F~122°F);
and hot areas, and Mobil
Mobil gear oil 424
424 with additives and
(-40°C~+50°C) \
Gear oil Shell SPIAX S6 AXME
(-40°F~122°F)with addi-
75W-90/LS in arctic
tives
areas.
Shell SPIAX S6 AXME
LS means the additives
75W-90/LS
are inclusive
(-40°C~+50°C)\
(-5°F~122°F)
3-8
Basic Information January 24, 2017
Maintenance and replacement of gearbox and drive axle oil CLG835H

Maintenance and replacement of 2) After the Oil sump tank of the gear box com-
pletely gets empty, wipe clean the mating
gearbox and drive axle oil surface on drain plug and gearbox housing
that contacting with O ring of the oil drain
The oil product added to the torque converter - plug. After the O-ring of the oil drain plug is
gearbox assembly must be consistent with oil list replaced, reassemble and tighten it.
TE-ML 03 recommended by ZF, the oil level shall 3) Add the oil in accordance with the oil list TE-
be checked once a week by the following ML 03 as recommended by ZF;
methods:
4) Check the oil level by the method as speci-
1) Park the machine on level ground; fied for transmission.
2) Place the gear box gear in the neutral posi- The fine oil filter is also replaced every time the
tion; oil change is done for the gear box. The oil filter
3) Torque converter - gearbox oil is at 80- may be installed by the following method:
95°C\176°F~203°F; 1) Apply a small amount of the gear box oil on
4) The engine is idling 800rpm); the oil seal of oil filter;
5) Observe the oil level gauge of gearbox and 2) The oil filter is screwed in until the oil seal of
it shall be in the "HOT" zone; oil filter contacts the filter head, tighten it 1/3
to 1/2 turn by hand.
After the torque converter and gearbox assembly
co-work for the first 100h, the oil shall be The oil product added in the drive axle must be
replaced every 1000h or at least once a year. Oil in accordance with the oil list of 85W-90 heavy-
can be replaced by the methods as below: load wheel gear oil (GL-5) recommended by
LiuGong. The oil level of LiuGong axle may be
1) Unscrew the drain plug on the torque con-
checked by the following methods:
verter - gearbox assembly to drain the oil.
Figure 3-5 Wheel drain plug and oil level check
plug

The waste oil shall be collected in a container

during oil drainage, in order to avoid environ-
mental contamination;
The oil shall be fully cooled before oil drain-
age, in order to avoid personal injury due to
hot oil splashing onto the body.
Figure 3-4 Gearbox drain plug

P18T00005

P18T00004
P18T00004
 3-9
January 24, 2017 Basic Information
CLG835H Universal tool, tooling list

1) Wheel reducer: place the axle according to the installation position, and turn the hub to keep the oil
level in a horizontal position, fill oil from left and right hubs respectively until the oil overflows the oil
level plug; park the reducer for ten minutes after the drive axle running, and then check the oil level,
and add enough lubricating oil.
Figure 3-6 Bevel gear refuel plug and oil level check plug
Bevel gear refuel plug and oil level check plug

P18T00006

2) Axle housing: the oil is added into axle housing until it overflows from the oil filler.
The axle oil shall be replaced at the first 500h, after that once every 1000h, or at least once a year.

Universal tool, tooling list

For the universal tools, tooling list, please see the torque converter-gear box system, drive axle system
and drive shaft system.

Special tool, tooling list

For the special tool, tooling list, please see "ZF Box Overhaul Manual" for details.
3-10
Structure Function Principle January 24, 2017
Torque Converter - Gearbox System CLG835H

Structure Function Principle Figure 3-8 Structural schematic diagram of

torque converter - gear box assembly
Clutch
Torque Converter - Gearbox Forward KV Clutch K1

System Converter

Input Pump
The torque converter -gearbox system equipped 1. Power Take -OFF
in this machine is ZF 4WG158 full auto type,
which mainly consists of a three-element, single- Clutch K2

turbo torque converter, mechanical gear box with

four forward gears, three reverse gears and Clutch K3
Clutch Reverse KR
electro hydraulic shift control system, as shown
Clutch K4
below: Parking Brake

Figure 3-7 External view of torque converter - LAYSHAFT

gear box assembly Output Output
KV - Gerar Rear Axle Front Axle

Idler Gear
Speedometer Drive
Oil Sump
K4 - Gerar P18T00008

P18T00007
 3-11
January 24, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

System technical parameters

The technical parameters of ZF 4WG158 torque converter - gear box assembly in this machine are listed
in Table 3-3.
Table 3-3 Technical parameter table of torque converter - gear box assembly

Remar
Component Items Parameters
ks
Model ZF 4WG158
Type Fixed shaft type
Gears Four forward gears, three reverse gears
Gearbox
Torque converter-gear box assembly
430\ 948.15
Quality (oil not included) /kg\lb
Type of emergence parking brake Shoe brake
Type Single-turbo, three-element
Circulation circle diameter of torque con-
340\ 13.39
verter/mm\In
Torque converter
Inlet pressure of torque converter/MPa\ psi 0.85\ 123.25
Outlet pressure of torque converter/MPa\
0.50\ 72.5
psi
System voltage/V 24
Shift control
Shift control mode Auto electro hydraulic power shift
system
System working pressure/MPa\ psi 1.6+0.2\ 232+29

System schematic diagram and working principle description

The torque converter of this system is a three-element with single-turbo structure, and the diagram for its
structure and working principle is as follows:
Figure 3-9 Structure diagram for torque converter

Turbine wheel
Pump wheel

From the engin

P18T00009
3-12
Structure Function Principle January 24, 2017
Torque Converter - Gearbox System CLG835H

Figure 3-10Schematic diagram for torque converter hydraulic

Hydraulic torque converter

Outlet constant
pressure valve of
torque converter

Inlet constant refined

pressure valve filtration
of torque converter
Radiator
Front pump

Transmission Engine Rough

—shaft lubrication filtration
Tank P18T00010

We can see from structure diagram for torque converter, a three-element, single-turbo torque converter
mainly consists of pump wheel, guide wheel and a turbine. As the pump wheel of torque converter is
directly coupled with and driven by the engine, the hydrodynamic drive oil between pump wheel and tur-
bine forms complex flow under rotation of pump wheel. The mechanical energy is converted into kinetic
energy of oil fluid. The fluid flow with kinetic energy strikes against the turbine at a high speed. The tur-
bine absorbs its kinetic energy and restores it to mechanical energy for gearbox. The guide wheel is sta-
tionary. When the fluid flow(which is from the turbine and has some kinetic energy) passes through the
curved blade of the guide wheel, the torque formed by the impact force and counterforce produced on
the blade acts on the engine base, and equivalent to the sum of increased torque of turbine from coun-
terforce and reduced torque of pump wheel from impact force. It is possible that the output torque of tur-
bine is greater than input torque of pump wheel, based on which, the torque converter is variable.
The working oil of torque converter is imported into the torque converter through the coarse and fine fil-
ters from the oil tank by the variable pump. There is a constant pressure valve (safety valve) set at the
inlet of torque converter, whose main role is to avoid excessive pressure in the torque converter to dam-
age the parts. There is another constant pressure valve (back pressure valve) at the outlet of torque con-
verter, whose main role is to ensure the torque converter is full of working oil in order to avoid cavitation
appeared during operation and impact on the performance of torque converter.
 3-13
January 24, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

An electro-hydraulic shift control valve is installed on the gear box assembly, see figure 3 -11 and 3-12
for structure composition and operating hydraulic pressure schematic diagram.
Figure 3-11 Diagram for structure and composition of electro-hydraulic shift control valve

CABLE HARNESS X HOSE LINE FROM

M4 TO REVERSING VALVE

CONTROL PRESSURE
SHIFT VALVE 4
VALVE

REVERSING VALVE
HOSE LINE FROM
M4 TO REVERSING VALVE
REDUCING VALVE

2-STAGE
PRESSURE
CONTROL VALVE PRESSURE CONTROL VALVE

SHIFT VALVE 2
BLEEDER VALVE

RESET VALVE

SHIFT VALVE 1 SHIFT VALVE 5 SHIFT VALVE 3

P18T00011
Figure 3-12 Schematic diagram for hydraulic pressure of torque converter - gear box assembly
OIL CIRCULATION DIAGRAM 4 WG-200 WITH 2-STAGE PRESSURE CONTROL VALVE -VARIANT II -

TABLE -20 NEUTRAL

THE MARKED POSITIONS (e.g.53) CORRESPOND WITH
THE POSITIONS ON THE TABLE -15

DIAGRAM CODE “G”

4 SPEED -VERSION

LEGEND
CONTROL PRESSURE
CONTROL PRESSURE REDUCED
CONTROL PRESSURE MODULATED
CONVERTER INLET PRESSURE
CONVERTER EXIT PRESSURE
LUBRICATION
RETUAN FLOW INTO THE SUMP

P18T00012
3-14
Structure Function Principle January 24, 2017
Torque Converter - Gearbox System CLG835H

The electro-hydraulic shift control valve consists Figure 3-15 Drive line of forward gear 3
of solenoid valves M1, M2, M3, M4, M5, valve
stem and body. When the electro-hydraulic shift ࠰
OUT

control valve is operating, the fluid flow in the Torque

valve stem oil passage is controlled by the power converter
turbine
of solenoid valves, which finally control the
engagement and disengagement of clutch in the
gear box, thus to make the gear box achieve
Input shaft
different shifts. For the power transferring line
and gear engagement with the gear box in
different gears, please see the figure of the
power transferring line for each gear as the
following figure 3-13 to 3-19.
Figure 3-13 Drive line of forward gear 1
OUT
࠰
OUT
Output Output
shaft shaft
Torque
converter P18T00015
turbine
Figure 3-16 Drive line of forward gear 4
Input shaft
࠰
OUT

Torque
converter
turbine

Input shaft

OUT
Output Output
shaft shaft
P18T00013

Figure 3-14 Drive line of forward gear 2

OUT

Output Output
࠰
OUT
shaft shaft
Torque
converter P18T00016
turbine

Input shaft

࠰
OUT
Output Output
shaft shaft

P18T00014
 3-15
January 24, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

Figure 3-17 Drive line of reverse gear 1 Figure 3-19Drive line of reverse gear 3

OUT
OUT
Torque Torque
converter converter
turbine turbine

Input shaft
Input shaft

OUT
OUT
Output Output Output Output
shaft shaft shaft shaft

P18T00017 P18T00019

Figure 3-18 Drive line of reverse gear 2

OUT
Torque
converter
turbine

Input shaft

OUT
Output Output
shaft shaft
P18T00018
3-16
Structure Function Principle January 24, 2017
Drive axle system CLG835H

Drive axle system

Composition and position of drive axle system

The basic function of drive axle for wheel loader is to reduce the gear box input speed with main drive
and wheel reducer and increase the torsion, thus to meet the requirements of driving, operating speed
and traction of the base machine. And also, change the straight line motion to vertical-lateral motion via
main drive, so that the drive wheel can be driven to rotate to make the base machine drive along the
straight route. The differential helps balance the speeds of left and right tires to make sure the machine
can still drive when the driving resistances on both sides are different.
In addition to basic features of drive axle for wheel loader, it is also a load-bearing unit for complete
machine, a support device for road wheel and mounting & support device for service brake. The drive
axle system mainly consists of front axle, rear axle and brake lines. The swing axle also includes front,
rear swing brackets, support shaft and other parts.

System technical parameters

Major technical parameters for the drive axle system of this machine are listed in Table 3-4.

Table 3-4 Main technical parameter table for drive axle

System components Items Parameters Remarks

Spiral gear level-I reduction, wheel
Drive mode
planetary gear reduction
Front axle
Brake mode Built-in wet multi-plate type
Brake pressure /MPa\psi 1450
Spiral gear level-I reduction, wheel
Drive mode
planetary gear reduction
Rear axle
Brake mode Built-in wet multi-plate type
Brake pressure /MPa\psi 1450
 3-17
January 24, 2017 Structure Function Principle
CLG835H Drive axle system

System schematic diagram and working

principle description Figure 3-21 Diagram of the wheel reducer

The drive axle for wheel loader is classified into

two classes, i.e. front axle and rear axle, the
main difference between which is the spiral
directions of the spiral bevel gear pairs in the
main drive. The driving spiral bevel gear of front 1 2
axle is left-handed, and that of rear axle is right-
handed. The structure diagram for bevel gear
3
and wheel reducer of this machine is as shown in
figure 3-20 and 3-21.
4
Figure 3-20 Structure diagram of the bevel gear

5 4 5
2

3
P18T00021
1. Axle shaft 4. Hub
2. Planetary gear 5. Sun gear
3. Brake
1 The bevel gear structure is shown in Figure 3-21.
The bevel gear includes two parts, one is the
bevel gear composed of driving spiral bevel gear
and large size spiral bevel gear; the other is the
differential composed of cross axle and bevel
gear. The power is transmitted to the driving
spiral bevel gear by the gear box through drive
P18T00020
shaft, thus to drive the large size spiral bevel
1. Driving spiral bevel gear 4. Carrier gear with differential to rotate together. The half
2. Axle housing 5. Differential shaft gear of differential passes the power to left/
3. Driven spiral bevel gear
right half shaft which is connected with the
splines, and further to the wheel reducer. The
power is then transmitted to hub and finally to
drive the tire to rotate after further speed
reduction, increasing torsion through wheel
reducer.
3-18
Structure Function Principle January 24, 2017
Drive Shaft System CLG835H

Drive Shaft System

In the wheel loader, the drive shaft system is mainly used to deliver the power between the two con-
nected shafts, of which the relative position changes constantly during operation. Because of the special
transmission characteristics of universal joint, the drive shaft may connect two transmission parts with
nominal concentric axial line. However, an error may occur during installation and axial line deviates
from the original position when operating, the drive shaft is widely used in shoveling transportation
machine.

System composition and position

The drive shaft system of wheel loader is composed by the following two structural types in accordance
with its formal layout, the drive shaft system shown in Figure 3-25 consists of rear and front drive shafts,
the one shown in Figure 3-26 consists of rear, front, intermediate shafts and support assembly.
Figure 3-22 Drive shaft system

1
3

P18T00022
1. Front drive shaft 2. Torque converter-gear box assembly 3. Rear drive shaft

Figure 3-23 Drive shaft system

1 2 4

P18T00023

1. Front drive shaft&support assembly 3. Torque converter-gear box assembly

2. Intermediate drive shaft 4. Rear drive shaft
 3-19
January 24, 2017 Structure Function Principle
CLG835H Tire&rim system

System technical parameters

The technical parameters for the drive shaft system are listed in Table 3-5.

Table 3-5 Technical parameter table for drive shaft system

Parts name Input-end coupling type Output-end coupling type

Rear drive shaft 7C FLANGE 7C FLANGE
Intermediate drive shaft 180 round flange 150 round flange
Front drive shaft&support assembly 150 round flange 150 round flange

Tire&rim system

System composition and position

Tire & rim system are both components bearing weight of a complete machine and direct components
driving the complete machine to walk. Tires can be classified into bias tires with an inner tube, bias tires
without an inner tube, radical tires, solid tires, etc. in accordance with it structural layouts. They can also
be classified into block pattern tires, traction pattern tires, skidding tires, etc. according to pattern form.

System technical parameters

The technical parameters for the tire & rim system equipped in this machine are listed in Table 3-6.

Table 3-6 Technical parameters of tire&rim system

System compo-
Items Parameters Remarks
nents
Tubeless bias tire or tubed bias
Tire structure Radial tire
tire is optional
Specification 17.5R25 two star L3
Level \
Tire Type of tread L-3 Ordinary block
Front wheel:0.55-0.58\79.75-
84.10
Tire pressure (MPa)\(psi)
Rear wheel: 0.52-0.55\75.40-
79.75
Rim Specification 25-14.00/1.5
3-20
Structure Function Principle January 24, 2017
Tire&rim system CLG835H

Common failure modes of tire and reasons

Common failure mode of tire and reasons are as follows:

Typical pictures Failure mode Main reasons

1. Reasons for manufacture:
there is impurities, oil stains
or water in the tread rubber
or cord ply or not firmly com-
pressed when being
molded, or gasoline does
Delaminating of not fully volatilize.
crown 2. Reasons for usage: speed is
too fast (beyond specified
speed), and directive pattern
is traveling in reverse direc-
tion.
P18T00024

1. Reasons for manufacture:

there is impurities, oil stains
or water in sidewall rubber
or cord ply or not firmly com-
pressed, or gasoline does
not fully volatilize.
2. Traveling with insufficient air
Shoulder will intensify wear of tire
delamination shoulders and cause exces-
blasting sive heat, which will sepa-
rate sidewall rubber from
cord ply and cause an explo-
sion when problem gets
worse.

P18T00025
 3-21
January 24, 2017 Structure Function Principle
CLG835H Tire&rim system

Typical pictures Failure mode Main reasons

1. Reasons for manufacture:
there is impurities, oil stains
or water in sidewall rubber
or cord ply or not firmly com-
pressed when being molded
or gasoline does not fully
volatilize.
2. Traveling on uneven road
Delaminating of
with insufficient air or over-
sidewall
load or operating in severe
working conditions will
cause tire body to deform
badly and cause excessive
heat in partial sidewall so
that sidewall peels off or
explodes.
P18T00026

Major reasons: mixing of

extruded tread compound is
uneven, surfaces of semi-
Double skin finished product have impurities,
vulcanization mold has oil
stains, and isolating agent is
unevenly applied.

P18T00027
3-22
Structure Function Principle January 24, 2017
Tire&rim system CLG835H

Typical pictures Failure mode Main reasons

Major reasons: traveling with

too high pressure will cause
Wearing of
earthed area reduction of tire
crown
crown, local load increase and
wear intensification.

P18T00028

Major reasons: during traveling,

outer tube is scratched by
Trauma
pointed objects or is stabbed
evenly by pointed objects.

P18T00029

Major causes: the vehicle

speeds up when steering, the
tire side rubs the roadside
Side trauma obstacles; and installed tire is
stuck with hard objects; the
machinery is damaged during
transportation, installation.

P18T00030
 3-23
January 24, 2017 Testing and adjustment
CLG835H Torque Converter - Gearbox System

Testing and adjustment 2) Start up the machine and step on the service
brake pedal until the oil overflows from the
exhaust plug.
Torque Converter - Gearbox 3) Tighten the exhaust plug.
System

1. Leakage check
Start up the machine and operate it for several
minutes, observe whether there is sign of
leakage from the hose assembly coupled with
gear box assembly, if so, re-tighten it.
2. Test of gear box shift pressure
Power on the machine, now the oil pressure
warning light of gear box flashes on the
instrument panel, and after startup of machine,
the warning light shall go out, if not, inspect the
oil level of gear box once again.

Drive axle system

1. Leakage check
Start up the machine, step on the service brake
pedal for several times after the air pressure of
energy accumulator gets normal, observe
whether there is sign of leakage at the joint of
steel pipe of front axle brake and service brake
hose.
2. Exhaust
Figure 3-24 Rear axle ventilation plug

P18T00031

1) Loosen the exhaust plugs at both ends of

axle.
3-24
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Removal and Installation

Removal and installation of torque converter-gearbox system

Removal of torque converter - gearbox system

Tools required
Reference picture Operation step
(Remarks)
1. Stop the machine on a level
ground, put the work imple-
ment, bucket levelly, and pull
up the emergency parking
brake lever.
2. Turn off the engine and
remove the key.
3. Remove the drain plug of
gear box assembly to drain
the oil.
Caution: The waste oil
shall be recovered in a
container during removal, in
order to avoid environmental
contamination. The removed 34# socket, 13#
hose is shielded to avoid con- socket,
tamination of parts. pneumatic
impact wrench
Danger: It is sure that the
P18T00032 hose pressure is fully
discharged and the oil is
cooled sufficiently before
removal of hose, in order to
avoid personal injury of hose
pressure and hot oil during
removal.
4. Remove the cab assembly
of machine, see section
“Removal and Installation of
Cab” for removal steps.
 3-25
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
5. Remove the hose assembly
connecting the oil filter pipe
to the gear box assembly
with wrench.
Caution: The waste oil
shall be recovered in a 41# wrench
container during removal, in
order to avoid environmental
contamination.
P18T00033
The removed hose is shielded
to avoid contamination of
parts.
6. Remove the test line con-
nected to gear box assem-
bly and test hose.

18# Wrench

P18T00034

7. Remove the hose assembly

with a wrench.

41# Wrench

P18T00035
3-26
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
8. Remove the clamping bolt
fixing the oil filler steel-pipe
with a wrench.

10# Wrench

P18T00036

9. Remove the coupling lock-

nut between rear drive shaft
and rear output flange of
gear box assembly.
Caution: The drive shaft
assembly is composed 18# Wrench
of slidable spline sleeve,
please take care to avoid per-
sonal injury caused by falling
P18T00037
of slide shaft fork during
removal.
10. Remove the coupling lock-
nut between intermediate
drive shaft and front output
flange of transmission
assembly.
21# Wrench

P18T00038
 3-27
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
11. Remove the hose assembly
or the hose connected with
hydraulic pump from the
gearbox assembly, and refer
to removal of hydraulic sys-
tem for detailed procedures.

P18T00039

12. Remove the hose assembly

connected with brake sys-
tem from the emergency
parking brake chamber.

24# Wrench

P18T00040

13. Remove the bolts and

washer for attaching the
transmission mount to the
frame with an air gun.
46# wrench, 46#
socket,
pneumatic
impact wrench

P18T00041
3-28
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
14. Pre-lift the gear box assem-
bly through the lugs with lift-
ing device.

Sling
(2 tons)

P18T00042

15. Remove the cover plate

from the transmission
assembly with a wrench.

13# Wrench

P18T00043

16. Remove the fastening bolts

used to attach the gear box
assembly to the engine fly-
wheel with a wrench.

16# Wrench

P18T00044
 3-29
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
17. Remove the fastening bolts
used for attaching the gear
box assembly-torque con-
verter case to the engine
housing with an blower gun 16# socket,
and socket. pneumatic
impact wrench

P18T00045

18. Separate the transmission

assembly from the engine,
and secure the torque con-
verter case and core
through the bolt holes with
ropes and steel wires. Steel wire

P18T00046

19. Lift up the gear box assem-

bly from the machine
through the lugs with the
hoisting device and ropes
and place it in a safe area.

Sling
(2 tons)

P18T00047
3-30
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Installation of torque converter-gear box system

Tools required
Reference picture Operation step
(Remarks)
1. Wipe clean the drain plug of
gear box, and then install it
in the threaded hole of gear 34# socket, 13#
box and tighten it with a socket,
torque of 600±70Nm\ pneumatic
442.5±51.6 lbf•ft. impact wrench,
open-end 34#
fixed torque
spanner
P18T00048

2. Secure the torque converter

to its housing through
threaded holes with the steel
wire or ropes.
Danger: The torque con-
verter can slide freely on
the guide wheel seat. When Steel wire
lifting up it, the torque con-
verter and its housing must
P18T00049
be secured firmly with the
steel wire or ropes, in order to
avoid personal injury due to
falling of torque converter.
3. Lift up the gear box assem-
bly onto the machine
through the lugs of gear box
assembly with the hoisting
device and ropes.

Sling
(2 tons)

P18T00050
 3-31
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
4. Move gear box assembly to
fit it with engine flywheel
housing, and install the bolts
and hard washer used for 16# socket,
tightening the torque con- pneumatic
verter case to the engine impact wrench,
housing and then tighten open-end 16#
them. Tightening torque: fixed torque
72±6Nm\ 53.1±4.4 lbf•ft. spanner

P18T00051

5. Crank the engine flywheel

case to make the torque
converter align with mount-
ing threaded hole on the 16# socket,
engine flywheel, screw and pneumatic
tighten the fastening bolts impact wrench,
and washer for attaching the open-end 16#
torque converter to the fixed torque
engine flywheel by hand spanner
with a torque of 60±5Nm\
P18T00052 44.25±3.7 lbf•ft

6. Install the mounting hole

cover plate on the gear box.

13# Wrench

P18T00053
3-32
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
7. Screw and tighten the bolts
and washer for fastening the
gear box mount to the frame 46# wrench, 46#
with the torque of socket,
2035±170Nm\ pneumatic
1500.8±125.38 lbf•ft. impact wrench,
open-end 46#
fixed torque
spanner
P18T00054

8. Attach the mounting end

flanges of drive shaft and
gear box to the rear output
flange of gear box, and
tighten the locknut to 18# wrench or
132±10Nm\ 97.35±7.38 open-end 18#
lbf•ft. fixed torque
spanner

P18T00055

9. Attach the intermediate drive

shaft to front output flange of
gear box and tighten the
locknut to 200±15Nm\
147.5±11.06 lbf•ft. 21# wrench or
open-end 21#
fixed torque
spanner

P18T00056
 3-33
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
10. Install the oil filler steel-pipe
on the gear box and tighten
the set bolts with a torque of
26±3Nm\ 19.18±2.21 lbf•ft.
13# wrench or
open-end 13#
fixed torque
spanner

P18T00058

11. Install the hose referring to

the hydraulic installation and
hydraulic pump.

P18T00058

12. Install the hose assembly

used for attaching the oil fil-
ter pipe to the gear box, and
the tightening torque of hose
joint is 137±6Nm\ 41# wrench or
101.04±4.43 lbf•ft. open-end 41#
Caution: Two hose fixed torque
assemblies are spanner
respectively connected to the
P18T00059
inlet, outlet of fine oil filter in
directions as required,
avoiding installation error.
3-34
Removal and Installation January 24, 2017
Removal and installation of torque converter-gearbox system CLG835H

Tools required
Reference picture Operation step
(Remarks)
13. Install the hose assembly
used for attaching the radia-
tor pipe to the gear box, and
the tightening torque of hose
joint is 137±6Nm\ 41# wrench or
101.04±4.43 lbf•ft. open-end 41#
fixed torque
spanner

P18T00060

14. Install the hose assembly

used for attaching the test
pipe to the gearbox, as
shown in the following figure
and table.
18# Wrench

P18T00061

Layout of test points of shift control valve

58

66
63

34
21
57 65 P18T00062

56
53

55 60 51

P18T00062
 3-35
January 24, 2017 Removal and Installation
CLG835H Removal and installation of torque converter-gearbox system

Tools required
Reference picture Operation step
(Remarks)
Logic diagram of test points and gear clutch

Theoretical S/N in the corre-

Decal marker Meanings
value sponding valve
PRESSURE OF IN FRONT Inlet pressure of torque Opening pres-
51
OF THE CONVERTER converter sure: 1.1 MPa
PRESSURE OF KV CLUTCH KV clutch pressure 1.6-1.8MPa 53
PRESSURE OF KR CLUTCH KR clutch pressure 1.6-1.8MPa 55
PRESSURE OF K1 CLUTCH K1 clutch pressure 1.6-1.8MPa 56
PRESSURE OF K2 CLUTCH K2 clutch pressure 1.6-1.8MPa 57
PRESSURE OF K3 CLUTCH K3 clutch pressure 1.6-1.8MPa 58
PRESSURE OF K4 CLUTCH K4 clutch pressure 1.6-1.8MPa 59

Mapping diagram of centralized measuring point

mounting plate and measuring point

P18T00063

15. Install the hose assembly

used for attaching emer-
gence parking brake cham-
ber to the brake system, the
tightening torque is 24# wrench or
37±2Nm\ 27.29±1.48 lbf•ft. open-end 24#
fixed torque
spanner

P18T00064
3-36
Removal and Installation January 24, 2017
Disassembly and assembly of torque converter-gearbox assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
16. Fill the gear box by referring
to the Operation Manual of
this machine, and check the
oil level according to the
specified method.

Disassembly and assembly of torque converter-gearbox assembly

For disassembly and assembly of torque converter-gear box assembly in this machine, refer to "ZF Gear
Box Overhaul Manual".
 3-37
January 24, 2017 Removal and Installation
CLG835H Removal and installation of drive shaft system

Removal and installation of drive shaft system

Removal of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
1. Park the machine on a level
ground, turn off the engine,
and place the gear box han-
dle in neutral position, pull
up the emergency parking
brake lever and place the
wedges.
Caution: The drive shaft
assembly is composed
of slidable spline sleeve,
please take care to avoid per-
sonal injury caused by falling
of slide shaft fork during
removal.
2. Remove the connecting
locknut between the rear
drive shaft and rear axle
input flange with a wrench.

18# Wrench

P18T00065

3. Remove the connecting

locknut between rear drive
shaft and rear output flange
of gear box with a wrench,
and place the rear drive
shaft assembly in a safe 18# Wrench
area.

P18T00066
3-38
Removal and Installation January 24, 2017
Removal and installation of drive shaft system CLG835H

Tools required
Reference picture Operation step
(Remarks)
4. Remove the connecting
locknut between intermedi-
ate drive shaft and front out-
put flange of gear box
assembly with a wrench.
21# Wrench

P18T00067

5. Remove tightening bolt and

nut between intermediate
drive shaft and front drive
shaft & bearing assembly,
and remove the intermediate
drive shaft from machine 18# Wrench
with a wrench.

P18T00068

6. Remove the bolts and

washer securely connecting
the front drive shaft and sup-
port assembly to middle
support plate with a wrench.
18# Wrench

P18T00069
 3-39
January 24, 2017 Removal and Installation
CLG835H Removal and installation of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
7. Remove the bolts and nuts
securely connecting the
front drive shaft and support
assembly and front axle,
and remove front drive shaft
and support assembly from 18# Wrench
machine with a wrench.

P18T00070

8. Remove the tightening bolts

and washers of the support
plate and frame with a
blower gun or a wrench.
24# socket,
pneumatic
impact wrench
or 24# wrench

P18T00071

Installation of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
1. Wipe clean the surface,
install rear drive shaft and
rear axle input flange, and
align the the mounting
holes, then insert the tight- 18# wrench or
ening bolt and screw in the open-end 18#
nut and tighten it with a fixed torque
torque of spanner
132±10Nm\97.35±7.38 lbf•ft.

P18T00072
3-40
Removal and Installation January 24, 2017
Removal and installation of drive shaft system CLG835H

Tools required
Reference picture Operation step
(Remarks)
2. Wipe clean the surface,
install the rear drive shaft
and rear output flange of the
gear box, and align the
mounting holes, screw in the
locknut and tighten it with a
torque of 132±10Nm\ 18# wrench or
97.35±7.38 lbf•ft. open-end 18#
fixed torque
Caution: When assem- spanner
P18T00073
bling, please make sure
to pay attention to the white
arrows on the identification of
drive shaft, both of which
must be aligned after assem-
bly!
3. Wipe clean the two mount-
ing surfaces of support
plates, and then pre-install it
onto the front frame. Set the
front drive shaft and support
assembly with middle sup-
port bearing on the front
frame middle support bear-
ing seat support plate.

P18T00074

4. Wipe clean the surface,

install the front drive shaft
and support assembly with
front axle input flange, and
align the mounting hole, 18# wrench or
screw in the locknut and open-end 18#
tighten it with a torque of fixed torque
132±10Nm\97.35±7.38 lbf•ft. spanner

P18T00075
 3-41
January 24, 2017 Removal and Installation
CLG835H Removal and installation of drive shaft system

Tools required
Reference picture Operation step
(Remarks)
5. Wipe clean the mounting
surfaces of front output
flange of gear box and inter-
mediate drive shaft flange,
and install the intermediate 21# wrench or
drive shaft to the front output open-end 21#
flange bolts of gear box, fixed torque
screw in the locknut and spanner
tighten it with a torque of
200±15Nm\ 147.5±11.06
P18T00076 lbf•ft.

6. Install the middle drive shaft,

front drive shaft and support
assembly, and align the
mounting holes. Insert the
tightening bolt and screw in
the locknut, and then tighten
them to 132±10Nm\ 18# wrench or
97.35±7.38 lbf•ft. open-end 18#
fixed torque
Caution: The intermedi- spanner
P18T00077
ate drive shaft middle
shaft fork must be aligned
with the fork which is coupled
with front axle on the front
drive shaft and support
assembly!
7. Adjust the front&rear,
left&right positions of inter-
mediate, front drive shafts
and support assembly to
make sure that the bolts Open-end 18#
between support plate and fixed torque
frame can be screwed in spanner or 18#
smoothly with torque of wrench
132±10Nm\ 97.35±7.38lbf•ft.

P18T00078
3-42
Removal and Installation January 24, 2017
Removal and installation of front axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
8. Install the tightening bolts
and washer of the middle
support bearing seat and
support plate, and tighten 24# socket, fixed
them to 22494±18.44 lbf•ft. torque blower
gun or open-end
24# fixed torque
spanner

P18T00079

Removal and installation of front axle assembly

Removal of front axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Stop the machine on a level
ground, put the work imple-
ment, bucket levelly, and pull
up the emergency parking
brake lever.
2. Turn off the engine, step on
the service brake pedal for Sling
several times, so as to
release the pressures of (12 tons)
energy accumulator and
axle brake pipe.
3. Lift up the machine with a
lifting device, and support it
up with a supporting device
with 4 tires off the ground
 3-43
January 24, 2017 Removal and Installation
CLG835H Removal and installation of front axle assembly

Tools required
Reference picture Operation step
(Remarks)
4. Pre-lift up the tires with a
hoist, remove the bolts and
nuts used for tightening the
rim and axle. Sling(2 tons)30#
socket,
5. Lift the tires away from pneumatic
machine and put them in a impact wrench
safe area. or open-end 30#
6. Repeat steps (4), (5), wrench
remove another tire installed
P18T00080 on the front axle.

7. Remove the hose assembly

connected to service brake
system and the front axle.
Caution: The waste oil
shall be recovered in a
container during removal, in
order to avoid environmental
contamination. The removed
hose is shielded to avoid con-
24# Wrench
P18T00081
tamination of parts.
Danger: It is sure that the
hose pressure is fully
discharged and the oil is
cooled sufficiently before
removal of hose, in order to
avoid personal injury of hose
pressure and hot oil during
removal.
8. Pre-lift the front axle assem-
bly with a sling.
9. Remove the bolts and nuts
for connecting the front axle
assembly to the front frame
with a blower gun. Sling(2 tons)40#
socket,
10. Put the axle assembly onto pneumatic
the ground slowly with a lift- impact wrench,
ing device. 40# wrench
P18T00082
11. Remove the axle assembly
from the bottom of machine
with a handling equipment,
and then put it on the appli-
ance for axle assembly.
3-44
Removal and Installation January 24, 2017
Removal and installation of front axle assembly CLG835H

Installation of front axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Take the front axle assembly
out of placed area with a
handling device, and posi-
tion it under its mounting Sling(2 tons) 46#
point. socket,
pneumatic
2. Lift up the front axle assem-
impact wrench,
bly with a hoist, and install it
open-end 46#
on the frame.
fixed torque
3. Install the tightening bolts spanner
P18T00083 and nuts and tighten them
with torque of 2035±170Nm\
1500.8±125.38 lbf•ft.
4. Install the front axle brake
pipe and service brake
hose. Tightening torque:
37±2Nm\ 27.29±1.48 lbf•ft.
Open-fixed 24#
fixed torque
spanner

P18T00084

5. Lift up the tire with a hoist

and install it onto the axle,
Sling
and then install the rim nut
and tighten it to 600±60Nm\ (2 tons)30#
442.5±44.25 lbf•ft. socket,
pneumatic
impact wrench,
open-end 30#
fixed torque
spanner
P18T00085

6. Lift the machine with a hoist,

remove the support device, Sling
and put the machine onto (12 tons)
the ground.
 3-45
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Removal and installation of rear axle assembly

Removal of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Stop the machine on a level
ground, put the work imple-
ment, bucket levelly, and pull
up the emergency parking
brake lever.
2. Turn off the engine, step on
the service brake pedal for Sling
several times, so as to
release the pressures of (12 tons)
energy accumulator and
axle brake pipe.
3. Lift up the machine with a
lifting device, and support it
up with a supporting device
with 4 tires off the ground
4. Pre-lift up the tires with a
hoist, remove the bolts and
nuts used for tightening the Sling
rim and axle.
(2 tons)30#
5. Lift the tires away from socket,
machine and put them in a pneumatic
safe area. impact wrench
or open-end 30#
6. Repeat steps (4), (5),
wrench
remove another tire installed
P18T00086 on the rear axle.

7. Remove the the rear axle

and hose assembly
connected to service brake
system.

24# Wrench

P18T00087
3-46
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
8. Remove the steel pipe
connected to the rear axle
and centralized lubricating
system.

Open-end 16#
wrench

P18T00088

9. Pre-lift the rear axle

assembly with a sling.
10. Remove the bolts and
locknuts for connecting the
rear axle assembly to the
rear frame. Sling (2 tons)
36# socket,
11. Put the axle assembly onto pneumatic
the ground slowly with a impact wrench,
lifting device. 36# wrench,
P18T00089
12. Remove the axle assembly
from the bottom of machine
with a handling equipment,
and then put it on the
appliance for axle assembly.
13. Place the axle assembly as
shown in the left figure to
make front swing frame
support shaft upward, and
rear swing frame support
shaft downward.

P18T00090
 3-47
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
14. Remove the seal ring and
snap ring from the front
swing support rack with a
screwdriver.
Straight
screwdriver

P18T00091
15. Remove the front swing
support rack from axle
assembly with a lifting
device and place it in a safe
area. Sling
(2 tons)

P18T00092
16. Place the axle assembly as
shown in the left figure to
make the rear swing support
rack upward.

P18T00093

17. Remove the bolts, washers

with a wrench or an
pneumatic tool.

Open-end 18#
wrench

P18T00094
3-48
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
18. Remove the cover.

Open-end 18#
wrench

P18T00095
19. Remove the thrust washer.

Straight
screwdriver

P18T00096

20. Remove the bolts and

washer tightening the
clamping plate.
Open-end 27#
wrench or 27#
socket,
pneumatic
impact wrench

P18T00097

21. Remove the clamping plate.

Straight
screwdriver

P18T00098
 3-49
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
22. Remove the thrust washer.

Straight
screwdriver

P18T00099
23. Remove the rear swing
support rack with a lifting
device.

Sling
(2 tons)

P18T00100

24. Screw the M8 bolt in the

dowel and remove the
dowel.

Open-end 13#
wrench

P18T00101

25. Remove the bolts and wash-

ers tightening the support
shaft.
Open-end 21#
wrench or 21#
socket,
pneumatic
impact wrench

P18T00102
3-50
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
26. Remove the support shaft
with a lifting device.

Sling
(2 tons)

P18T00103

Installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
1. Lift up the axle assembly
and position it as shown in
the left figure onto a special
assembly device.

P18T00104

2. Wipe clean the mounting

face between the support
shaft and the axle case
connected to it with a clean
cloth, install the support
shaft onto the axle and align Copper bar
two dowel pins accurately,
strike it into the dowel pin
with a copper bar.

P18T00105
 3-51
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
3. Apply thread lock sealant to
thread portions of bolts,
screw them into support
24# socket,
thread holes by 2-3 threads
pneumatic
by hand, and tighten them
impact wrench,
with an air gun. Tightening
open-end 24#
torque: 305±25Nm\
fixed torque
22494±18.44 lbf•ft.
spanner

P18T00106

4. Horizontally place rear

swing frame with the thread
hole end upward, and install
the bush into rear swing
support rack.

P18T00107

5. Turn over swing frame by

180°, install seal ring and
knock it to the end with
nylon hammer.

Nylon hammer

P18T00108

6. Turn over swing frame group

by 180°, evenly apply
molybdenum disulfide
lithium base grease to
bushing cone, and install
rear swing frame group into
spindle with lifting device.

P18T00109
3-52
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
7. Install thrust washer and
pressing plate and align the
holes well.

P18T00110

8. Apply thread lock sealant to

thread portion of bolt, screw
bolts and hard washers into
the clamping plate thread 24# socket,
holes by 2-3 teeth by hand, pneumatic
and drive them in impact wrench,
symmetrically with open-end 24#
pneumatic impact wrench fixed torque
with the tightening torque of spanner
305±25Nm\ 224.94±18.44
P18T00111 lbf•ft.

9. Put a thrust washer and

cover and align the holes
well.

P18T00112

10. Apply thread lock sealant to

thread of bolts, screw bolts
and hard washers into cover
thread holes by 2-3 teeth by 21# socket,
hand, and drive them in pneumatic
symmetrically with impact wrench,
pneumatic impact wrench open-end 21#
with the tightening torque of fixed torque
195±15Nm\ 143.81±11.06 spanner
lbf•ft.
P18T00113
 3-53
January 24, 2017 Removal and Installation
CLG835H Removal and installation of rear axle assembly

Tools required
Reference picture Operation step
(Remarks)
11. Horizontally place front
swing frame, and knock seal
ring into front swing frame
mounting hole to the end
with nylon hammer.
Nylon hammer
Caution: The seal ring lip
faces outward.
Seal
Sealring
ringliplip

P18T00114

12. Press the bushing into the

front swing frame to the bot-
tom
Caution: The small hole
of bushing must toward
the lug end of front swing
support.

P18T00115

13. Install the snap ring into the

groove with straight screw-
driver.

Straight
screwdriver

P18T00116

14. Knock seal ring into front

swing frame mounting slot to
the end with nylon hammer;
Caution:The seal ring lip
faces outward.

Seal
Sealring
ringliplip

P18T00117
3-54
Removal and Installation January 24, 2017
Removal and installation of rear axle assembly CLG835H

Tools required
Reference picture Operation step
(Remarks)
15. Evenly apply the molybde-
num disulfide lithium base
grease to bushing cone, and
then lift and install the front
swing support subassembly
onto the bearing seat of the
main transmission.
Sling
16. Place the axle assembly on
a transport device with a lift- (2 tons)
P18T00118
ing device, and right under
mounting point of rear axle.
17. Install the axle assembly
onto the rear frame with a
lifting device and align the
mounting holes.
18. Install the mounting bolts,
washers and nuts of the axle
assembly and tighten them
with an blower gun to 36# socket,
1122±90Nm\ 827.28±66.38 pneumatic
lbf•ft. impact wrench,
open-end 36#
fixed torque
spanner

P18T00119

19. Install the axle and hose

connecting the service brake
pipe and tighten it to
37±2Nm\ 27.29±1.48 lbf•ft.

Open-end 24#
wrench

P18T00120
 3-55
January 24, 2017 Removal and Installation
CLG835H Disassembly and assembly of the drive axle

Tools required
Reference picture Operation step
(Remarks)
20. Lift up the tire with a hoist
and install it onto the axle,
and then install the rim nut
and tighten it to 600±60Nm\ 30# socket,
442.5±44.25 lbf•ft. pneumatic
impact wrench
or open-end 30#
fixed torque
spanner

P18T00121

21. Install the steel pipe con-

necting the centralized lubri-
cating system and axle.

Open-end 16#
wrench

P18T00122

22. Lift the machine with a hoist,

remove the support device, Sling
and put the machine onto (12 tons)
the ground.

Disassembly and assembly of the drive axle

For disassembly and assembly of the drive axle in this machine, see "835H Drive Axle Service Manual"
for details.
3-56
Fault Diagnosis and Troubleshooting Methods January 24, 2017
Disassembly and assembly of the drive axle CLG835H

Fault Diagnosis and Troubleshooting Methods

Fault inspection and

Fault features Main reasons
troubleshooting
1. Start circuit of the base machine (such as 1. Check the circuit of the base machine.
power voltage, electric lock, startup relay
and startup motor) has faults.
2. The lever is not at the neutral position. 2. Shift the lever to neutral position.
The engine can not 3. The fuse to the control circuit on the base 3. Replace the fuse.
1
Activation machine is burnt.
4. Poor contact of handle plug or the handle 4. Organize the plugs.
is failed.
5. Poor contact of controller plug or the con- 5. Organize the plugs.
troller is failed.
1. Oil pressure gauge is failed. 1. Replace the oil pressure gauge
2. Insufficient tightening torque for bolt of 2. Tightening torque for M8-8.8 bolt of shift
Low shift pressure shift control valve. control valve is 26Nm.
2 at all gears 3. Spring of main pressure valve is broken. 3. Replace it.
Low pressure 4. Gear shift pump is worn 4. Replace the gear shift pump.
5. Fragments enter into shift control valve or 5. Replace the filter, and clean the control
valve is stuck valve.
1. O-ring in throttle plug is damaged 1. Replace the O-ring
Too short shifting
3 2. The tightening torque of pressure control 2. Tightening torque for M8-8.8 bolt of shift
time at all gears
valve bolts is out of specified range control valve is 26Nm.
Too long shifting 1. Throttle plug is blocked. 1. Clean and dredge.
4
time at all gears 2. Pressure control valve is stuck. 2. Wash and check.
1. Oil temp sensor is failed. 1. Replace the part.
2. Oil temperature gauge is failed. 2. Replace the part.
The oil tempera- 3. Insufficient oil level. 3. Check oil level following the correct
5 ture of the torque method.
converter is high 4. Air found in torque converter oil radiator. 4. Exhaust.
5. Oil line from torque converter to radiator is 5. Check oil pipe from radiator to gear box
poor. and radiator for blockage.
1. Poor cooling capability of radiator. 1. Check whether cooling capability is suffi-
cient, such as checking the degree of
tightness for engine fan belt and dirt
The oil tempera- attached to outer surface of radiator.
6 ture of the torque 2. Back pressure valve of torque converter 2. Be careful to check hose connector from
converter is high stuck. gear box to radiator. If hose connector
enters housing too deeply, pushes spool
of pressure valve and cause valve to stick,
oil line will be getting blocked.
 3-57
January 24, 2017 Fault Diagnosis and Troubleshooting Methods
CLG835H Disassembly and assembly of the drive axle

Fault inspection and

Fault features Main reasons
troubleshooting
1. Insufficient oil level. 1. Check oil level and add the oil by following
the right operation.
2. Elastic plate connecting engine and 2. Replace the elastic plate or replace the
torque converter is torn, or power connec- related damaged parts.
tion from torque converter to gear box
input gear has faults.
3. Circuit failure of the complete machine. 3. Check the power voltage for abnormal
Vehicle does not and the cable for damage.
7
move at any gear
4. Shift pressure is too low. 4. Refer to the troubleshooting above.
5. Solenoid valve is damaged. 5. Check if the rated current of solenoid
valve is 830 mA.
6. Shift lever is damaged. 6. Refer to the troubleshooting for lever.
Replace it.
7. Controller is damaged. 7. Refer to the fault inspection of controller.
Replace it
3-58
Testing and adjustment January 24, 2017
Power Train Test CLG835H

Testing and adjustment

Power Train Test

Detection point layout of torque converter - gear box assembly as is shown in Figure 3-25, and names
and parameters of each detection point can be found in Table 3-7.
Figure 3-25 Measuring point layout

58

66
63

34
21
57 65

56
53

55 60 51
P18T00123

Table 3-7 Parameter list of the measuring point

S/N of the S/N of the

Name of the measuring Name of the Theoretical
measur- Theoretical value measuring
point measuring point value
ing point point
Input sensor of the gear
21 \ 55 Reverse gear clutch 1.6-1.8MPa
box
Output sensor of the
34 \ 58 Gear 3 clutch 1.6-1.8MPa
gear box
Inlet pressure of torque
51 Opening pressure: 0.85 56 Gear 1 Clutch 1.6-1.8MPa
converter
53 Forward gear clutch 1.6-1.8MPa\232-261psi 57 Gear 2 Clutch 1.6-1.8MPa
Pressure of shift control Outlet pressure of Opening
65 1.6-1.8MPa\232-261psi 63
system torque converter pressure: 0.5
60 Gear 4 Clutch 1.6-1.8MPa\232-261psi

Logical relations between gear states and working conditions of shift control valve solenoid valve can be
found in Table 3-8.
 3-59
January 24, 2017 Testing and adjustment
CLG835H Power Train Test

Table 3-8 Logical relations between gear states and working conditions of shift control valve
solenoid valve

Electric condition of the solenoid valve

Sole-
noid Forward gear Reverse gear Neutral gear
valve
1 2 3 4 1 2 3 1 2 3 4
M1 ● ● ●
M2 ● ● ●
M3 ● ● ●
M4 ● ● ● ● ● ●
M5 ●
Clutch KV KV KV K4 KR KR KR
K3
Clutch K1 K2 K3 K3 K1 K2 K3

Remarks: ● means the solenoid valve is energized;

Test Requirements:
Testing dynamic unbalance value
After the drive shaft is repaired, a professional dynamic unbalance test must be performed.
3-60
Testing and adjustment January 24, 2017
Power Train Test CLG835H
 4-1
January 24, 2017 Hydraulic System
CLG835H

Hydraulic System
Basic Information ............................................................................................................4-5
Safety precautions for hydraulic system ................................................................................................4-5
Overviews of hydraulic system...............................................................................................................4-8
Technical parameters of hydraulic system...........................................................................................4-11
Hydraulic System Principle Schematic.................................................................................................4-11
Universal tools and tooling for hydraulic maintenance.........................................................................4-12
Special tools and tooling for hydraulic maintenance ............................................................................4-13

Structure Function Principle ........................................................................................4-18

Work hydraulic system .........................................................................................................................4-18
Hydraulic oil tank..............................................................................................................................4-19
Plunger pump...................................................................................................................................4-20
Boom cylinder ..................................................................................................................................4-22
Bucket cylinder.................................................................................................................................4-22
Control valve ....................................................................................................................................4-23
Pilot valve.........................................................................................................................................4-36
Steering hydraulic system ....................................................................................................................4-37
Steering pump..................................................................................................................................4-40
Metering pump .................................................................................................................................4-40
Priority valve.....................................................................................................................................4-42
Steering cylinder ..............................................................................................................................4-45
Brake system .......................................................................................................................................4-46
Brake pump......................................................................................................................................4-50
Brake valve ......................................................................................................................................4-54
Charge valve ....................................................................................................................................4-57
Accumulator assembly .....................................................................................................................4-59
Brake cylinder ..................................................................................................................................4-62
Hydraulic cooling system .....................................................................................................................4-64
Cooling pump ...................................................................................................................................4-68
Cooling motor...................................................................................................................................4-68
Solenoid directional valve ................................................................................................................4-69
Emergency steering system.................................................................................................................4-71
Pilot system of electronic control third linkage .....................................................................................4-73

Testing and Adjustment................................................................................................4-75

4-2
Hydraulic System January 24, 2017
CLG835H

Pressure release of hydraulic system ..................................................................................................4-75

Pressure test of work hydraulic system................................................................................................4-78
Positions of every gauging points of working hydraulic system .......................................................4-78
Description of every gauging points of working hydraulic system....................................................4-79
Inspection and adjustment for pressure of working hydraulic pressure system...............................4-80
Pressure inspection and adjustment of overload valve of bucket tilting large chamber...................4-84
Pressure inspection and adjustment of overload valve of bucket tilting small chamber ..................4-86
Pressure inspection and adjustment of main safety valve of control valve ......................................4-88
Inspection and adjustment for cut-off pressure of working pump.....................................................4-90
Adjustment for LS relief pressure of control valve............................................................................4-92
Pressure inspection and adjustment of the pilot oil supply valve .....................................................4-94
Boom cylinder test............................................................................................................................4-96
Bucket cylinder test ..........................................................................................................................4-97
Steering hydraulic system test .............................................................................................................4-98
Measuring point position of steering hydraulic system.....................................................................4-98
Description of measuring points of steering hydraulic system .........................................................4-99
Pressure testing and adjustment of steering hydraulic system ........................................................4-99
Steering cylinder test......................................................................................................................4-101
Brake system test ..............................................................................................................................4-102
Layout of pressure measuring points of brake system...................................................................4-102
Test method of rear axle brake pressure ......................................................................................4-103
Test method of front axle brake pressure ......................................................................................4-105

Removal and Installation ............................................................................................4-106

Work hydraulic system .......................................................................................................................4-106
Removal and installation of hydraulic oil tank assembly ................................................................4-106
Removal and installation of the plunger pump ...............................................................................4-110
Removal and installation of boom cylinder.....................................................................................4-115
Disassembly and assembly of boom cylinder ................................................................................4-120
Removal and installation of bucket cylinder ..................................................................................4-133
Disassembly and assembly of bucket cylinder...............................................................................4-137
Removal and installation of control valve.......................................................................................4-150
Removal and installation of pilot valve assembly..........................................................................4-159
Steering hydraulic system ..................................................................................................................4-163
Removal and installation of metering pump ...................................................................................4-163
Removal and installation of priority valve.......................................................................................4-167
 4-3
January 24, 2017 Hydraulic System
CLG835H

Removal and installation of steering cylinder.................................................................................4-170

Disassembly and assembly of steering cylinder ............................................................................4-174
Brake system .....................................................................................................................................4-187
Removal and installation of brake pump ........................................................................................4-187
Removal and installation of brake valve.........................................................................................4-187
Disassembly and assembly of brake valve ....................................................................................4-190
Removal and installation of charge valve.......................................................................................4-202
Disassembly and assembly of charge valve ..................................................................................4-205
Removal and installation of accumulator .......................................................................................4-219
Removal and installation of brake cylinder.....................................................................................4-220
Hydraulic cooling system ...................................................................................................................4-221
Removal and installation of cooling pump......................................................................................4-221
Removal and installation of cooling motor ....................................................................................4-224
Removal and installation of solenoid directional valve...................................................................4-227
Secondary steering system................................................................................................................4-229
Removal and installation of secondary steering pump...................................................................4-229
Pilot system of electronic control third linkage ...................................................................................4-231
Removal and installation of proportional valve...............................................................................4-231

Fault Diagnosis and Troubleshooting .......................................................................4-233

Common troubleshooting for brake system .......................................................................................4-233
4-4
Hydraulic System January 24, 2017
CLG835H
 4-5
January 24, 2017 Basic Information
CLG835H Safety precautions for hydraulic system

Basic Information

Safety precautions for hydraulic

system

Compressed air
P11000204
Compressed air may cause personal injury.
Even if the pressured liquid is leaked from a hole
When using the compressed air for cleaning,
as small as a pin hole, it may penetrate the
wear the mask, protection suits and shoes. Do
muscles and lead to death. If shot by the spouted
not point the compressed air at yourself or
high-pressure oil, please contact a doctor and
anyone. The compressed air may penetrate the
take a medical treatment immediately.
skin and lead to severe injury or even death. The
maximum pressure of the compressed air for Safe disposal of waste liquid
cleaning should be lower than 0.2 Mpa(29psi).
Inappropriate disposal of waste liquid will
High-pressure solution endanger environment and ecology. Please
observe local laws and regulations when dispose
Prevent from being scalded by high-pressure oil.
the waste liquid.
When overhauling or replacing the pipes of
hydraulic system, check whether the pressure of It is mandatory and necessary to collect the
system had been released. Hydraulic oil under liquid with containers spattered during the
pressure will damage your skin severely when it inspection, maintenance, test, adjustment and
spattered on you. repair of machine. Proper container shall be
prepared well before opening any fluid cavity or
Take care when remove the hydraulic pipelines
disassembling the parts containing liquid. Use
or connectors. When the oil spouts, the released
proper container when draining liquid.
high-pressure oil may lead to the continuous
movement of the hoses. Do not use the food or drink containers because
they may be drunk by others by mistake.
Please wear safety glasses and leather gloves
when checking for leakages. Do not use bare
hands to check the leakage but plate or paper
plate.

P11000134 P19M00059

Precautions for accumulator application

The dangerous high-pressure nitrogen is

contained in the accumulator, so read the
following requirements and properly use the
accumulator.
4-6
Basic Information January 24, 2017
Safety precautions for hydraulic system CLG835H

The accumulator shall be checked before charge When working under the work implement, you
of nitrogen. It is prohibited to charge the shall support the equipment properly. Do not
accumulator with gas if the accumulator does not support the work implement depending on
have a nameplate, or the words on the hydraulic cylinder. If control mechanism moves
nameplate are missed so that its type can not be or hydraulic oil line leaks, work implement will
identified, or if the steel seal marks are drop. If it is necessary to remove the shield, you
incomplete or cannot be read clearly, or if there is shall fix it well after the repair.
defect with the housing and therefore safe use
Unless otherwise stated, any adjustment is not
cannot be ensured.
permitted to be performed when machine or
The accumulator can only be filled with nitrogen engine is running. If the repair procedure must
other than oxygen, compressed air or other be performed when machine is running, do not
flammable air to avoid explosion. let the machine stay in an unattended status.
Arrange one operator seated in the seat and
Slowly charge the nitrogen into the accumulator
prepare to shut down the engine at any time.
so as to avoid the breakage of the rubber bag.
Do not use twisted or worn wire rope. Wear
gloves during operation and move.
When forcing to extrude the bayonet, you shall
make sure no one is standing around it. You shall
wear safety goggles in order to protect your
eyes.
When knocking object with hammer, please
make sure the flying debris will not hurt others.
P11000190
Oil
The air valve of the accumulator shall be
installed upward vertically. The accumulator shall Hot oil and parts will cause personnel injury, and
be stably fixed on the bracket without being do not let the hot oil and parts contact your skin.
welded.
Do not drill any hole on the accumulator or carry
open fire or heat sources close to the
accumulator.
Do not conduct any welding operation on the
accumulator.
Since the accumulator is a high-pressure
container, it shall be replaced and repaired by P11000148
professional operators.
At working temperature, the hydraulic oil tank is
Release the air before discarding the waste hot and contains pressure. When opening oil
accumulator. filler cap of hydraulic oil tank, shut off the engine
and cool the filler cap down until it can be
Preventing extruding or cut off opened by bare hands. Remove the tank cover
slowly to release the pressure of hydraulic oil
Do not have your hands, arms or any other
tank so as to prevent from being scalded by hot
bodies placed between moving parts. For
oil.
example, between work implement and cylinder,
between machine and working implement. Release pressure of the system before
disassembling all pipes, connector, or relevant
parts.
 4-7
January 24, 2017 Basic Information
CLG835H Safety precautions for hydraulic system

Pipeline, pipe and hose Do not use the accessories unauthorized by

LiuGong. Using unauthorized accessories will
Do not warp or knock the high-pressure pipeline, cause safety issues, do harm on the normal
and do not install the abnormally warped or operation of machine and influence its service
broken pipe or hose onto the machine. life.
Repair the loose or damaged pipe and hose of It is forbidden to make any refit on the
fuel and lubricant pipeline and hydraulic system accessories without permissions; otherwise you
in time. Leakage will cause fire hazard, and if shall bear the responsibility.
repair or replacement is necessary, please
contact the authorized dealer by LiuGong LiuGong Machinery Co., Ltd will not be
Machinery Co., Ltd. responsible for the injury, accident and damage
of machine due to using unauthorized
If following problems occur, it shall be replaced. accessories.
● Damage or leakage of connector.
● The outer layer of hose is worn or cracked,
and reinforced steel wires are exposed.
● Partial bulge of hose.
● The hose is twisted or flattened.
● The hose reinforcement steel has embedded
to the outer layer.
● Misplacement of the end connectors.
Make sure all clamps, guard and heat shield are
installed correctly to prevent shaking or
overheating by friction with other parts.
Otherwise, it will generate toxic gases resulting
in poisoning.

Precautions for accessories

It shall be installed and commissioned by

qualified personnel; the operator shall be trained,
and his/her operation and maintenance shall be
performed strictly according to the operation
instructions for accessories.
When installing and using the spare accessory,
please read related instructions, manuals and
informations about the accessories.
Incorrect installation or purchase of accessories
will not only cause safety issues, but also have
the negative effect on service life and operation
of the machine.
4-8
Basic Information January 24, 2017
Overviews of hydraulic system CLG835H

Overviews of hydraulic system

The hydraulic system is the actuator of the loader, mainly composed of four functional modules, i.e. a
work implement hydraulic system, a steering hydraulic system, a brake system and a hydraulic cooling
system. Where, the steering hydraulic system supplies oil for the steering circuit preferentially through
the priority valve to ensure steering function; the work hydraulic system controls the coordinated actions
of all oil cylinders through the control valve so that the loader can adapt to the requirements of different
working conditions; the brake system can realize the function of service brake and parking brake; the
hydraulic cooling system cools the hydraulic oil to ensure oil temperature within the reasonable scope of
work. Layout of CLG835H-T4F hydraulic system is as follows:
CLG835H-T4f Work hydraulic system

4
1
2 3

6 7
5 8
9 10
P18H00006

1. Bucket cylinder 6. Control valve

2. Proportional pressure-reducing valve 7. Shuttle valve
3. Hydraulic oil tank 8. Pilot oil filter
4. Pilot valve 9. Pilot oil supply valve
5. Boom cylinder 10.Plunger pump
 4-9
January 24, 2017 Basic Information
CLG835H Overviews of hydraulic system

CLG835H-T4f Steering hydraulic system

2
1
3

P18H00007

1. Steering cylinder 2. Metering pump 3. Priority valve

4-10
Basic Information January 24, 2017
Overviews of hydraulic system CLG835H

CLG835H-T4f brake system

1
2

6
3 4 7
5
P18H00008

1. Brake valve 5. Brake valve assembly

2. Gear pump 6. Accumulator assembly
3. High-pressure oil filter 7. Brake cylinder
4. Charge valve
 4-11
January 24, 2017 Basic Information
CLG835H Technical parameters of hydraulic system

Technical parameters of hydraulic system

Main technical parameters of CLG835H-T4F hydraulic system

Items Unit Theoretical value

Single-pump variable hydraulic
Type
system
Working pressure of the system Mpa\psi 19\2755
Pilot working pressure Mpa\psi 3.5\507.5
Work
hydraulic Displacement of working pump ml/r\cc/r 100\100
system Rated speed of the working pump r/min 2200
Boom cylinder (cylinder number --
mm\in 2-φ125×728\2-φ4.92×28.66
cylinder bore × stroke)
Bucket cylinder (cylinder number -
mm\in 1-φ140×520\1-φ5.51×20.47
cylinder bore × stroke)
Articulation frame and full hydrau-
Type
lic steering system
Working pressure of the system Mpa\psi 17.5
Displacement of steering pump ml/r\cc/r 100\100

Steering Rated speed of the steering pump r/min 2200

hydraulic Metering pump ml/r\cc/r 739/739
system
Amplification ratio of metering
1.6
pump
Steering angle ° 38°±1°for both left and right sides
Steering cylinder (cylinder number
mm\in 2-φ80×420\2-φ3.15×16.54
-- cylinder bore × stroke)
Dual-circuit full-hydraulic wet
Service Type
brake
brake system
System oil pressure Mpa\psi 6±0.4\870±58
Parking & Type Push-button hydraulic brake
emergency
brake system System oil pressure Mpa\psi 16\2320

Working Hydraulic oil L\US gal 105\27.7

medium Cleanliness NAS1638 ≤Grade 9

Hydraulic System Principle Schematic

Refer to attached drawing in Chapter 9 for schematic of hydraulic system

4-12
Basic Information January 24, 2017
Universal tools and tooling for hydraulic maintenance CLG835H

Universal tools and tooling for hydraulic maintenance

Common tools table

Name Specifications (Qty.)

Open-end wrench 8#, 13#, 15#, 17#, 19#, 21#, 22#, 24#, 27#, 30#, 32#, 36#, 41#, 44#, 46#
Straight screwdriver
Cross screwdriver
Pliers
20~100N•m\ 14.75~73.75lbf•bt, 90~300N•m\ 66.38~221.25lbf•bt, 160~680N•m\
Torque wrench
118~501.5lbf•bt
Inner hexagon spanner One set in metric standard and one set in British standard
Lifting equipment 2t
Sling 2t
Caution: the removed standard parts should be placed with relevant material together to
avoid being mixed.
 4-13
January 24, 2017 Basic Information
CLG835H Special tools and tooling for hydraulic maintenance

Special tools and tooling for hydraulic maintenance

List of special tools and tooling for boom and bucket cylinder

Quantity for
LiuGong
S/N Tool description Figures Purpose full-time
No.
service dealers

For assembling the O-

1 SP130702 Pry bar 1
ring of piston

For assembling dust

2 SP129313 Rubber hammer 1
ring of cylinder head

Tooling for com- For compressing dust

3 SP130917 1
pressing dust ring ring of cylinder head

For assembling the O-

4 SP130915 Guide sleeve 1
ring of piston rod
4-14
Basic Information January 24, 2017
Special tools and tooling for hydraulic maintenance CLG835H

Quantity for
LiuGong
S/N Tool description Figures Purpose full-time
No.
service dealers

For assembling
cylinder head
5 SP130700 Guide sleeve 1
assembly onto piston
rod

For aligning flange bolt

6 SP129308 Positioning tool hole with cylinder head 1
through hole

For aligning flange bolt

7 SP130698 Dowel pin hole with cylinder head 1
through hole

8 SP133205 Blower gun For pre-tightening bolt 1

9 SP129309 Socket For tightening bolt 1

 4-15
January 24, 2017 Basic Information
CLG835H Special tools and tooling for hydraulic maintenance

Quantity for
LiuGong
S/N Tool description Figures Purpose full-time
No.
service dealers

For snap ring of

10 SP130929 Steel wire scissors
cylinder head

List of special tools and tooling for steering cylinder:

Quantity for
LiuGong
S/N Tool description Figures Purpose full-time
No.
service dealers

Tooling for press For pressing and fitting

1 SP130702 fitting of friction the friction ring onto 1
ring piston

Tooling for com-

For compressing the
2 SP129313 pressing friction 1
friction ring
ring

For assembling
cylinder head
3 SP130917 Guide sleeve 1
assembly onto piston
rod

For assembling the O-

4 SP130915 Guide sleeve 1
ring of piston rod
4-16
Basic Information January 24, 2017
Special tools and tooling for hydraulic maintenance CLG835H

Quantity for
LiuGong
S/N Tool description Figures Purpose full-time
No.
service dealers

For assembling the

Tooling for press
5 SP130700 bushing onto cylinder 1
fitting of bushing
block

For supporting the

Cylinder block sup- cylinder block and
6 SP129308 1
port pressing the bushing
to the cylinder block

For detecting the size

of bushing which is
7 SP130698 Bushing detection 1
assembled onto the
cylinder block

For tightening the

8 SP133205 Blower gun 1
nylon locknut

For pressing the piston

9 SP129309 Copper bar rod into the cylinder
block
 4-17
January 24, 2017 Basic Information
CLG835H Special tools and tooling for hydraulic maintenance

Quantity for
LiuGong
S/N Tool description Figures Purpose full-time
No.
service dealers

For pre-tightening the

10 SP130929 Hook spanner cylinder head
assembly

For locking the

11 SP129306 Socket cylinder head
assembly
4-18
Structure Function Principle January 24, 2017
Work hydraulic system CLG835H

Structure Function Principle

Work hydraulic system

A: Overview-components and position

The work hydraulic system is used to control the actions of the boom and bucket of the loader work
implement and other additional work implement. It is a single-pump load sensing system (see schematic
diagram of work hydraulic system). It is composed of one hydraulic oil tank, one variable plunger pump,
one load sensing control valve and oil cylinders and pipelines of all work implements. The hydraulic oil
from the tank flows into the plunger pump, after passing through the priority valve, it flows into the control
valve by which controls telescoping of all cylinders so as to further control the loader work implement's
actions of tilting back and dumping of the bucket and raise, lowering and floating lowering of the boom.
Layout drawing of CLG835H_T4f work hydraulic system is as follows: refer to attached drawing in Chap-
ter 9 for schematic of hydraulic system
Layout drawing of work hydraulic system

4
1
2 3

6 7
5
8
9 10
P18H00009

1. Bucket cylinder 6. Control valve

2. Proportional pressure-reducing valve 7. Shuttle valve
3. Hydraulic oil tank 8. Pilot oil filter
4. Pilot valve 9. Pilot oil supply valve
5. Boom cylinder 10.Plunger pump
 4-19
January 24, 2017 Structure Function Principle
CLG835H Work hydraulic system

1. When there is no action in the work hydraulic Hydraulic oil tank

system, i.e. boom reversing valve and bucket
reversing valve in the control valve are in Installation position and functional structure
neutral position, and variable plunger pump
is at minimum displacement position, the The hydraulic oil tank is side-sited type, which is
variable pump hardly has oil to output (only located on the rear frame in the middle of a
the minimum displacement required to keep machine, the right side of a cab. The main
self-running), oil passages of the control function is to store the hydraulic oil required for
valve connected to both of big and small cav- work cycle of the hydraulic system and
ities of the boom cylinder and bucket cylinder precipitate the pollutant of oil in hydraulic tank,
are sealed, and boom and bucket are kept in separate the air from oil and cool the hydraulic
original position. oil. A return oil filter has been set in the oil tank to
filter the pollutant in oil lines of the hydraulic
2. Operate the boom reversing valve controlled
system so as to guarantee the cleanliness of
by the pilot valve to lift, lower or float the
hydraulic oil. Structural diagram of hydraulic oil
boom and manipulate the bucket tilting
tank is as follows:
reversing valve controlled by the pilot valve to
tilt the bucket forward or backward. There is Structural diagram of hydraulic oil tank
an automatic leveling device of bucket
5
installed on bucket hydraulic cylinder. 1
3. Big and small cavities double-acting safety
valves are installed in oil lines of the control 6
valve connected with big and small cavities of
the bucket cylinder to protect the big and
small cavities of the bucket cylinder from
overload and fill oil and play the role of stabi-
lizing system work and protecting the rele-
vant elements of the system. 2
7
B: Technical parameters of work system ·

Items Parameters
System pressure 19±0.3Mpa\2755±43.5psi
3
System flow 210L/min@2200r/min
Pressure of overload 8
23±0.3MPa\3335±43.5psi
valve at A1 port
Pressure of overload
23±0.3MPa\3335±43.5psi 4
valve at B1 port
Pressure of overload P18H00010
23±0.3MPa\3335±43.5psi
valve at A2 port 1. Oil return chamber 5. Ventilated oil conduit
Pressure of overload and oil return filter 6. Oil filler, oil filter element and
23±0.3MPa\3335±43.5psi 2. Baffle breather
valve at B2 port
3. Washing port 7. Sight glass
Pressure of overload 4. Oil drain hole 8. Oil suction port
23±0.3MPa\3335±43.5psi
valve at A3 port
Pressure of overload
23±0.3MPa\3335±43.5psi
valve at B3 port
Pressure of main safety
21±0.3MPa\3045±43.5psi
valve
4-20
Structure Function Principle January 24, 2017
Work hydraulic system CLG835H

In which, the oil return chamber is used to Items Parameters Remarks

temporarily store the hydraulic oil that returns
from the system to effectively reduce the back- Anti-wear
Operating fluid 46#
flow velocity so as to avoid bubbles in the hydraulic oil
hydraulic oil tank resulted from too fast oil return.
Structure and working principle of plunger
The oil return filter mainly filters the oil returning
pump
to the hydraulic oil tank to prevent pollutant from
entering into the system through the oil tank to Same pump is used for the plunger pump of work
cause pollution. The baffle is used to form hydraulic system and that of steering hydraulic
isolation circulation for cold and hot oil in the oil system, that is, work hydraulic system and
tank to prevent oil shake from generating large steering hydraulic system share one pump. The
quantities of bubbles and isolate oil suction port plunger pump is located under cab and installed
from oil return port to ensure gas separates out on the right power take-off of the transmission
of hydraulic oil return. Washing port is used to and tightened it by stud and nut. It is driven by
clean the dirt in the oil tank. Oil drain hole is used engine via torque converter and transmission to
to drain fluid out of oil tank when replace oil or supply oil for work and steering hydraulic system.
clean oil tank. Oil suction port is used to supply
oil for hydraulic pump. The ventilated oil conduit Outline diagram and working principle of
is used for exhalation of a breather and to lead plunger pump:
the oil vapor exhaled by the breather to
underbody. Hydraulic oil is filled from the oil filler Schematic of working pump
after filtration by the oil filter vehicle. Oil filler filter
element is used to prevent large particles from
entering into oil tank when replacing and filling
hydraulic oil. The function of the breather is that it 4
sucks air from atmosphere to fill the air space
when the air pressure in oil tank is negative and
3
that exhaust extra air to realize the protection
function when the air pressure in oil tank is out of
limit. Oil level gauge is used to observe the oil
level of oil tank. Oil suction port is used to supply 5
oil for hydraulic pump. 2 6
Plunger pump
7
Main technical parameters
8
Items Parameters Remarks
1
Rated pressure 19Mpa\ 2755psi
Displacement 100ml/r\ 100cc/r
Direction of rotation Left rotation
P18H00011
Rated speed 2200rpm
Pressure of the shut- 1. Hydraulic oil tank 5. Flow compensation
20Mpa\ 2900psi 2. Swashplate valve
off valve 6. Pressure shut-off valve
3. Control valve (simpli-
Pressure of flow fied) 7. Variable cylinder
2.6Mpa\ 377psi 4. Load sensing port 8. Power control valve
compensator valve
 4-21
January 24, 2017 Structure Function Principle
CLG835H Work hydraulic system

Exterior drawing of working pump 4. When the opening of the control valve 3
increases further, throttling effect fades, ΔP
1 decreases, flow compensator valve 5 moves
leftwards under the action of its spring force
PK, the big cavity of differential variable cylin-
2 der 7 returns oil gradually, the swashplate
turns clockwise and the displacement of
3 pump starts to increase. ΔP is also increased
with the increase of displacement (flow),
when flow of the system is stable, ΔP= PK =
4 fixed value, otherwise, balance of the flow
compensator valve 5 will be disturbed.
5. When the opening of the control valve 3
P18H00012
decreases, throttling effect becomes
1. Load sensing port 3. Housing return oil enhanced, ΔP increases, the flow compensa-
2. Oil outlet 4. Oil suction port tor valve 5 moves rightwards under the action
1. Before starting, the pressure of pump open- of ΔP, oil enters big cavity of variable cylinder
ing P=0, the pressure of load sensing port 4 7, the swashplate turns anticlockwise and the
PLS=0, the pressure difference between both displacement of pump is reduced to the mini-
ends of control valve 3 ΔP= P- PLS =0 and mum. When the system is stable, ΔP= PK =
the swashplate is in the maximum displace- fixed value.
ment position. 6. When the load pressure increases up to the
2. After starting, when the control valve 3 has setting pressure value of the system, the
no opening, PLS=0, the pressure P of pump pressure shut-off valve 6 opens the pump
opening acts on left end of flow compensator pressure oil way to the big cavity of variable
valve 5, the flow compensator valve 5 moves cylinder 7 so as to reduce the displacement
rightwards, oil enters big cavity of variable of the pump rapidly. As shown, the action of
cylinder 7, the swashplate turns anticlock- the pressure shut-off valve has the priority to
wise and the displacement of pump is the flow compensator valve 5, that is, it works
reduced to the minimum. The pressure P of as long as the pressure reaches the setting
the pump opening is generally set to 2.6Mpa\ value.
377psi at this time, i.e. the setting pressure of 7. From above, we can learn that the flow com-
the flow compensator valve 5, in order to pensator valve is in balanced state when the
improve the response speed of the system flow of the system is stable: ΔP= PK = fixed
and compensate a small amount of leak. value (without change). Therefore, the dis-
3. When the control valve 3 has an opening to placement of the pump is only related with
some extent, PLS occurs, ΔP starts to the opening of main control valve other than
decrease from the maximum value, the flow the load (i.e. pressure). This is the pump load
compensator valve 5 moves leftwards under sensing control.
the action of its spring force PK. The big cav- 8. When pressure of pump opening reaches
ity of differential variable cylinder 7 returns oil setting value, power control valve 8 moves
gradually, the swashplate turns clockwise rightwards, pressure oil at pump opening
and the displacement of pump starts to enters into big cavity of variable cylinder 7 via
increase. power control valve 8, swashplate turns anti-
clockwise and the displacement of pump
starts to decrease.
4-22
Structure Function Principle January 24, 2017
Work hydraulic system CLG835H

Boom cylinder Bucket cylinder

Main technical parameters Main technical parameters

Items Parameters Remarks Items Parameters Remarks

Cylinder bore (mm\in) 125\4.92 Cylinder bore (mm\in) 140\5.51
Rod diameter (mm\in) 80\3.15 Rod diameter (mm\in) 80\3.15
Stroke (mm\in) 728\28.66 Stroke (mm\in) 520\20.47
Minimum mounting Minimum mounting
1287\50.67 1110\43.70
distance (mm\in) distance (mm\in)

Structure and working principle of boom Structure and working principle of bucket
cylinder cylinder

The boom cylinder, which is installed at the The bucket cylinder, which is installed at the
articulated joint of boom cylinder on the front articulated joint of the front frame and bucket
frame and the articulated joint of boom cylinder, cylinder and the articulated joint of bucket lever
is the actuator of the work hydraulic system. It and cylinder, is the actuator of the work hydraulic
realizes the raise and lowering of the bucket system. It realizes the tilting forward and
through pushing the boom to move up and down backward of the bucket through the movement of
by piston rod telescoping actions of the boom oil bucket lever pushed by piston rod actions of the
cylinder. bucket cylinder.
Structure of boom cylinder Structure of bucket cylinder

1 2
P18H00013 2
1
P18H00014
1. Oil port of big cavity 2. Oil port of small cavity
1. Oil port of big cavity 2. Oil port of small cavity
 4-23
January 24, 2017 Structure Function Principle
CLG835H Work hydraulic system

Control valve

Main technical parameters

Service
Items Parameters Remarks
conditions
Rated flow (L/min\ US gpm) 180\ 47.56 / /

Pressure loss under rated flow △ P (Mpa\psi) 2.5\ 362.5

Setting pressure of main safety valve (MPa\psi) 21\ 3045 / /
Pressure of safety valve of bucket cylinder small
23\ 3335 / /
cavity (Mpa\ psi)
Pressure of safety valve of bucket cylinder big cavity
23\ 3335 / /
(Mpa\ psi)
Operating fluid Anti-wear hydraulic oil HM46/HV46 /

Structure and working principle of control valve

3 5
1 7 2
4
10 6
11
9
8

15 14

12 13
P18H00015

1. Control valve oil return port 9. Boom lifting pilot port

2. Control valve oil inlet 10.Bucket tilting and retracting pilot port
3. Oil outlet of bucket big cavity 11.Bucket tilting and tipping pilot port
4. Oil outlet of boom big cavity 12.Oil outlet of multi-functional way big cavity
5. Control valve LS port 13.Oil outlet of multi-functional way small cavity
6. Oil outlet of boom small cavity 14.Oil outlet of multi-functional way small cavity
7. Oil outlet of bucket small cavity 15.Oil outlet of multi-functional way big cavity
8. Boom lowering pilot port
4-24
Structure Function Principle January 24, 2017
Work hydraulic system CLG835H

Exploded view of control valve

P18H00016
 4-25
January 24, 2017 Structure Function Principle
CLG835H Work hydraulic system

Exploded view of control valve

P18H00017
4-26
Structure Function Principle January 24, 2017
Work hydraulic system CLG835H

Hydraulic schematic of control valve

P18H00018

1. Boom overload valve 5. Main safety valve 9. LS flow controller

2. Oil supplement valve 6. Bucket way 10.LS Relief valve
3. Bucket overload valve 7. Pressure compensation valve 11.Multi-functional way
4. Backpressure valve 8. Boom 12.Multi-functional union overload valve
 4-27
January 24, 2017 Structure Function Principle
CLG835H Work hydraulic system

Installation position and working principle

The control valve is installed on the mounting board in front frame. The function of the control valve is to
control moving direction and speed of the bucket cylinder and the boom cylinder by changing the flowing
direction of oil so as to satisfy loader's working requirements under different work conditions.
Configuration: whole tandem closed neutral position slide valve;
Oil lines type: cascade and paralleling bucket tilting priority ;
Main components: bucket reversing valve, boom reversing valve, safety valve, pressure compensation
valve, LS relief valve, LS flow controller, etc.
The bucket reversing valve is a three-stack valve, which can control three actions of the bucket, i.e. to
tilting forward, backward and keeping.
The boom reversing valve is a four-stack valve, which can control four actions of the boom, i.e. raising,
keeping, lowering and floating lowering.
The safety valve controls the pressure of system. When the pressure of system exceeds the setting
value, oil will overflow to the oil tank to protect system from being damaged.
Pressure compensation valve, operated in multiple circuit, can guarantee that the flow of main valve can
not be changed by different loads so that the system has the performance of composite operation.
LS relief valve controls the pressure of LS oil line. When the LS pressure exceeds the setting value, oil
will overflow to the oil tank. The pressure of work system is the sum of setting pressure of LS relief valve
and the pump flow control valve in work hydraulic system.
LS flow controller can guarantee that the LS oil line has continuous flow and improve the response
speed of LS oil line.
Back pressure valve increases the oil return pressure at the time of bucket dumping and boom descend-
ing and improves the stability of bucket dumping and boom descending.
4-28
Structure Function Principle January 24, 2017
Work hydraulic system CLG835H

1. Neutral position of control valve

When the control valve is in neutral position, bucket valve rod 6 and boom union valve rod 8 are in neu-
tral position. As for the closed neutral position structure, LS pressure is zero, the variable pump under
the action of pump outlet pressure is in minimum displacement and the pump is in low-pressure standby
state.

P18H00019

As for the closed neutral position structure of valve rod, oil line between big & small cavities of cylinder
and valve rod is kept closed, the pressure of control valve oil inlet, which is the same as that of pump
outlet, is in low-pressure state.