201711000

CLG835H
WHEEL LOADER

SERVICE MANUAL

Applicable type and model: CLG835H T3 (CUMMINS Engine QSB6.7 + LIUGONG Wet Axle + ZF
4WG158 Gearbox)
November 17, 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 and Covering Parts ...................................................................................6-1
Structure...........................................................................................................................7-1
Electrical System.............................................................................................................8-1
Appendix ..........................................................................................................................9-1
Contents November 17, 2017
CLG835H
 1-1
November 17, 2017 General Information
CLG835H

General Information
How to Use the Manual ...................................................................................................1-3
Important Safety Information .........................................................................................1-4
Manual Identification.......................................................................................................1-5
Engine Identification .......................................................................................................1-6
Cable Code Identification ...............................................................................................1-7
Coating Materials.............................................................................................................1-9
Weight Table ..................................................................................................................1-11
Unit Conversion Table ..................................................................................................1-12
Standard Torque Table .................................................................................................1-13
Torque Specifications--Metric Hardware..........................................................................................1-13

Oil Specifications ..........................................................................................................1-16

Technical Specification of the Machine ......................................................................1-20
Application........................................................................................................................................1-20
Main Components ............................................................................................................................1-21
Performance Parameters .................................................................................................................1-22

Machine Inspection Table.............................................................................................1-27

1-2
General Information November 17, 2017
CLG835H
 1-3
November 17, 2017 How to Use the Manual
CLG835H

How to Use the Manual User's Guidance

● Because the influences from area or

This manual is written for an experienced processing are different of the machine, it
technician. Essential tools required in performing shall confirm which machine is applicable,
certain service work are identified in this manual and what work implements it has.
and are recommended for use. ● Some accessories and optional parts in the
This is the safety-alert symbol. When Manual may not be transported to relevant
you see this symbol on the machine areas, and consult your local LiuGong dealer
or in this manual , be alert to the if required.
potential for person injury. ● The materials and technical specifications in
Technical manuals are divided in several parts : the Manual are changed with variation of
repair and test. Repair sections tell how to repair products, and all information, diagrams and
the components. Tests sections help you identify specifications in the Manual are the latest
the majority of routine failures quickly. product information obtained at the time of
publication. The company reserves the right
Information is organized in groups for the various
to make modification without any notice. If it
components requiring service instruction. At the
needs to obtain the latest technical
beginning of each group are summary listings of
information, please consult the dealer of
all applicable essential tools, service equipment
LiuGong in local area or Service Department
and tools, other materials needed to do the job,
of LiuGong Wheel Loader Marketing Co., Ltd.
service part kit, specifications,wear tolerances,
and torque values.
Technical Manuals are concise guides for
specific 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
operation, fundamentals of troubleshooting,
general maintenance, and basic type of failures
and their causes.

Other reference manuals

● Parts Manual
● Operation and Maintenance Manual
● Cummins Engine Parts Manual
● Cummins Engine Overhaul Manual
● ZF Gearbox Overhaul Manual
1-4
Important Safety Information November 17, 2017
CLG835H

Important Safety Information

Most accidents involving product operation, LiuGong cannot anticipate every possible
maintenance and repair are caused by failure to circumstance that might involve a potential
observe safety rules or precautions. An accident hazard. The warnings in this publication and on
can often be avoided by recognizing potentially the product are therefore not all inclusive. If a
hazardous situations before an accident occurs. tool, procedure, work method or operating
A person must be alert to potential hazards. This technique not specifically recommended by
person should also have the necessary training, LiuGong is used, you must satisfy yourself that it
skills and tools to perform these functions is safe for you and others. You should also
properly. ensure that the product will not be damaged or
made unsafe by the operation, lubrication,
Improper operation, lubrication, maintenance or
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,
available at the time when it was written. The
maintenance or repair on this product, until you
specification, torques, pressures,
have read and understood the operation,
measurements, adjustments, illustrations, and
lubrication, maintain and repair information.
other items can change at any time. These
Safety precautions and warnings are provided in changes can affect the service given to the
this manual and on the product. If these hazard product. Obtain the complete and most current
warnings are not heeded, bodily injury or death information before starting any job. LiuGong has
could occur to you or other persons. the most current information available.
The hazards are identified by the "Safety Alert
Symbol" and followed by a "Signal Word" such
as "WARNING" as shown following.

The meaning of this safety alert symbol is as

follows:
Attention. Be alert. Your safety is involved.
The message that appears under the warning,
explaining the hazard, can be either written or
pictorially presented.
Operations that may cause product damage are
identified by NOTICE labels on the product and
in this publication.
 1-5
November 17, 2017 Manual Identification
CLG835H

Manual Identification

IMPORTANT: Use only supporting manuals

designed for your specific machine. If incorrect Pin Plate
manual is chosen, improper service may occur.
Verify product identification number (PIN) and
engine model number when choosing the correct
manual.

Choosing the Correct Supporting Manuals

LiuGong wheel loaders are available in different

machine configurations based on the various
markets into which they are sold. Different
supporting manuals exist for different machine
configurations.
When necessary, product serial numbers and P28100307
engine model numbers are listed on the front
covers of loader manuals. These numbers are
used to identify the correct supporting manual for
your machine.

Product Serial Number Identification

The product identification number (PIN) plate is

located on right side of machine front frame
under the pin of boom. Each machine has a 17-
character PIN or shown on this plate and under
this plate, The last 6 characters of the PIN
represent the machine’s product serial number.
PIN Plate Location

P28M00016
1-6
Engine Identification November 17, 2017
CLG835H

Engine Identification

The engine serial number plate is located on the

top of engine. 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.
Engine serial number plate location

P28100308

Engine Serial Number Plate

P28100309
 1-7
November 17, 2017 Cable Code Identification
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 temperature environment of various wires, see following table.

Heat
S/N Wire type Wire name Description
resistance
70 °C (158°F) heat-resisting,
1 QVR Low voltage wire for road vehicles ≤ 70°C(158°F)
copper 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
1-8
Cable Code Identification November 17, 2017
CLG835H

Color abbreviation codes

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
Remark: 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 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
20 135 148 121 133 105 116 85 94 60 66
area (mm2)
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
 1-9
November 17, 2017 Coating Materials
CLG835H

Coating Materials

Name Specification Main features and purposes

1. Features: anaerobic and fast air drying.
1277 Thread locker 1277
2. Purposes: used for parts not frequently removed
1243 Thread locker 1243 Used for removable parts (speed sensor in general)
1. Features: rust protection for a long time
Long-term anti-rust agent LONG#2 light yellow 2. Purposes: used for mounting face of pump, sensor,
hydraulic fitting, etc
Efficient cleaning agent 1. Features: strong ability of cleaning
1755
1755 2. Purposes: used for pump and motor
1. 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
2. Purposes: used for water temperature sensor and oil
pressure sensor
Cleaning agent for
electromechanical HD-10 Used for cleaning oil pipe connectors, etc.
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 this machine:
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
Paint film color, and no blistering, crack, requirements at all levels
1 Visual inspection
appearance wrinkle, under screen, rust, of surface for details of
damage, dirt and so on allowable defects
For details, see the
Meet the minimum requirements at all levels
Paint film
2 requirements of paint film Visual/gloss meter of surface. For matte
gloss
gloss at all levels of surface paint, refer to the special
requirements
Meet the minimum
For details, please see
Paint film requirements of paint film
3 Thickness gauge of paint film the requirements at all
thickness thickness at all levels of
levels of surface
surface
1-10
Coating Materials November 17, 2017
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 of Good adhesion and no peeling The distance between the scribing lines
4 film drops. (Little film
paint film in detection of paint film is 1 mm~1.5 mm and the depth can
drop around the scribing
reach the steel plate substrate. Then
lines can be allowable.)
stick the transparent adhesive tape and
compact, then tear off the tape
Meet color difference For details, please see
Color
5 requirements at all levels of Visual inspection/Color difference meter the requirements at all
difference
surface levels of surface
There is no paint
6 Shield contamination, mechanical Visual inspection
impurity, rust and dirts
The decal should be correct,
7 Decal complete, decorous, firm, Visual inspection
smooth and no popping
 1-11
November 17, 2017 Weight Table
CLG835H

Weight Table

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

Components Weight (kg \ lb)

Engine 485 kg\ 1069 lb
Radiator 291 kg\ 642 lb
Fuel tank 117 kg\ 258 lb
Front axle 766 kg\ 1689 lb
Rear axle 760 kg\ 1676 lb
Tire rim 228 kg\ 503 lb
Driven shaft 79 kg\ 174 lb
Gearbox & torque converter assembly(with oil) 480 kg\ 1058 lb
Cab assembly 685 kg\ 1510 lb
Seat 29 kg\ 64 lb
Engine hood as 210 kg\ 463 lb
Left front fender 15 kg\ 33 lb
Right front fender 15 kg\ 33 lb
Left rear fender 21 kg\ 46 lb
Right rear fender 21 kg\ 46 lb
A/C compressor 5 kg\ 11 lb
Working pump 20 kg\ 44 lb
Steering pump 25 kg\ 55 lb
Control valve 38 kg\ 84 lb
Fan drive motor 7 kg\ 15 lb
Hydraulic oil tank 170 kg\ 375 lb
Boom cylinder assembly (single) 101 kg\ 223 lb
Bucket tilting cylinder assembly 105.5 kg\ 233 lb
Secondary steering pump 20 kg\ 44 lb
Ride control accumulator 41 kg\ 90 lb
Rocker arm 140 kg\ 309 lb
Boom 700 kg\ 1544 lb
Front frame 912 kg\ 2011 lb
Rear frame 840 kg\ 1852 lb
LH battery box 170 kg\ 375 lb
RH battery box (with counterweight) 430 kg\ 948 lb
Linkage 37 kg\ 82 lb
Bucket 750 kg\ 1654 lb
1-12
Unit Conversion Table November 17, 2017
CLG835H

Unit Conversion Table

The Manual uses ISO International System of Units, and ISO international units are converted into
British 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 kgf/cm3 10.197
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
-1 rpm 1.0
min
L/min US gpm 0.2642
Flow
mL/rev cc/rev 1.0
 1-13
November 17, 2017 Standard Torque Table
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±1.1N.m \ 5.7±0.8lbf·ft
M8 19±2.9N.m \ 14±2.1lbf·ft
M10 38±5N.m \ 28±4lbf·ft
M12 66±9N.m \ 48±7lbf·ft
M14 107±15N.m \ 79±11lbf·ft
M16 166±26N.m \ 122±19lbf·ft
M18 229±33N.m \ 169±24lbf·ft
M20 302±37N.m \ 223±27lbf·ft
M22 443±59N.m \ 327±44lbf·ft
M24 561±74N.m \ 414±55lbf·ft
M27 811±111N.m \ 598±82lbf·ft
M30 1106±148N.m \ 816±109lbf·ft
M33 1512±221N.m \ 1115±163lbf·ft
M36 1955±258N.m \ 1442±190lbf·ft

Grade 10.9 /12.9 Bolts, Nuts, and Studs

Size N.m\ lbf•ft
M10 72±6N.m \ 53±4lbf·ft
M12 120±10N.m \ 89±7lbf·ft
M14 195±15N.m \ 144±11lbf·ft
M16 305±25N.m \ 225±18lbf·ft
M18 415±35N.m \ 306±26lbf·ft
M20 600±50N.m \ 443±37lbf·ft
M22 800±70N.m \ 590±52lbf·ft
M24 1020±100N.m \ 752±74lbf·ft
M27 1500±100N.m \ 1106±77lbf·ft
M30 1850±150N.m \ 1364±111lbf·ft
M33 2900±400N.m \ 2139±295lbf·ft
M36 3100±250N.m \ 2286±184lbf·ft
1-14
Standard Torque Table November 17, 2017
CLG835H

Tightening torque of 24° cone O-ring sealed connector

Hose inner Tightening torque

Series Thread size
diameter (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 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
 1-15
November 17, 2017 Standard Torque Table
CLG835H

Tightening torque of flange-type sealed 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
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 connector

Material of
Carbon steel, alloy steel Aluminum products
fastenings
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 / /

Joint 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
1-16
Oil Specifications November 17, 2017
CLG835H

English system thread tightening torque

Tightening torque Tightening torque

Thread size Thread size
lb.ft (N•m) lb.ft (N•m)
1/4 9 ± 3 (12 ± 4) 9/16 110 ± 15 (150 ± 20)
5/16 18 ± 5 (25 ± 7) 5/8 148 ± 18 (200 ± 25)
3/8 33 ± 5 (45 ± 7) 3/4 266 ± 37 (360 ± 50)
7/16 52 ± 11 (70 ± 15) 7/8 420 ± 59 (570 ± 80)
1/2 74 ± 11 (100 ± 15) 1 645 ± 74 (875 ± 100)

Oil Specifications
Fluids and lubricants
Category Name Capacity Application parts
≥-10°C(14°F) ★ SAE 15W/ 40CH-4 15L \3.96 US
Engine oil Diesel engine
≤-10°C(14°F) SAE 5W/ 40CH-4 gal

Diesel ≥-10°C(14°F) ★ 0# diesel 187L \49.41 US

Diesel engine
fuel ≤-10°C(14°F) -20# diesel gal

-15~40°C(5~104°F) ★ HM-46 anti-wear hydraulic oil

Hydraulic 100L \26.42 US Work hydraulic system, steering
oil -25~40 ℃ HV-46 low temperature anti- gal hydraulic system
(-13 ℉ ~104°F) wear hydraulic oil

Torque ★ SAE 15W-40 Mobil Delvac

≥-10°C(14°F) 40L \10.57 US Torque converter and power shift
converter 1300
gal gearbox
oil ≤-10°C(14°F) S4 TXM 10W-30
★ SAE 80W-90/LS Heavy-load
≥-10°C(14°F)
wheel gear oil Front and rear axle bevel gear and
Gear oil 34L \9 US gal
75W-90/LS Heavy-load wheel wheel reducer
≤-10°C(14°F)
gear oil
Refrigerant ★ R134a 1.1Kg\2.4 lb Air conditioner
★ 2# Molybdenum disulfide Roller bearing, slide bearing, pin
Manual lubrication
lithium grease shaft of work implement, pin shaft
0# Composite lithium base of steering cylinder, pin shaft of
Grease ≤-10°C(14°F) 2L \0.53 US gal
grease vehicle frame, swing frame of rear
axle, spline of drive shaft, cardan
2# Composite lithium base
Central lubrication joint, and water pump shaft
grease
32L \8.45 US
Coolant ★ SHELL anti-freezing solution
gal
Note: " ★ " used by the manufacturer after the machine is newly produced.
 1-17
November 17, 2017 Oil Specifications
CLG835H

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.
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.
Low sulfur fuel should be used. The wrong fuel used will cause the engine damaged as a result.

Maintenance schedule

Frequency in Hours
Intervals
Service

Service

Lubricate
Initial

Replace
Change

Adjust
Service Points
Check

Clean

Drain

Radiator coolant level ★

Tires ★
Hydraulic filter ★
Air cleaner ★ ★
As required
Alternator, A/C, drive belt ★
Fire extinguisher ★
Check, replace cab fresh air filter ★ ★
Check, replace A/C return air filter ★ ★
Every 10
Check engine oil level 10
hours
Check engine coolant level 50
Check transmission oil level 50
Every 50
Check hydraulic oil level 50
hours
Grease bucket mounting fittings 50
Bleed fuel filter of condensation 50
Change engine oil and filters 100
Replace fuel filters 100
First 100
Change hydraulic filter 100
hours
Change transmission oil and filter 100
Change oil in axles 100
Grease front drive shaft support bearing 100
Every 100 Grease steering cylinder pivots (4 fittings) 100
hours Grease lift & tilt cylinder pivots (6 fittings) 100
Grease articulation fittings 100
1-18
Oil Specifications November 17, 2017
CLG835H

Maintenance schedule

Frequency in Hours
Intervals
Service

Service

Lubricate
Initial

Replace
Change

Adjust
Service Points

Check

Clean

Drain
Check radiator coolant level 250
Check tire pressure & wheel torque 250
Every 250
Check drive belts 250
hours
Check air filter 250
Change engine oil and replace filter 250
Check axle oil level 500
Every 500 Check battery volt and nuts torque 500
hours Replace fuel water separator 500
Replace fuel filter 500
Replace hydraulic oil filter 500 1000
Replace pilot hydraulic oil filter 500 1000
Every 1000 Change front & rear axle oil 1000
hours Change transmission oil and filter 100 1000
Check accumulator nitrogen pressure 500 1000
Clean fuel tank 100 1000
Every 2000 Change hydraulic oil & filter 2000
hours Change coolant 2000
Note: ★ means service as required.
 1-19
November 17, 2017 Technical Specification of the Machine
CLG835H

Technical Specification of the Machine

P28100311

Application

This machine is a kind of engineering machinery

mainly used for loading & unloading loose
materials. It is mainly used for loading, Do not operate machine in conditions with
unloading, bulldozing and traction operation etc. rollover or falling object risk.
at mine 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 machine is a kind of general-purpose maintenance and safety rules outlined on this
engineering 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
Altitude: ≤3000 m safety liabilities will be born by users. Under
any cases, do not use the forbidden
Environmental temperature: -12°C~40°C (The operation outlined in this manual.
cold starting Aid device is not available)
Water Depth: ≤ 630mm
1-20
Technical Specification of the Machine November 17, 2017
CLG835H

Main Components

LEFT
1
REAR
2

RIGHT

FRONT
5
6 11 8
7 9 P28100313

FRONT 10
RIGHT
12

左
LEFT REAR
P28100312

1. Cab 5. Counterweight 9. Boom

2. Tilting cylinder 6. Rear axle 10.Front fender
3. Rocker arm 7. Rear fender 11.Hydraulic oil tank
4. Bucket 8. Front axle 12.Engine hood
 1-21
November 17, 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

P18M00230
1-22
Technical Specification of the Machine November 17, 2017
CLG835H

Machine Specifications

NO. Item Unit CLG835H

1 Rated load weight kg 3000
2 Rated power KW 119
3 Operating mass kg 10800
4 Rated bucket capacity m3 1.8
5 Dumping height mm 2920
6 Max. breakout force (bucket tilting) kN 105
7 Tipping load (aligning) Kg 7900
8 Tipping load (full steering) Kg 6800
9 Boom lifting time (full load) s 5.06
10 Total time s 9.27
11 Max. traveling speed km/h 36
12 Max. gradeability ° 28
13 Min. turning radius (outside of front wheel) mm 5090
Overall Dimensions
1 A: Height to hinge pin, fully raised mm 3730
2 B: Dumping height, fully raised mm 2920
3 C: Dumping reach, fully raised mm 1014
4 D: Max. digging depth mm 40
5 E: Min. ground clearance (at articulation joint) mm 335
F: Distance from centre of rotation to the centre of the front
6 mm 1435
wheels
7 G: Wheel base mm 2870
8 H: Overall height (top of cab) mm 3232
9 J: Tread width mm 1850
10 K: Overall width (outside of wheel) mm 2295
11 L: Over length (bucket on ground) mm 7060
12 M: Max. steering angle ° 40
13 W: Overall width (outside of bucket) mm 2460
14 R1: Turning radius (outside of bucket) mm 5600
15 R2: Turning radius (center of rear wheel) mm 4867.5
16 P: Departure angle ° 28
17 S1: Bucket tilt back angle (on ground) ° 41
18 S2: Bucket tilt back angle (in transport position) ° 48
19 S3: Bucket tilt back angle (in highest position) ° 61
20 S4: Dumping angle (in highest position) ° 45
21 T: Bucket articulation height (in transport position) mm 500
 1-23
November 17, 2017 Technical Specification of the Machine
CLG835H

Main Components Specifications

Engine
1 Manufacturer / CUMMINS Power
2 Model / QSB6.7
3 Type / Electronic fuel injection
4 Displacement L 6.7
5 Rated power kW 119
6 Emission level / U.S.EPA Tier3
7 Number of cylinders and arrangement / Straight-six cylinders
Turbocharging & air-air inter-
8 Intake type /
cooling
9 Rated speed r/min 2200
10 Max. rotating speed (no-load) r/min 2350
11 Min. rotating speed (no-load) r/min 600
12 Rotating speed at max. torque r/min 1400
13 Max. torque Nm 732
14 Start motor V-Kw 24V-7.5 KW
15 Alternator V-A 24V- 70A
Power train system
1 Torque converter Type Single turbine, three members
2 Manufacturer ZF
3 Model 4WG158
4 Type Fixed shaft type, power shift
Transmission Four forward gears and three
5 Number of gears
reverse gears
Operating pressure of shift oil
6 1.6~1.8MPa (232~261psi)
pump (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 20.267
12 Rear axle swing angle 11°
13 Wheels Tire model 17.5-25PR12 TT
14 F1/ R1 7/ 7km/h
15 F2/ R2 11.7/ 11.7km/h
Traveling speed
16 F3/ R3 23.2/ 23.2km/h
17 F4 36km/h
1-24
Technical Specification of the Machine November 17, 2017
CLG835H

Main Components Specifications

Work hydraulic system

1 Work pump Type Gear pump
2 Work pump displacement ml/r 50
3 System pressure MPa 18
Two spools (third spool is
4 Control valve /
optional)
5 System flow L/min 102
6 Lifting time (full load) s 5.06
7 Dumping time s 1.11
8 Float lowering time s 3.1
9 Total time s 9.27
Steering hydraulic system
1 Steering angle ° 40
2 Steering pump Type Gear pump
3 Steering pump displacement ml/r 52.2
4 System pressure MPa 17.2
5 System flow L/min 107
Brake hydraulic system
1 Service brake Type Full hydraulic wet type brake
2 Brake pump Type Gear pump
3 Brake pressure MPa 4.8
Nitrogen Pre-charge pressure of
4 MPa 5.5
Accumulator
5 Parking brake Type Drum type parking brake
6 Parking brake control mode / Electro-hydraulic control
Nitrogen Pre-charge pressure of
7 MPa 9.2
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 187
2 Engine oil L 15
3 Cooling system L 32
 1-25
November 17, 2017 Technical Specification of the Machine
CLG835H

Main Components Specifications

4 Transmission oil L 45
Front: 28
5 Drive axle oil L
Rear: 28
6 Hydraulic oil L 145
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.
1-26
Machine Inspection Table November 17, 2017
CLG835H

Machine Inspection Table

Inspection
S/N Inspection method and acceptance criteria
item
Machine information: visually check the complete machine number for compliance with
1
description of model.
Fastening bolt: visually check whether the left and right mounting bolts of front axle are
2 tightened firmly in place; visually check whether the left and right front rim bolts are installed and
tightened.
Fastening bolt: visually check the mounting bolts between front drive shaft and front axle,
3
output flange of transmission and middle bearing fastened.
Fastening bolt: visually check whether the emergency braking flexible shaft is connected
4
reliably; brake cylinder for oil leakage and connected reliably.
5 Fastening bolt: visually check whether mounting bolts of upper and lower hinge are tightened.
Fastening bolt: visually check the left and right mounting bolts of rear axle are tightened;
6
visually check the left and right rear rim bolts are installed and tightened.
Inspection 7 Water level: anti-freeze level shall be over the middle line in the level window of expansion tank.
before test
run Oil: pull out the oil dipstick and the engine oil level shall be between the MIN and MAX marks of
8
the dipstick, and the oil is not in white.
Hydraulic oil: lay flat the bucket, lower the boom to the minimum at idling, and visually check
9 the 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 oil: when the engine is idling and the transmission fluid temperature is not more
than 40°C, check that the level shall be between cold fluid MAX and MIN marks. Then, place the
shift control lever at four gear and depress the brake, then the accelerator to run the
10 transmission for 5~8min to make the transmission fluid temperature reach 100~110°C. Release
the accelerator and place the shift control 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°C.
Air-tightness: visually check each hydraulic line, cylinder, transmission, axle, oil tank, radiator,
11
diesel 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 (If equipped): 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
4
Climbing up at the front of suspension, the suspension rises, otherwise goes down. There is no abnormal
the cab sound and parts interference during air-filled detection.
Turning on the engine start switch: turn on the front floodlight, work light, alarm light, parking
5
light by order and get off the vehicle to check if they function normally.
Starting the machine: operate the engine speed adjustment switch and visually check the
6
corresponding change to the speed of the tachometer on the instrument panel.
7 Starting the machine: operate the switch of LCD to switch the voltage and timing display.
8 Visual check: timer displays and record the time.
 1-27
November 17, 2017 Machine Inspection Table
CLG835H

Inspection
S/N Inspection method and acceptance criteria
item
Steering column: it can be adjusted forward and backward, upward and downward normally; no
looseness after locking. Lift the steering wheel upwards by hand and no axial runout occurs
9
(≤3mm). If the machine is equipped with an immovable steering column, just need to check the
Climbing up steering column for stableness.
the cab
Horn: press the horn button on the lever of the horn button/control lever on the combination
10 lever horn button/steering wheel and listen, no abnormal sound and failure to the horn should
occur.
Air The air volume switch, temperature setting switch, defrost setting switch, air mode switch, auto
conditioning 1 mode switch on the A/C panel functions normally and is indicated correspondingly on the LCD;
system the temperature, air volume, direction at the air outlet is the same with setting value on the panel.
Starting the machine: it starts normally, and listen to the engine and air filter, no abnormal
1 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 machine: adjust the machine operating idle speed to a level more than 950rpm and
2
the engine does not stall with the bucket lifted.
Starting the machine: visually check that no trouble code appears on the LCD of instrument
3 panel, and no indicating identification, alarm and flashing appears on the instrument panel or
normally on.
Backup monitor system (If equipped): when placing the shift control lever at reverse, the
4
backup monitor activates automatically and the image shall be clear.
Work implement control lever: there is no seizing and interference with other parts when
5 operating the pilot control lever to achieve lifting and lowering of boom and tilting back and
dumping of the bucket.
Pilot shutoff function: the pilot shutoff lever is at OFF position, operate the pilot lever and the
Driving test 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 moving automatically and then control lever returns back to neutral position when the
7
bucket 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
8 when it reaches the setting highest position; the control lever returns back to neutral position
automatically. 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).
1-28
Machine Inspection Table November 17, 2017
CLG835H

Inspection
S/N Inspection method and acceptance criteria
item
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 (the
front wheels off the ground), visually check that the boom does not drop quickly; when the bucket
11
is jacked up (the front wheels off the ground), push the control lever to the boom lowering and
floating position, visually check that the boom shall be floating and lowering.
Ride control (If equipped): park the machine on the level ground, disconnect the ride control
12 system 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&electrical
circuit and other sharp edges.
With steering cushion: turn the complete machine to the limit position, and the steering
14
cushion is compressed (8-12) mm.
Secondary steering (If equipped): turn on the electric lock without starting, the secondary
15 steering indicator on the instrument panel comes on when the secondary steering switch is
pressed, and the steering can be normally performed
Gear inspection (If equipped): Manual shift. 1) Turn the manual/auto shift switch to "Manual";
16 2) Start the machine and idle; 3) Release the parking brake; 4) Operate the shift control lever and
all the gears shall be available freely.
Gear inspection (If equipped): Semi-automatic shift 1) Place the manual/auto shift rocker
Driving test switch at neutral position; 2) Start the machine and idle; 3) Release the parking brake; 4) Oper-
ate the shift lever, and place it at F1 position, and the gear to machine transmission shall be F1
5) Operate the shift lever, and place it at F2 position, and the gear to machine transmission shall
be F2; 6) Operate the shift lever, and place it at F3 position, and the gear to machine transmis-
17 sion shall still be F2, depress the accelerator gradually to the maximum and hold it, increase the
speed of machine, and when it reaches a certain value, 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 auto-
matically 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 (If equipped): Full-automatic shift. 1) Turn the manual/auto shift switch to
"Auto" position; 2) Start the complete machine; 3) Release the parking brake; 4) Operate the shift
control 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;
18 5) Keep the opening of throttle, and continuously increase the vehicle speed and operate the
shift control 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)
KD function test (If equipped): place the shift control lever at 2 with low speed, test the key KD
19 on the shift control lever and FNR switch respectively, press the key KD and the gear is switched
to first gear.
FNR control lever test (If equipped): 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
20
pressed. When the FNR function is activated, the FNR lever can be used to perform F(forward)\
N(neutral)\ R(reverse) and KD function operation.
 1-29
November 17, 2017 Machine Inspection Table
CLG835H

Inspection
S/N Inspection method and acceptance criteria
item
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 vehicle;
4) depress the service brake pedal and when it reaches a certain level, the gear shall shift down
21
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.
Backup alarm: when the shift control lever is placed at reverse, the reverse alarm begins to
22
perform buzzing alarm immediately.
Brake system: Drive the vehicle for 10 laps, during which depress the brake pedal and the
23 complete machine is braked, two times per lap; no seizing shall be felt when depressing the
accelerator 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
24
instrument panel indicates alarm during driving; visually 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
Driving test 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
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 clockwise and counterclockwise rotation: the engine is idling, press the fan reverse
switch for less than 60 seconds, and then fan can be switched to rotate counterclockwise with
29
indicator on; press the switch again for less than 60 seconds and the fan is switched to rotate
clockwise 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, visually check that the tire has no interference with frame,
30
fender, rear cover (with clearance more than 20 mm) pipe on axle has no interference with diesel
engine after stopping the vehicle.
Centralized lubrication line (If equipped): 1) fastened to pin lubrication pipe joints without oil
leakage; 2) centralized lubricator time is correctly set; 3) oil pipe is not bent and twisted; 4) oil
31
pipe runs smoothly without interference with proper length and beautiful appearance; there is no
pulling interference during turning and operation of work implement.
1-30
Machine Inspection Table November 17, 2017
CLG835H

Inspection
S/N Inspection method and acceptance criteria
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; visually 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
amplifying valve, unload valve, combination valve, electric proportioning valve, steering pump,
6
priority 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
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
9 accumulator, transmission oil filter and its joint, charge valve and its joint and hydraulic rising
Static check mechanism.
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
13 interference 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.
Visual check: there is no interference between hydraulic oil tank and cab; there is no
15
interference 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
18 edges (harness is far away from high temperature area and not interfered with fuel pipe); there is
no interference between filters and sharp edges and other parts, and the hoses are not twisted.
 1-31
November 17, 2017 Machine Inspection Table
CLG835H

Inspection
S/N Inspection method and acceptance criteria
item
Visual check: urea heating pipe, cool water pipe, post-processor water pipe runs smoothly
19
without interference and is far away from high temperature area. (If equipped)
20 Visual check: arrow of solenoid water valve shall face the urea tank. (If equipped)
Visual check: harness at upper side of post-processor is far away from high temperature area.
21
(If equipped)
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
24
pulley is not interfered with fan guard.
Static check 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,
26
pipe 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, fan pump joint.
Inspection of quick coupler (If equipped): 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,
29 open the pilot shutoff 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 and close the
pilot shutoff valve to OFF position. Turn the spool lever to Aux position.
1-32
Machine Inspection Table November 17, 2017
CLG835H
 2-1
November 17, 2017 Power System
CLG835H

Power System
Basic Information ............................................................................................................2-3
Safety .....................................................................................................................................................2-3
Overview-Components and Position......................................................................................................2-5
Main Technical Parameters of Power System .......................................................................................2-8
Universal Tool, Tooling List....................................................................................................................2-9

Structure and Function .................................................................................................2-10

Engine System .....................................................................................................................................2-10
Intake and Exhaust Assembly..............................................................................................................2-11
Air Pre-filter ......................................................................................................................................2-14
Air Filter............................................................................................................................................2-14
Turbocharger....................................................................................................................................2-15
Fuel System .........................................................................................................................................2-16
Fuel Line ..........................................................................................................................................2-16
Cooling System ....................................................................................................................................2-17
Overview ..........................................................................................................................................2-17

Removal and Installation ..............................................................................................2-21

Removal and Installation of Air Pre-filter..............................................................................................2-22
Removal of Air Pre-filter ...................................................................................................................2-22
Installation of Air Pre-filter ................................................................................................................2-22
Removal and Installation of Air Filter ...................................................................................................2-23
Removal of Air Filter.........................................................................................................................2-23
Installation of Air Filter......................................................................................................................2-24
Air Filter--Maintain............................................................................................................................2-25
Removal and Installation of Turbocharger ...........................................................................................2-26
Removal and Installation of Fuel Lines ................................................................................................2-27
Removal of Fuel Lines .....................................................................................................................2-28
Installation of Fuel Lines ..................................................................................................................2-30
Removal and Installation of Fuel Tank Assembly ................................................................................2-31
Removal of Fuel Tank Assembly .....................................................................................................2-32
Cleaning of Fuel Tank ......................................................................................................................2-33
Installation of Fuel Tank ...................................................................................................................2-33
Removal and Installation of Radiator Pipelines ..................................................................................2-34
Removal of Radiator Pipelines.........................................................................................................2-35
2-2
Power System November 17, 2017
CLG835H

Installation of Radiator Pipelines......................................................................................................2-38

Removal and Installation of Radiator Assembly...................................................................................2-39
Removal of Radiator Assembly........................................................................................................2-39
Installation of Radiator Assembly.....................................................................................................2-43
Disassembly, Check and Assembly of Radiator Assembly..................................................................2-44
Disassembly of Radiator Assembly..................................................................................................2-45
Check of Radiator Assembly............................................................................................................2-47
Assembly of Radiator Assembly ......................................................................................................2-47
Disassembly and Assembly of Radiator Group....................................................................................2-48
Disassembly of Radiator Group .......................................................................................................2-49
Refilling and Replacement of Coolant..................................................................................................2-50

Fault Diagnosis and Troubleshooting .........................................................................2-51

Air Pre-filter Fault .............................................................................................................................2-51
Air Filter Fault...................................................................................................................................2-51
Turbocharger Fault...........................................................................................................................2-51
 2-3
November 17, 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 0.2MPa (29psi).

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
2-4
Basic Information November 17, 2017
Safety CLG835H

Fire & Explosion Prevention

● All fuels, such as most of lubricants and

some cooling agent are flammables.
● 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
November 17, 2017 Basic Information
CLG835H Overview-Components and Position

Overview-Components and Position

Functions of power system

Supplying the machine with the mechanical energy converted from the chemical energy of fuel. Power
system includes: engine system, cooling system and fuel tank assembly. Engine system is composed of
engine mounting assembly, intake and exhaust assembly and fuel lines; cooling system is composed of
radiator mounting assembly and radiator lines. Among them, the engine mounting assembly consists of
engine, and the radiator mounting assembly consists of cooler components.
Module structure figure of power system

Engine mounting assembly (Include the engine)

Engine system Intake and exhaust assembly

Fuel lines
Power System Cooling system Radiator mounting assembly
(Include radiator group)

Radiator lines
Fuel tank assembly

Position of power system in the machine

1 2

P28P00578

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

2-6
Basic Information November 17, 2017
Overview-Components and Position CLG835H

Components of power system

6
5
4

3
2
1 P28P00579

1. Engine 3. Fuel tank 5. Muffler

2. Engine mounting assembly 4. Auxiliary water tank 6. Exhaust pipe
 2-7
November 17, 2017 Basic Information
CLG835H Overview-Components and Position

Components of power system

11

10

9
8
7

P28P00580

7. Fan 10.Air filter

8. Radiator group 11.Air pre-filter
9. Fuel-water separator
2-8
Basic Information November 17, 2017
Main Technical Parameters of Power System CLG835H

Main Technical Parameters of Power System

Model CUMMINS QSB6.7

Type Six-cylinder in-line, four-stroke, turbocharged
Emission U.S.EPA Tier3
*Rated power 160BHP(119kW)@2200r/min
Engine
*Maximum idling speed 2376±50r/min
*Minimum idling speed 750±50r/min
Engine oil level 15L
Rotation direction Clockwise (viewed from the fan end to flywheel housing end)
Fan Diameter 760mm, 9 blades, induced draft iron fan
Drive ratio of fan belt pulley 0.87:1
Cooling system
Opening temperature: 82°C (179.6°F)
Thermostat
Fully open temperature: 95°C (203°F)
Engine oil system Oil filter Full flow type and replaceable (oil filter is rotatable)
Preheating system Preheating method /
Core type Plate-fin type
Water radiator Core size (height × width × 1100mm X 409mm X 140mm
thickness) (31.5 InX17.7 In X3.15In)
Core type Plate-fin type
Hydraulic oil radiator Core size (height × width × 1100mm X 180mm X 140mm
thickness) (31.5 InX 8.86InX3.15 In)
Core type Plate-fin type
Torque converter oil radiator Core size (height × width × 1100mm X 195.5mm X 140mm
thickness) (31.5 InX8.78 In X3.15In)

Note: Data marked with * is based on engine with fuel system and water pump under intake resistance of 250 mm H2O
(2.449Pa) and exhaust resistance of 50 mm Hg (7kPa) but not including alternator, fan, optional configurations and
drive components.
 2-9
November 17, 2017 Basic Information
CLG835H Universal Tool, Tooling List

Universal Tool, Tooling List

Name Specifications
Open-end wrench 7#, 8#, 10#, 11#, 12#, 13#, 16#, 18#, 19#, 20#, 22#, 24#, 30#
Ratchet wrench, 10#, 11#, 12#, 13#, 16#, 18#, 19#, 20#, 22#, 24# and
Ratchet wrench and socket
30# socket
Torque wrench 120±6N.m, 1020±6N.m
Traveling crane More than 2t
Wire rope with hooks Weight bearing over 840Kg
Steel ruler Steel ruler
Straight screwdriver
Cross screwdriver T25
Lifting eye
Plastic sealing membrane
Waste oil tank
Remarks:

Precautions on removal and installation:

1. Assembly and disassembly must be carried out when engine is cool. In general, open engine hood
after engine is shut down, and wait for 15 minutes before the engine is cooled down.
2. Measurement equipment and tools such as torque wrench shall have compliance certificates issued
by metrological department;
3. Because many other related components on the Machine are concerned during the removal and
installation of each component, removed components (especially standard parts) shall be reasonably
placed to avoid wrong installation, neglected installation, part missing, etc. during reassembly.
4. When other components are involved in the removal and installation of each component, please refer
to the list of tools for removing and installing other components from/on the complete machine, these
tools will not be 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.
2-10
Structure and Function November 17, 2017
Engine System CLG835H

Structure and Function

Engine System
Overview--Components and position
Engine system consists of engine mounting assembly, intake and exhaust assembly and fuel pipeline.

2
3

10 P28P00581

6
5
4

8
9
P28P00582

1. Belt pulley system 5. Ventilating device for crankcase 9. Start motor

2. Turbocharger 6. Alternator 10.Oil sump
3. Fuel filter 7. Oil cooler
4. Flywheel housing 8. Oil filter

Engine installed on this machine is Cummins engine QSB6.7. For working principles, maintenance and
service information, refer to Operation and Maintenance Manual for Cummins Engine. Cummins Inc. still
reserves the right for all information on the manual. During "warranty" period of engine, contact the
Cummins dealer closest to the maintenance location for all maintenances.
LiuGong Machinery Co., Ltd. will assume no responsibility for any loss caused by the user violating
these instructions.
 2-11
November 17, 2017 Structure and Function
CLG835H Intake and Exhaust Assembly

Intake and Exhaust Assembly

Components and Position

Structural drawing of engien intake and exhaust system

P28P00583

1. Air filter 9. Electronic service indicator 16.Bolt 23.Tube

2. Air pre-filter 10.Bellows 17.Bolt 24.Exhaust pipe
3. Intake line 11.Clip 18.Bolt 25.Plug
4. Exhaust pipe 12.Washer 19.Nut 26.Clamp
5. Muffler support 13.Bolt 20.Clip 27.Bolt
6. Outrigger 14.Washer 21.Clip 28.Bracket
7. Angle block 15.Screw 22.Muffler 29.Bolt
8. Clip
2-12
Structure and Function November 17, 2017
Intake and Exhaust Assembly CLG835H

Working principle description

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.

Working principle of the intake and exhaust assembly:

Air is taken in through air pre-filter. There are fixed whirling blades inside the air pre-filter, which can
discharge big dust in intake air through the bye hole of air pre-filter. Intake air becomes clean and dry
after removing small dust and moisture via the element in air filter and then be sent to turbocharger.
Driven by engine exhaust, the turbocharger pressurize the air and increase intake density to ensure the
fuel combusts sufficiently. Air coming out of turbocharger enters into the engine cylinder body to combust
after being cooled by air-air inter cooler. Exhaust gas generated after combustion reaches turbocharger
via exhaust manifold, drives turbocharger to pressurize intake air and then discharged to muffler to
reduce exhaust noise, after which emitted into atmosphere quitely.
Air intake path figure of engine

Hot gas

Cold gas

P28P00584
 2-13
November 17, 2017 Structure and Function
CLG835H Intake and Exhaust Assembly

Exhaust path figure of engine

Hot gas

Cold gas

P28P00585
2-14
Structure and Function November 17, 2017
Intake and Exhaust Assembly CLG835H

Air Pre-filter

Principle Introduction

2 3 5
1 7
4 6
P28P00588
1. Housing 5. Lock handle
2. Safety filter element 6. End cover
3. Main filter element 7. Dust exhausting cap
4. Seal ring
2

1 1
P28P00280

1. Clean air 2. Impurity

Air pre-filter is specially designed into rotary 2

intake channel, and air passes through specially
designed blade surfaces and rotates. When air
rotates fast, it generates a certain centrifugal
force to separate dust, water and other impurities
from air. Dust and impurities are driven by intake P28P00589
air flow and blown to a special discharge outlet 1. Main filter element 2. Safety filter element
by a fast rotating rotator so as to achieve the
action of air filtration. Air filter blocked alert of this machine is the
electronic induction type. When the filter works
Air Filter for a period of time, much dust is accumulated on
filter element, and air resistance through filter is
Part structure and principle introduction increased. When circulating air resistance is
above 6.2KPa, air filter clogging sensor installed
Air filter ensures clean and dry air to enter engine between air filter and turbocharger will transmit
through main filter element and safety filter signal to air filter alert indicator on instrument
element. panel. When the indicator goes on, air filter shall
be maintained.
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:
 2-15
November 17, 2017 Structure and Function
CLG835H Intake and Exhaust Assembly

Turbocharger Maintenance

Turbocharger is mainly used to increase intake Turbocharger is a precision machine running at a

pressure and improve intake quantity (intake high speed, and thus random removal is
density) so as to improve the power and forbidden. If severe wear or damage is found
economy of the engine. during inspection, corresponding parts shall be
adjusted, repaired or replaced. If turbocharger is
Installation location of turbocharger and its damaged or improperly adjusted, it cannot
illustration. function sufficiently, that is, it cannot deliver
sufficient air to engine. In case of malfunction,
contact Cummins maintenance center for repair.

Proper operation:

1. Before engine lubricant pressure is built,

keep the engine in idling status.
2. Before engine is stopped, gradually lower its
temperature and revolutions from maximum
values (for approximately 5 minutes).
3. Pre-lubricate the turbocharger. After
replacement of lubricant or any services
(including draining lubricant), pre-lubrication
is required for turbocharger. Turn the
crankshaft disc several times before the
P28P00596 engine starts. After engine starts and before it
1 2 begins to run at a high speed, keep engine
3 idling for a period so pressure of whole
5 7 lubricant circulation can be built.
8
4 6 4. Be cautious when start the engine at low
temperature. When the ambient temperature
is too low or vehicle is not used for a long
time, the engine’s ability to build proper
lubricant pressure and flow will be affected.
In that case, the engine can not work
properly after starting until idles for several
minutes.
5. Prevent the engine from running at idling
10 9
speed for a long time. In addition, whenever
lubricant is replaced, oil filter is washed or
engine is rest for a long period
(approximately more than a week), loosen oil
inlet joint of turbocharger and inject clean
lubricant so turbocharger lubrication system
P28P00597
is filled with lubricant.
1. Exhaust pipe 6. Bearing 6. For other maintenance information on
2. Nozzle cup 7. Diffuser
3. Turbine 8. Compressor impeller turbocharger, refer to the Accompanying
4. Turbine housing 9. Compressor housing Operation and Service Manual for Engine.
5. Rotor shaft 10.Intake line
2-16
Structure and Function November 17, 2017
Fuel System CLG835H

Fuel System

Fuel Line

Components and Position

The fuel line is mainly composed of fuel hose and fuel filter.

5
4

2
3

P28P00598

1. Fuel tank 3. Fuel transfer pump 5. High pressure pump

2. Fuel-water separator 4. Fuel filter

Working principle

The fuel system provides engine with clean and sufficient fuel, which thus ensures proper operation of
engine. Its working principle is shown above: when engine works, fuel transfer pump sucks fuel from fuel
tank, and eliminates water from fuel through fuel water separator, then eliminates impurities from fuel
through fuel filter, and finally fuel enters high pressure pump. The fuel is pressurized by the high
pressure 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 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 pump and then back to fuel tank after cooled.
 2-17
November 17, 2017 Structure and Function
CLG835H Cooling System

Cooling System

Overview

Working principle

Heat dissipation system comprises radiators and corresponding connecting lines, where the radiators
are composed of air-air intercooler, water,hydraulic oil and torque converter oil radiators. 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 inlet and outlet pipes, etc.

3 2 1 10
9

5 6 7
4 P28P00363

1. Water outlet pipe assembly 6. Water pump

2. Small circulation 7. Engine oil radiator
3. Thermostat 8. Drain valve
4. Radiator 9. Heating valve
5. Fan 10.Water temperature sensor

Cooling system of this machine adopts engine direct drive fan and cooled in the way of suction. 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 82°C, thermostat is
closed, and all coolant is bypassed to water pump inlet. At the moment, the coolant is only circulating
between cylinder block and head, so that warm-up can be quickly realized. When coolant temperature
reaches 82 °C, 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, 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 figure.
2-18
Structure and Function November 17, 2017
Cooling System CLG835H

Engine water circulation

P28P00601

1. Engine 2. Water radiator

 2-19
November 17, 2017 Structure and Function
CLG835H Cooling System

Air-air intercooler radiator

Air-air intercooler radiator has the main function of cooling high-temperature and high-pressure gas via
turbocharger, reducing temperature of air entering engine combustion chamber to increase air density.
Its working principle is shown in the figure below. After air is pressurized by turbocharger, temperature
rises up sharply and pressure is increased. The 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 so as to reduce its temperature to 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.

6 3

4
1
7

2
8 9
P28P00602

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

2. Turbocharger air outlet 5. Pressurized cold air 8. Exhaust gas
3. Pressurized hot air 6. Intake manifold 9. Muffler

The air-air intercooler heat dissipation system of the vehicle arranged as the drawing below.

2
P28P00603

1. Air-air intercooler 2. Turbocharger

2-20
Structure and Function November 17, 2017
Cooling System CLG835H

Hydraulic oil radiator

Hydraulic oil radiator has the main function of radiating heat generated by hydraulic oil during the
working of hydraulic system to avoid temperature of hydraulic oil line from being too high.

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.

Torque converter oil

Hydraulic oil

2
P28P00604

1. Hydraulic oil radiator 2. Torque converter oil radiator

 2-21
November 17, 2017 Removal and Installation
CLG835H Cooling System

Removal and Installation

Relevant preparation before starting:

See the section of Machine Placement, and park the machine well.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.

The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil can cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, there is water vapor and hot
water in the water radiator, wait until the water temperature drops to below 50°C during repair and
then open the water tank cap, otherwise the serious personal injury or even death may be
caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by hand.
2-22
Removal and Installation November 17, 2017
Removal and Installation of Air Pre-filter CLG835H

Removal and Installation of Air Pre-filter

Removal of Air Pre-filter

Tools required
Tool(s) Part description Standard Quantity

1 Open-end wrench 8#, 13# 2

2 Steel ruler 1

Figures Operation instructions

1. Unscrew the connecting clamp (34) of air pre-
filter and bellows.

Tool: Open-end wrench 8#

34

P28P00608
2. Remove 4 captive bolts (3) of the air pre-filter
and remove pre-filter (1).
1 3. Remove 4 captive bolts (3) of the pre-filter
bracket and remove pre-filter bracket (2).
4. Seal every port with plastic sealing membrane
3 as required.

Tool: Open-end wrench 13#

2
P28P00607

Installation of Air Pre-filter

Install the air pre-filter in reverse order of the removal steps.

 2-23
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Air Filter

Removal and Installation of Air Filter

Removal of Air Filter

Tools required
Tool(s) Part description Standard Quantity

1 Open-end wrench 8#, 13#, 16# 4

2 Straight screwdriver 1
3 Shielding film 1

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.

Figures Operation instructions

1. Remove air pre-filter according to removal and
installation requirements and steps of air filter
hereinafter.
2. Loosen connecting clamp (33) of air filter and
33 bellows with open-end wrench or blower gun
(ratchet wrench) and socket, remove clamp
4 and bellows (4), and seal each end with plastic
sealing film as required.

Tool: Open-end wrench 8#

P28P00616
2-24
Removal and Installation November 17, 2017
Removal and Installation of Air Filter CLG835H

Figures Operation instructions

3. Loosen clamp (31) connecting air filter and
31
intake pipe with open-end wrench or blower
gun (ratchet wrench) and socket, plug intake
pipe (12) out of air filter end, and seal each end
12 with plastic sealing film as required.

Tool: Open-end wrench 8#, 13#

P28P00617
4. Remove captive bolts (5) of air filter with open-
end wrench, and remove air filter (17).
5

Tool: Open-end wrench 16#

17 P28P00619

Installation of Air Filter

Install the air filter in reverse order of the removal steps.
 2-25
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Air Filter

Air Filter--Maintain 3. Take out the main filter element along with
the housing direction.
Air filter ensures the air entered engine is clean
and dry through main filter element and safety
filter element.

If the engine air filter alert indicator on the

instrument panel is on, then maintain the
engine air filter.
Engine air filter alert indicator P18P00066

4. Check the main filter element.

a) Replace the main filter element if any
damage is found to pleats and gaskets.
b) Clean the main filter element if it is not
damaged.
5. Clean the inner wall of the air filter housing.

P18E00280

Air filter elements include main filter element and

safety filter element, maintain the filter element
according to the following steps:
1. Stop the engine and open the engine hood.
P18P00068
2. Remove outer cover of the air filter.
6. Clean the main filter element with
compressed air (below 300kPa) from inside
to outside.

P18P00067

P18P00069
2-26
Removal and Installation November 17, 2017
Removal and Installation of Turbocharger CLG835H

Removal and Installation of

Turbocharger
It is not allowed to clean the main element
from outside to inside with compressed air. Refer to CUMMINS Engine Service Manual for
Do not use oil or water to clean the main the removal and installation of turbocharger.
element.
Do not hit the main element when cleaning it.
Otherwise the engine could be damaged.
7. After cleaning the main filter element, check
with a bulb, if small holes and particles as
well as damage of the washer and seal are
found, replace with a new main filter element.

P18P00065

8. Install a clean main filter element into the air

filter and ensure an even contact with the
housing.
9. Clean and install the cap of the air filter, make
sure that the inner cap gasket in the air filter
contacts evenly with the air filter housing.

The main element should be replaced after

being cleaned for 4-5 times. It is forbidden to
remove the safety element when servicing
the main element.

10. Close the engine hood. The maintenance

steps of safety filter element is the same with
the main filter element. The difference is that
the safety filter element is only allowed to
replace, it is forbidden to use after cleaning.
Replace the main filter element at the same
time when replacing the safety filter element.
 2-27
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Fuel Lines

Removal and Installation of Fuel Lines

Tools required
Tool(s) Part description Standard Quantity

1 Open-end wrench 7#, 16#, 18#, 19# 3

2 Oil container 1
3 Plastic seal bag 1
Note: The removed standard parts should be placed together with the relative matter in order to avoid confusion.

Fuel lines comprise fuel inlet tube, fuel return tube, fuel water separator, etc., whose detailed
composition is shown below and in detail list.

P28P00627

1. Angle block 6. Joint 11.Fuel hose 16.Bolt

2. Double clamp 7. Screw 12.Fuel hose 17.Nut
3. Fuel filter 8. Washer 13.Fuel hose 18.Bolt
4. Angle block 9. Joint 14.Clamp 19.Washer
5. Washer 10.Screw 15.Bolt 20.Bolt
2-28
Removal and Installation November 17, 2017
Removal and Installation of Fuel Lines CLG835H

Removal of Fuel Lines

Figures Operation instructions Tools

1. Remove fuel return tube (13) (line
from fuel tank to fuel return joint
of engine)
(1) Remove the hose clamp (2)
fixing the fuel pipe.
Open-end
wrench 16#

2 P28P00628
(2) Unscrew turbine worm clamp (14)
connecting fuel tube and engine
fuel return port, take down fuel
tube here and recover fuel
flowing out of line and engine fuel
Open-end
return port with waste fuel drum.
wrench 7#,
(3) Block the engine return oil port 19#, waste
14
with clean plastic bags. oil drum

P28P00629
(4) Remove screw (10) connecting
fuel tube and fuel tank end, take
down fuel tube, and install screw
back on fuel return port of fuel
tank. Mask the fuel hose with a
Open-end
clean plastic bag.
wrench 7#,
19#, waste
fuel drum

10

P28P00630
 2-29
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Fuel Lines

Figures Operation instructions Tools

2. Remove fuel inlet tube (12) (fuel
water separator to fuel tube of
fuel transfer pump):
(1) Remove the hose clamp (2)
fixing the fuel tube.
(2) Remove screw (7) of fuel tube at
fuel transfer pump end, take Open-end
down fuel tube, recover fuel in wrench
line with waste fuel drum and 16#, 19#,
7 waste fuel
install screw back on fuel inlet of
fuel transfer pump. drum
7
(3) Remove screw (7) of fuel tube at
2 fuel water separator end, install
P28P00631 screw back on fuel water
separator after taking down fuel
tube, and mask fuel tube with
clean plastic bag.
3. Remove fuel inlet tube (11) (fuel
tank to fuel water separator fuel
tube).
(1) Remove the hose clamp (2)
fixing the fuel tube.
(2) Remove screw (7) of fuel tube at Open-end
fuel water separator end, take wrench
down fuel tube, and recover fuel 16#, 19#,
in line with waste fuel drum. Then waste fuel
put bolt back onto fuel water drum
7 separator.
10 (3) Remove screw (10) of fuel tube at
2
P28P00632
fuel tank end, install screw back
on fuel tank after taking down fuel
tube, and mask fuel tube with
clean plastic bag.
2-30
Removal and Installation November 17, 2017
Removal and Installation of Fuel Lines CLG835H

Figures Operation instructions Tools

4. Remove fuel water separator (9):
remove 2 bolts (20) on fuel water
separator mounting bracket, take
down fuel water separator and
bracket, and put them away Open-end
properly. wrench
18#, waste
fuel drum

20

P28P00633

Installation of Fuel Lines

Install the fuel lines in reverse order of the removal steps.

 2-31
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Fuel Tank Assembly

Removal and Installation of Fuel Tank Assembly

Tools required
Tool(s) Part description Standard Quantity

1 Open-end wrench 7#, 16#, 18#, 19#, 20#, 24#, 30# 7

2 Socket wrench, bushing 24# 2
3 Oil container, washcloth 2
4 Plastic seal bag 1
5 Forklift 1
Note: The removed standard parts should be placed together with the relative matter in order to avoid confusion.

Fuel tank assembly

14

13

10 2
3
11 6
7

12 4

5
P28P00637

1. Housing 5. Drain plug 9. Tank cover assembly 12.Bolt

2. O-ring 6. Washer 10.Shock cushion 13.Hard washer
3. Flange cover 7. Bolt 11.Washer 14.Locknut
4. O-ring 8. Strainer
2-32
Removal and Installation November 17, 2017
Removal and Installation of Fuel Tank Assembly CLG835H

Removal of Fuel Tank Assembly

Figures Operation instructions Tools

1. Drainage of diesel fuel:
Clean drain hole of fuel tank, place a
5 clean container under the fuel tank,
and unscrew drain plug (5). After fuel 24# socket,
is drained, fix drain plug back to fuel socket
tank. Drained fuel should be strictly wrench
sealed for preservation to prevent
pollution to fuel.

P28P00638
2. Removal of pipe clamp:
Remove the clamp bolt on the fuel
tank, and take off the hose clamp.

Open-end
wrench 16#
and 18#

P28P00639
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
Open-end
screw back to fuel return hole. Mask
wrench 19#
the fuel hose with a clean plastic bag.

P28P00639
4. Removal of fuel sensor wire
harness:
Remove the wire harness connector
of fuel tank level sensor.

P28P00640
 2-33
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Fuel Tank Assembly

Figures Operation instructions Tools

5. Removal of fuel tank (1): remove
4 mounting bolts (12) and nuts
(14) on the fuel tank.

CAUTION: Fuel tank is

connected to frame through bolts
and nuts in four mounting points. Open-end
After mounting bolts are loosened, wrench
fuel tank will separate from frame. 30#,
12 14 Before removal, use a reliable tool
(e.g., forklift) with sufficient Carrier tool
bearing capacity to support fuel or tooling
tank.
Before step 5, make sure steps 2~4
P28P00641 have been done; otherwise,
corresponding parts will be
damaged, and even a safety
accident will occur.

Cleaning of Fuel Tank

Remove suction flange cover at upper end of fuel tank, and wash internal surface of fuel tank with clean
fuel. 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.

Installation of Fuel Tank

Install the fuel tank in reverse order of the removal steps.

Tightening torque of the fuel tank mounting bolts is 600±50N.m.

2-34
Removal and Installation November 17, 2017
Removal and Installation of Radiator Pipelines CLG835H

Removal and Installation of Radiator Pipelines

Tools required
Tool(s) Part description Standard Quantity
1 Open-end wrench 7#, 8#, 12#, 16# 4
2 Clean container, hose 2
3 Plastic seal bag 1
4 Nipping pliers 1
Note: The removed standard parts should be placed together with the relative matter in order to avoid confusion.

Radiator lines

13
3
13 23
15 24
19
16 17
18
1 11
13 4 18 12
23
3 11 17
23 10
16 22
13
18 23
14 13
21
13 12
11 6

3 7 11
5 15
13 2 11
3
13
11 9
11

11 8
28 P28P00642

1. Intercooler tube 8. Lower hose 15.U-clamp 22.Hose

2. Intercooler tube 9. Lower water tube 16.Washer 23.Clamp of worm
3. Intake hose 10.Refill water pipe 17.Washer 24.Hose
4. Upper hose 11.Clamp 18.Nut 25.Washer
5. Upper hose 12.Clamp of worm 19.Angle block 26.Bolt
6. Upper water tube 13.Clamp 20.Angle block 27.Hose
7. Lower hose 14.Angle block 21.U-clamp 28.Water drain valve
 2-35
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Radiator Pipelines

Removal of Radiator Pipelines

Figures Operation instructions Tools

1. Park the complete machine:
(1) Park complete machine on flat
ground, apply parking brake and
shut down engine. Remove the
anti-rotating bumper with a
nipper plier, connect the bumper
with the front and rear frames
with its pin.
P28P00643 (2) Open engine hood, and turn Nipping
disconnect switch to "OFF" pliers
position.

P28P00609
2. Draining (oil/water)
(1) Loosen water drain valve (28),
select a proper container to
recover anti-freeze (total capacity
Clean
of anti-freeze is about 45 L), or
container,
28 select a proper hose to introduce
rubber tube
water flowing out of water drain
valve into a container prepared in
advance, and tighten water drain
P28P00644 valve after emptying coolant.
(2) Loosen hydraulic oil cooler drain
valve (26) or torque converter oil
cooler drain valve (27), select a
26 proper container to recover oil
(total capacity of hydraulic oil
Clean
cooler is about 5 L/total capacity
27 container,
of torque converter oil cooler is
rubber tube
about 7 L), or select a proper
hose to introduce oil flowing out
of drain valve into a container
prepared in advance, and tighten
P28P00645 drain valve after emptying oil.
2-36
Removal and Installation November 17, 2017
Removal and Installation of Radiator Pipelines CLG835H

Figures Operation instructions Tools

3. Remove the steam hose (25)
from expansion tank to the
engine, unscrew turbine worm
25 clamps (24) at both ends of
24 steam hose, and remove steam
hose. Shield the port and steam
hose with clean plastic bags.
Open-end
wrench 7#

P28P00646
4. Remove the steam hose (22)
from expansion tank to the water
radiator, unscrew turbine worm
clamps (23) at both ends of
steam hose, and remove steam
hose. Shield the port and steam
23 hose with clean plastic bags.
Open-end
22 wrench 7#,
16#

P28P00647
5. Remove the refill hose 10 from
expansion tank to water hose,
unscrew turbine worm clamps
(12) at both ends of refill hose,
and remove refill hose. Shield the
port and water make-up pipe with
12
clean plastic bags.

P28P00648
 2-37
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Radiator Pipelines

Figures Operation instructions Tools

6. Remove the radiator water hose
6 and 9.
(1) Unscrew captive bolt (18) of U-
clamp, and remove U-clamp (21).

Open-end
18 wrench 16#
21

P28P00649
(2) Unscrew clamp (11) of water
11 hose gasket, remove water hose,
and shield ends and water hose
with clean plastic bags.

Open-end
wrench 8#

P28P00650
7. Remove the inter-cooler tubes 1
and 2.
(1) Unscrew retaining nut (18) of U-
clamp, and remove U-clamp (15).
15 18

Open-end
wrench 16#

P28P00651
2-38
Removal and Installation November 17, 2017
Removal and Installation of Radiator Pipelines CLG835H

Figures Operation instructions Tools

(2) Unscrew clamps 13 on intake
hose connecting both ends of
intercooler tube, remove
intercooler tube and intake hose,
and shield ends, intercooler tube
and intake hose with clean plastic
bags. Open-end
13 wrench 12#

13

P28P00652

Installation of Radiator Pipelines

Install the radiator pipelines in reverse order of the removal steps.

 2-39
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Radiator Assembly

Removal and Installation of Radiator Assembly

Tools required
Tool(s) Part description Standard

1 Open-end wrench 7#, 8#, 10#, 12#, 13#, 16#, 20#, 24#
2 Torque wrench 160~680 N•m
3 Inner hexagon spanner 8mm
4 Clean container, rubber tube, plastic sealing bag
Nipper pliers, scissors, nylon ties and cross
5
screwdriver
6 Crane and sling
Note: The removed standard parts should be placed together with the relative matter in order to avoid confusion.

Removal of Radiator Assembly

Figures Operation instructions Tools

1. Park the complete machine
Refer to step 1 of removal and
installation of radiator lines.
2. Draining (oil/water)
Refer to step 2 of removal and
installation of radiator lines.
3. Disassemble auxiliary
radiator to steam hose of Open-end
engine wrench 16# and
Refer to step 3 of removal and 7#
installation of radiator lines.
4. Disassemble the hose
Open-end
Refer to step 5 of removal and wrench 7#
installation of radiator lines.
5. Remove the water hose
mounting bracket Open-end
Refer to step 6a of removal and wrench 8#
installation of radiator lines.
6. Remove the water hose
Open-end
Refer to step 6b of removal and wrench 16#
installation of radiator lines.
2-40
Removal and Installation November 17, 2017
Removal and Installation of Radiator Assembly CLG835H

Figures Operation instructions Tools

7. Disassemble air inlet hose
connecting air-cooler
Refer to Step 7b in removal and
installation of cooling line (only
intake hose at radiator end is
removed).

P28P00653
Open-end
wrench 12#

P28P00654
 2-41
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Radiator Assembly

Figures Operation instructions Tools

8. Remove of hose of oil cooler
Loosen screws on press plate
fixing hose, remove press plate
and hose, and shield ends and
hose with clean plastic bags.

P28P00655
Inner hexagon
spanner 8mm

P28P00656
2-42
Removal and Installation November 17, 2017
Removal and Installation of Radiator Assembly CLG835H

Figures Operation instructions Tools

9. Remove the hose of
transmission oil cooler
Loosen screws on press plate
fixing hose, remove press plate
and hose, and shield ends and
hose with clean plastic bags.

P28P00657

Inner hexagon
spanner 8mm

P28P00658
10. Remove the A/C
compressor
Remove the A/C compressor Open-end
according to removal and wrench 10 # and
installation requirements and 16#
steps of A/C compressor
hereinafter.
11. Remove upper cover
Open-end
Remove engine hood according
wrench 12#,
to removal and installation
requirements and steps of Traveling crane
engine hood hereinafter.
 2-43
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Radiator Assembly

Figures Operation instructions Tools

12. Disassemble the protection
shield
Remove shield according to Open-end
removal and installation wrench 13#
requirements and steps of
shield hereinafter.
13. Remove the radiator
(1) Install lifting eyes on lifting
lugs on both sides of
radiator, and screw them in
at least by three turns.
Splice and tighten the lifting
tools to lifting eyes.
P28P00659
(2) Unscrew 4 mounting bolts
(17) on the radiator. Slowly
lift radiator onto special tool
with traveling crane and
lifting sling, and put away Open-end
and collect shim. wrench 24#
17

P28P00660

Installation of Radiator Assembly

Install the radiator assembly in reverse order of the removal steps.

Make sure radial clearance between engine fan and shroud is not less than 10 mm in assembly.
Tightening torque of radiator mounting bolts is 305 ± 25 N•m.
2-44
Removal and Installation November 17, 2017
Disassembly, Check and Assembly of Radiator Assembly CLG835H

Disassembly, Check and Assembly of Radiator Assembly

Tools required
Tool(s) Part description Standard

1 Open-end wrench 10#, 16#, 21#

Note: The removed standard parts should be placed together with the relative matter in order to avoid confusion.

Exploded view of radiator assembly

23

34

13
3 13
6
20 1
14
5
22 2
10 4 3
9
21
11 19
8

30 29 18
15
7
36 34
31 32 10
33
28 22
27 12 11
25

13
16
17 35 13
37 P28P00661

1. Radiator group 11.Handrail 20.Rubber plate 29.Hard washer

2. Angle block 12.Retainer 21.Bolt 30.Nylon locknut
3. Seal 13.Bolt 22.Press plate 31.Lock pin
4. Hard washer 14.Angle block 23.Auxiliary tank 32.Bolt
5. Bolt 15.Shroud 24.Bolt 33.Lock
6. Bracket 16.Self-lubricating hinge 25.Baffle 34.Bolt
7. Fan drive motor 17.Bolt 26.Bolt 35.Angle block
8. Shock cushion 18.Bolt 27.Baffle 36.Adhesive tape
9. Nut 19.Seal 28.Knob 37.Seal
10.Bolt
 2-45
November 17, 2017 Removal and Installation
CLG835H Disassembly, Check and Assembly of Radiator Assembly

Disassembly of Radiator Assembly

Figures Operation instructions Tools

1. Remove the handle (11)
Unscrew 4 captive bolts (10) at left
and right ends of radiator, and
remove the support.

Open-end
wrench 16#
10

11 P28P00662
2. Remove the left and right plates
(2) and rubber plates (3)
3
Unscrew 6 mounting bolts of left and
right plates and remove the plates
and left and right rubber plates.

34 Open-end
wrench 10#

P28P00663
3. Remove the upper support (6)
13 Unscrew the 4 mounting bolts (13)
of the upper support, and remove
the rubber plates.
6
Open-end
wrench 16#

P28P00664
2-46
Removal and Installation November 17, 2017
Disassembly, Check and Assembly of Radiator Assembly CLG835H

Figures Operation instructions Tools

4. Remove the rubber plate (20)
20 and press plate (22); unscrew 4
captive bolts for the rubber plate
of the baffle and remove the
rubber plate and press plate.
22
Open-end
wrench 16#

P28P00664
5. Remove the sealing strip (37)
13 and plate (35).

35 37

P28P00665
6. Remove the self-lubricating
16 hinge (16) and fan drive motor
17
(7).
Unscrew 12 captive bolts of self-
lubricating hinge and remove the
self-lubricating hinge and fan drive
motor. Open-end
wrench 16#
35

7
P28P00666
 2-47
November 17, 2017 Removal and Installation
CLG835H Disassembly, Check and Assembly of Radiator Assembly

Figures Operation instructions Tools

7. Remove the retainer-ball (12)
Unscrew 2 mounting bolts (13) of
retainer-ball, and remove retainer-
ball.

Open-end
wrench 16#

12 13
P28P00667
8. Remove the shroud 15
Unscrew 8 mounting bolts (18) of
shroud, and remove shroud.

18 Open-end
wrench 18#

P28P00668

Check of Radiator Assembly

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 and
clean it with compressed air. Please notice that the direction of compressed air shall be inverse with that
of air which passes through the radiator during normal operation of the machine.

Assembly of Radiator Assembly

Assemble the radiator assembly in reverse order of the disassembly steps.

2-48
Removal and Installation November 17, 2017
Disassembly and Assembly of Radiator Group CLG835H

Disassembly and Assembly of Radiator Group

Tools required
Tool(s) Part description Standard

1 Open-end wrench 18#

Note: The removed standard parts should be placed together with the relative matter in order to avoid confusion.

Exploded view of radiator group

10

2
6 3

4 8

7
4
5

9
P28P00669

1. Air-air intercooler 4. Water drain valve 7. Plate 9. Bolt

2. Water radiator 5. Torque converter oil radiator 8. Sponge 10.Connecting bracket
3. Hydraulic oil radiator 6. Mounting plate-rh
 2-49
November 17, 2017 Removal and Installation
CLG835H Disassembly and Assembly of Radiator Group

Disassembly of Radiator Group

Figures Operation instructions Tools

1. Remove the upper connecting
1 10 plate (10), left mounting plate (7),
right mounting plate (6), air-air
intercooler (1), water radiator (2),
hydraulic oil radiator (3) and torque
converter oil radiator (5)
Unscrew 30 bolts (9) at left and right
sides of the radiator, remove the upper
connecting plate, left mounting plate, Open-end
right mounting plate, air-air intercooler, wrench
water radiator, hydraulic oil radiator, 16#
torque converter oil radiator, and
collect the sponge (8) properly.

9
7 5
3 2
6 P28P00670
2-50
Removal and Installation November 17, 2017
Refilling and Replacement of Coolant CLG835H

Refilling and Replacement of

Coolant

1. Completely mix water and anti-freeze in

advance according to selected cooling
proportion. (CUMMINS Power Company
suggests to use mix-fluid with 50% pure soft
water and 50% antifreeze solution or
refrigerant with strict proportion when refilling
cooling system. The antifreeze solution or
refrigerant with strict proportion must meet
the technical specification of TMC RP 329 or
TMC RP 330.) P28P00605
2. Park machine on flat ground, apply parking Base of the wellhead
brake and shut down engine.
3. Turn on the battery disconnect switch; insert
the key into the start switch and turn to 1st
gear clockwise to power on the machine, pull
the change-over switch of air conditioning
system to heating position.
4. (Only operate this step in replacing coolant.)
Put a container with the capacity of about 35
L at rear right side of machine, connect one P28P00247
hose into water drain valve of drain hose,
unscrew auxiliary tank cover, loosen water 6. Tighten auxiliary tank cover, start engine,
drain valve so that coolant flows into the firstly operate it for 5 minutes at low idle
container, and tighten water drain valve after speed, then operate it for 5 minutes at high
draining coolant. idle speed, and increase coolant temperature
to be above 85°C(185°F).
5. Slowly open auxiliary tank cover (wait until
engine coolant temperature drops to be 7. After engine coolant temperature drops to
below 50°C\122°F), slowly add coolant until below 50°C(122°F), continue to refill coolant
coolant level is within 1 cm higher than until level is within the scope of 1 cm higher
wellhead bottom, and remain stable within than wellhead bottom as necessary.
ten minutes.
8. Close the engine hood.

Do not use the water alone as coolant.

When filling coolant, air in engine cooling
system pipe must 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).
 2-51
November 17, 2017 Fault Diagnosis and Troubleshooting
CLG835H Refilling and Replacement of Coolant

Fault Diagnosis and Troubleshooting

Air Pre-filter Fault

Fault cause Troubleshooting methods

1. Dust blockage Clear
2. The revolving shaft is stuck Clean or replace

Air Filter Fault

Engine weakness and generating black smoke

Fault cause Troubleshooting methods

1. Blockage of filter element Blow and clean the filter element or replace the filter
element
2. Air filter sucks in paper scrap or rag and other things Clear

Early wear of the engine

Fault cause Troubleshooting methods

1. Air intake short circuit Check for error proofing
2. Filter element is damaged or fails Replacement
3. The dusting bag fails Replacement

Turbocharger Fault

Fault mode Troubleshooting methods

1. Air intake system is blocked Check lines between air filter and air compressor, lines
between air compressor outlet and air intake pipe and the
intake pipe, and keep them clean and clear
2. Air inlet leakage Check lines between air filter and air compressor, lines
between air compressor outlet and air intake pipe, and
connection between air intake pipe and engine for leakage,
tighten the fastening bolts and replace the gaskets and
other parts
3. Exhaust system is blocked Maintain or replace the related components
4. Air inlet leakage Check connection between exhaust pipe and engine,
between turbine inlet and exhaust pipe, between turbine
housing and middle housing as well as between turbine
outlet and exhaust pipe for leakage, if any, replace the
sealing gaskets and tighten the fastening bolts.
5. Air compressor rotor collides with air compressor
Replace the assembly.
housing, and turbine collides with turbine housing;
6. Fuel inlet line or fuel return line leaks; Replace related parts.
2-52
Fault Diagnosis and Troubleshooting November 17, 2017
Refilling and Replacement of Coolant CLG835H
 3-1
November 17, 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....................................................................................................................3-9
Special Tool, Tooling List .......................................................................................................................3-9

Structure Function Principle ........................................................................................3-10

Torque Converter - Gearbox System ...................................................................................................3-10
Drive axle system.................................................................................................................................3-16
Drive Shaft System ..............................................................................................................................3-19
Tire & Rim System ...............................................................................................................................3-21

Testing and adjustment ................................................................................................3-22

Power Train Test..................................................................................................................................3-22
Torque Converter - Gearbox System ...................................................................................................3-23
Drive Axle System................................................................................................................................3-24

Removal and Installation ..............................................................................................3-25

Removal and Installation of Torque Converter-Gearbox System.........................................................3-25
Removal of Torque Converter - Gearbox System............................................................................3-25
Installation of Torque Converter-Gearbox System...........................................................................3-30
Disassembly and Assembly of Torque Converter-Gearbox Assembly ................................................3-35
Removal and Installation of Drive Shaft System ..................................................................................3-36
Removal of Drive Shaft System .......................................................................................................3-36
Installation of Drive Shaft System ....................................................................................................3-38
Removal and Installation of Front Wet Axle Assembly ........................................................................3-41
Removal of Front Wet Axle Assembly..............................................................................................3-41
Installation of Front Wet Axle Assembly...........................................................................................3-43
Removal and Installation of Rear Wet Axle Assembly .........................................................................3-44
Removal of Rear Wet Axle Assembly ..............................................................................................3-44
Installation of Rear Wet Axle Assembly ...........................................................................................3-49
3-2
Power Train System November 17, 2017
CLG835H

Disassembly and Assembly of the Drive Axle......................................................................................3-54

Fault Diagnosis and Troubleshooting .........................................................................3-55

Common Failure Mode of Tire and Reasons .......................................................................................3-56
 3-3
November 17, 2017 Basic Information
CLG835H Safety

Basic Information "Caution" is also used for reminding the safety

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

This word means existing potential danger,

and if no avoidance, it may cause death or
serious personal injury.

This word means danger will occurred imme-

diately, and if no avoidance, it may cause
death or serious personal injury.

This word means existing potential danger,

and if no avoidance, it may cause slight or
medium personal injury.
3-4
Basic Information November 17, 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.
Schematic diagram of position for wheel loader

P18T00001
 3-5
November 17, 2017 Basic Information
CLG835H System Technical Parameters

System Technical Parameters

Main technical parameters for the power train system of this machine are listed in Table below.
Main technical parameter table for power train system

System components Items Parameters Remarks

Model ZF 4WG158
Type Fixed shaft type
Gear box
Semi-auto electro hydraulic Full-auto electro hydraulic
Control mode
power shift control is optional.
Torque converter Type Single-turbo, three-element
Spiral gear level-I reduction,
Drive mode
Drive axle wheel planetary gear reduction
Brake mode Wet-type brake
Tubeless bias tire or tubed bias
Tire structure Bias tire with an inner tube
tire is optional
Tire Specification 17.5-25PR12 TT
Level \
Type of tread L-3 Ordinary block
Rim Specification 25-14.00/1.5
3-6
Basic Information November 17, 2017
System Schematic Diagram and Working Principle Description CLG835H

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:
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

Structure diagram for drive axle assembly

2 3
Axle 4
1 housing bevel gear of the wheel reduction half shaft
P18T00003
P18T00003
1. Wheel reduction gear 2. Axle shaft 3. Axle housing 4. Bevel gear
 3-7
November 17, 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 of lubricant application

Ambient temperature Recommended

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

Mobil Delvac Super 1300

ZF torque converter &
engine oil
Torque transmission assembly
(-15°C~+50°C)\
converter - uses SAE 15-40 in gen-
(-5°F~122°F)
gearbox eral areas and in hot des-
Mobil ATF 220
assembly ert areas; and uses Mobil
(-35°C~+50°C)\
ATF220 in arctic areas.
(-31°F~122°F)
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 November 17, 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 The fine oil filter is also replaced every time the
position; oil change is done for the gear box. The oil filter
(3) Torque converter - gearbox oil is at 80-95°C\ may be installed by the following method:
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 it (2) The oil filter is screwed in until the oil seal of
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.
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.
Gearbox drain plug

P18T00005

P18T00004
P18T00004
 3-9
November 17, 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.
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 November 17, 2017
Torque Converter - Gearbox System CLG835H

Structure Function Principle 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 semi/ full auto
Clutch K2
type, which mainly consists of a three-element,
single-turbo torque converter, mechanical gear
box with four forward gears, three reverse gears Clutch Reverse KR
Clutch K3
and electro hydraulic shift control system, as Clutch K4
shown below: Parking Brake

External view of torque converter -gear box LAYSHAFT

assembly Output Output
KV - Gerar Rear Axle Front Axle

Idler Gear
Speedometer Drive
Oil Sump
K4 - Gerar P18T00008

P18T00007
 3-11
November 17, 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 below.
Technical parameter table of torque converter - gear box assembly

Component Items Parameters Remarks

Model ZF 4WG158
Gearbox Type Fixed shaft type
Gears Four forward gears, three reverse gears
Model WG300
Type Single-turbo, three-element
Circulation circle diameter of torque con-
300mm
Torque converter verter/mm\In
Inlet pressure of torque converter/MPa\ psi 0.85\ 123.25
Outlet pressure of torque converter/MPa\
0.50\ 72.5
psi
Shift control mode Auto electro hydraulic power shift
Shift control system
System working pressure/MPa\ psi (1.6~1.8)MPa(236~261)PSI

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:
Structure diagram for torque converter

Turbine wheel
Pump wheel

From the engin

P18T00009
3-12
Structure Function Principle November 17, 2017
Torque Converter - Gearbox System CLG835H

Schematic 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
November 17, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

An electro-hydraulic shift control valve is installed on the gear box assembly, see figure 1 and 2 for struc-
ture composition and operating hydraulic pressure schematic diagram.
Figure 1 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 2 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 November 17, 2017
Torque Converter - Gearbox System CLG835H

The electro-hydraulic shift control valve consists Drive line of forward gear 2
of solenoid valves M1, M2, M3, M4, M5, valve
stem and body. When the electro-hydraulic shift
࠰
control valve is operating, the fluid flow in the Torque
OUT

valve stem oil passage is controlled by the power converter

of solenoid valves, which finally control the turbine
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 below.
Drive line of forward gear 1
࠰
OUT
Output Output
࠰
OUT
shaft shaft

Torque
converter P18T00014
turbine
Drive line of forward gear 3
Input shaft
࠰
OUT
Torque
converter
turbine

Input shaft

OUT
Output Output
shaft shaft
P18T00013

OUT
Output Output
shaft shaft
P18T00015
 3-15
November 17, 2017 Structure Function Principle
CLG835H Torque Converter - Gearbox System

Drive line of forward gear 4 Drive line of reverse gear 2

࠰
OUT OUT
Torque
Torque converter
converter turbine
turbine

Input shaft Input shaft

OUT
OUT
Output Output Output Output
shaft shaft shaft shaft
P18T00016 P18T00018

Drive line of reverse gear 1 Drive 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
3-16
Structure Function Principle November 17, 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.
Drive axle system assembly drawing

P28T00363
 3-17
November 17, 2017 Structure Function Principle
CLG835H Drive axle system

Drive axle system assembly drawing

1 2 4 5

6
Front axle

6
5
4
1 2 7
3

8 Rear axle
P28T00683

1. Wheel reduction gear assembly 4. Brake line 7. Front swing frame

2. Wet-type brake 5. Main speed reduction assembly 8. Rear swing frame
3. Install bolt and nut 6. Input flange

System technical parameters

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

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 4.8MPa (696Psi)
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 4.8MPa (696Psi)
3-18
Structure Function Principle November 17, 2017
Drive axle system CLG835H

System schematic diagram and working principle description

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 axle is left-handed, and that of rear axle is right-handed. The bevel gear
structure is shown in Figure below. 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 shaft, thus to drive the large size spiral bevel gear with differential to rotate together. The half shaft
gear of differential passes the power to left/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.

Wet axle structure diagram

The structure diagram for bevel gear and wheel reducer of this machine is as shown in below figure.

3
2 4
1 5 P28T00681

1. Wheel reduction gear 3. Axle housing 5. Brake line joint

2. Wet brake 4. Final drive unit

6 7 P28T00682

6. Fuel added hole

7. Oil drain hole
8. Wheel reduction differential gear fuel added hole and oil drain hole
 3-19
November 17, 2017 Structure Function Principle
CLG835H Drive Shaft System

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 1 consists of rear and front drive shafts, the
one shown in Figure 2 consists of rear, front, intermediate shafts and support assembly.
Figure 1 Drive shaft system

1
3

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

Figure 2 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
3-20
Structure Function Principle November 17, 2017
Drive Shaft System CLG835H

System technical parameters

The technical parameters for the drive shaft system are listed in Table below.

Technical parameter table for drive shaft system

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

Front drive shaft Round flange Round flange
Intermediate drive shaft Round flange Round flange
Rear drive shaft 7C Round flange
Dynamic unbalance test ≥ G16

Transmission shaft fastener torque must be strictly guaranteed. Any bolt that has been loosened
and tightened again must have corresponding torque.

Fastener part specification Fastener part torque

M12 × 1.5 132 ± 10Nm (98 ± 7lbf·ft)
M12 × 1.25 132 ± 10Nm (98 ± 7lbf·ft)
M16 305 ± 25Nm(225 ± 18lbf·ft)
 3-21
November 17, 2017 Structure Function Principle
CLG835H Tire & Rim System

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 below.

Technical parameters of tire& rim system

System compo-
Items Parameters Remarks
nents
Tubeless bias tire or radial tire
Tire structure Tubed bias tire
is optional
Specification 17.5-25PR12 TT
Level PR12
Tire Type of tread L-3 Ordinary block
Front wheel: 0.35-0.38MPa
(50.75~55.1Psi)
Tire pressure (MPa)\(psi)
Rear wheel: 0.32-0.35MPa
(46.4~50.75Psi)
Rim Specification 25-14.00/1.5
3-22
Testing and adjustment November 17, 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 below, and names
and parameters of each detection point can be found in Table below.
Measuring point layout

58

66
63

34
21
57 65

56
53

55 60 51
P18T00123

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
 3-23
November 17, 2017 Testing and adjustment
CLG835H Torque Converter - Gearbox System

Logical relations between gear states and working conditions of shift control valve solenoid valve can be
found in Table below.

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.Left
unbalance volumn should not below balance quality level G16.

Torque Converter - Gearbox 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.
3-24
Testing and adjustment November 17, 2017
Torque Converter - Gearbox System CLG835H

Drive Axle System

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.

Exhaust

Wash the ventilation plug at both sides of ventilation plug drive axle and bleed the air following the
methods below before first use and replacing the lubricant within the lubricant replacement time interval.
There are 2 exhaust points both on the front and rear drive axles which are respectively located at two
wheel sides. Exhaust points on the same axle shall be operated separately to bleed the air.
Rear axle assembly ventilation plug location

P28T00684

1. Park the machine on flat ground. Put the shift control lever at neutral position, and place wedges at
front and rear wheels.
2. Loosen the exhaust plugs at both ends of axle.
3. Start the machine and depress the service brake pedal until the oil overflows from the ventilation
plug.
4. Tighten the exhaust plug.
Try the operations above to exclude some influence factors when the brake system has abnormal sound
and weak braking.
 3-25
November 17, 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

Reference picture Operation step Tools required

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 con-
tainer during removal, in
order to avoid environmental
34# socket, 13#
contamination. The removed
socket,
hose is shielded to avoid con-
pneumatic
tamination of parts.
impact wrench
DANGER: It is sure that
P18T00032 the hose pressure is fully dis-
charged and the oil is cooled
sufficiently before removal of
hose, in order to avoid per-
sonal 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 November 17, 2017
Removal and Installation of Torque Converter-Gearbox System CLG835H

Reference picture Operation step Tools required

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 con- 41# wrench
tainer during removal, in
order to avoid environmental
contamination.The removed
P18T00033
hose is shielded to avoid con-
tamination 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

8. Remove the clamping bolt

fixing the oil filler steel-pipe
with a wrench.

10# Wrench

P18T00036
 3-27
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Torque Converter-Gearbox System

Reference picture Operation step Tools required

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

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
3-28
Removal and Installation November 17, 2017
Removal and Installation of Torque Converter-Gearbox System CLG835H

Reference picture Operation step Tools required

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

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
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Torque Converter-Gearbox System

Reference picture Operation step Tools required

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 November 17, 2017
Removal and Installation of Torque Converter-Gearbox System CLG835H

Installation of Torque Converter-Gearbox System

Reference picture Operation step Tools required

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
converter 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
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Torque Converter-Gearbox System

Reference picture Operation step Tools required

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 November 17, 2017
Removal and Installation of Torque Converter-Gearbox System CLG835H

Reference picture Operation step Tools required

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

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
 3-33
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Torque Converter-Gearbox System

Reference picture Operation step Tools required

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 respectively spanner
connected to the inlet, outlet
P18T00059
of fine oil filter in directions
as required, avoiding
installation error.
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
3-34
Removal and Installation November 17, 2017
Removal and Installation of Torque Converter-Gearbox System CLG835H

Reference picture Operation step Tools required

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

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
 3-35
November 17, 2017 Removal and Installation
CLG835H Disassembly and Assembly of Torque Converter-Gearbox Assembly

Reference picture Operation step Tools required

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

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".
3-36
Removal and Installation November 17, 2017
Removal and Installation of Drive Shaft System CLG835H

Removal and Installation of Drive Shaft System

Removal of Drive Shaft System

Reference picture Operation step Tools required

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
 3-37
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Drive Shaft System

Reference picture Operation step Tools required

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

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
3-38
Removal and Installation November 17, 2017
Removal and Installation of Drive Shaft System CLG835H

Reference picture Operation step Tools required

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

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!
 3-39
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Drive Shaft System

Tools required
Reference picture Operation step
(Remarks)
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

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.
3-40
Removal and Installation November 17, 2017
Removal and Installation of Drive Shaft System CLG835H

Tools required
Reference picture Operation step
(Remarks)
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 18# wrench or
them to 132±10Nm\ open-end 18#
97.35±7.38 lbf•ft. 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

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
 3-41
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Front Wet Axle Assembly

Removal and Installation of Front Wet Axle Assembly

Removal of Front Wet Axle Assembly

Reference picture Operation step Tools required

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
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.
3-42
Removal and Installation November 17, 2017
Removal and Installation of Front Wet Axle Assembly CLG835H

Reference picture Operation step Tools required

7. Remove the hose assembly
connected to service brake
system and the front axle.
CAUTION: The waste oil
shall be recovered in a con-
tainer 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 dis-
charged and the oil is cooled
sufficiently before removal of
hose, in order to avoid per-
sonal 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.
 3-43
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Front Wet Axle Assembly

Installation of Front Wet Axle Assembly

Reference picture Operation step Tools required

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.
3-44
Removal and Installation November 17, 2017
Removal and Installation of Rear Wet Axle Assembly CLG835H

Removal and Installation of Rear Wet Axle Assembly

Removal of Rear Wet Axle Assembly

Reference picture Operation step Tools required

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
 3-45
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Rear Wet Axle Assembly

Reference picture Operation step Tools required

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
3-46
Removal and Installation November 17, 2017
Removal and Installation of Rear Wet Axle Assembly CLG835H

Reference picture Operation step Tools required

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 sup-
port rack upward.

P18T00093

17. Remove the bolts, washers

with a wrench or an
pneumatic tool.

Open-end 18#
wrench

P18T00094
 3-47
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Rear Wet Axle Assembly

Reference picture Operation step Tools required

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 clamp-
ing plate.
Open-end 27#
wrench or 27#
socket,
pneumatic
impact wrench

P18T00097

21. Remove the clamping plate.

Straight
screwdriver

P18T00098
3-48
Removal and Installation November 17, 2017
Removal and Installation of Rear Wet Axle Assembly CLG835H

Reference picture Operation step Tools required

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
 3-49
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Rear Wet Axle Assembly

Reference picture Operation step Tools required

26. Remove the support shaft
with a lifting device.

Sling
(2 tons)

P18T00103

Installation of Rear Wet Axle Assembly

Reference picture Operation step Tools required

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
3-50
Removal and Installation November 17, 2017
Removal and Installation of Rear Wet Axle Assembly CLG835H

Reference picture Operation step Tools required

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
 3-51
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Rear Wet Axle Assembly

Reference picture Operation step Tools required

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
3-52
Removal and Installation November 17, 2017
Removal and Installation of Rear Wet Axle Assembly CLG835H

Reference picture Operation step Tools required

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 sup-
port.

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
 3-53
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Rear Wet Axle Assembly

Reference picture Operation step Tools required

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
3-54
Removal and Installation November 17, 2017
Disassembly and Assembly of the Drive Axle CLG835H

Reference picture Operation step Tools required

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 "Wet-type Axle Service Manual" for
details.
 3-55
November 17, 2017 Fault Diagnosis and Troubleshooting
CLG835H Disassembly and Assembly of the Drive Axle

Fault Diagnosis and Troubleshooting

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.
3-56
Fault Diagnosis and Troubleshooting November 17, 2017
Common Failure Mode of Tire and Reasons 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

Common Failure Mode of Tire and Reasons

Common failure mode of tire and reasons are as follows:

Failure mode Typical pictures Main reasons

Reasons for manufacture: there is

impurities, oil stains or water in the
tread rubber or cord ply or not firmly
compressed when being molded, or
Delaminating gasoline does not fully volatilize.
of crown
Reasons for usage: speed is too fast
(beyond specified speed), and
directive pattern is traveling in reverse
direction.
P28T00060
 3-57
November 17, 2017 Fault Diagnosis and Troubleshooting
CLG835H Common Failure Mode of Tire and Reasons

Failure mode Typical pictures Main reasons

Reasons for manufacture: there is

impurities, oil stains or water in
sidewall rubber or cord ply or not
firmly compressed, or gasoline does
Shoulder not fully volatilize.
delamination Reasons for usage: traveling with
blasting insufficient air will intensify wear of tire
shoulders and cause excessive heat,
which will separate sidewall rubber
from cord ply and cause an explosion
when problem gets worse.

P28T00061

Reasons for manufacture: there is

impurities, oil stains or water in
sidewall rubber or cord ply or not
firmly compressed when being
molded or gasoline does not fully
volatilize.
Delaminating
of sidewall Reasons for usage: traveling on
uneven road with insufficient air or
overload 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.
P28T00062

Mixing of extruded tread compound is

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

P28T00063
3-58
Fault Diagnosis and Troubleshooting November 17, 2017
Common Failure Mode of Tire and Reasons CLG835H

Failure mode Typical pictures Main reasons

Traveling with too high pressure will

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

P28T00064

During traveling, outer tube is

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

P28T00065

The vehicle speeds up when steering,

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

P28T00066
 4-1
November 17, 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 ........................................................................................4-17

Work Hydraulic System........................................................................................................................4-17
Hydraulic Oil Tank............................................................................................................................4-18
Working Pump..................................................................................................................................4-19
Boom Cylinder..................................................................................................................................4-20
Bucket Cylinder ................................................................................................................................4-20
Control valve ....................................................................................................................................4-21
Pilot Valve ........................................................................................................................................4-26
Pilot Supply Oil Valve.......................................................................................................................4-27
Oil Filter............................................................................................................................................4-29
Steering Hydraulic System...................................................................................................................4-30
Steering Pump .................................................................................................................................4-31
Metering Pump.................................................................................................................................4-32
Priority Valve ....................................................................................................................................4-33
Steering Cylinder..............................................................................................................................4-34
Brake system .......................................................................................................................................4-35
Brake Pump .....................................................................................................................................4-38
Brake Valve......................................................................................................................................4-41
Charge Valve ...................................................................................................................................4-46
Accumulator Assembly.....................................................................................................................4-52
Brake Cylinder..................................................................................................................................4-54
Hydraulic Cooling System ....................................................................................................................4-56
Cooling Pump...................................................................................................................................4-61
Cooling Motor...................................................................................................................................4-63

Testing and Adjustment................................................................................................4-65

Work Hydraulic System Test................................................................................................................4-65
4-2
Hydraulic System November 17, 2017
CLG835H

Pressure Release of Work Hydraulic System ..................................................................................4-65

Pressure Test of Work Hydraulic System ........................................................................................4-66
Steering Hydraulic System Test...........................................................................................................4-75
Pressure Testing and Adjustment of Steering Hydraulic System.....................................................4-76
Brake System Test...............................................................................................................................4-79

Removal and Installation ..............................................................................................4-82

Work Hydraulic System........................................................................................................................4-82
Removal and Installation of Hydraulic Oil Tank Assembly...............................................................4-82
Removal of Working Pump Assembly..............................................................................................4-86
Removal and Installation of Boom Cylinder .....................................................................................4-91
Disassembly and Assembly of The Boom Cylinder .........................................................................4-95
Removal and Installation of Bucket Cylinder....................................................................................4-98
Disassembly and Assembly of Bucket Cylinder .............................................................................4-102
Removal and Installation of Control Valve Assembly.....................................................................4-105
Removal and Installation of Pilot Valve Assembly .........................................................................4-110
Removal and Installation of Pilot Oil Valve Assembly....................................................................4-112
Removal and Installation of Oil Filter .............................................................................................4-113
Steering Hydraulic System.................................................................................................................4-114
Removal and Installation of Steering Pump Assembly ..................................................................4-114
Removal and Installation of Metering Pump ..................................................................................4-119
Disassembly and Assembly of Metering Pump..............................................................................4-122
Removal and Installation of Priority Valve......................................................................................4-128
Disassembly and Assembly of the Priority Valve ...........................................................................4-131
Removal and Installation of Steering Cylinder ...............................................................................4-133
Disassembly and Assembly of Steering Cylinder...........................................................................4-137
Brake System.....................................................................................................................................4-140
Removal and Installation of Brake Pump .......................................................................................4-140
Removal and Installation of Brake Valve .......................................................................................4-140
Disassembly and Assembly of Brake Valve...................................................................................4-143
Removal and Installation of Charge Valve .....................................................................................4-158
Disassembly and Assembly of Charge Valve ................................................................................4-160
Removal and Installation of Accumulators .....................................................................................4-185
Removal and Installation of Brake Cylinder ...................................................................................4-187
Hydraulic Cooling System ..................................................................................................................4-188
Removal and Installation of Cooling Pump ....................................................................................4-188
 4-3
November 17, 2017 Hydraulic System
CLG835H

Disassembly and Assembly of Cooling Pump0..............................................................................4-190

Removal and Installation of Cooling Motor ....................................................................................4-194

Fault Diagnosis and Troubleshooting .......................................................................4-197

Troubleshooting of Metering Pump ....................................................................................................4-197
Common Troubleshooting for Brake System .....................................................................................4-199
Troubleshooting for Brake Pump .......................................................................................................4-200
Troubleshooting for Cooling Pump ....................................................................................................4-201
4-4
Hydraulic System November 17, 2017
CLG835H
 4-5
November 17, 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 0.2MPa (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
4-6
Basic Information November 17, 2017
Safety Precautions for Hydraulic System CLG835H

Precautions for Accumulator Application Preventing Extruding or Cut Off

The dangerous high-pressure nitrogen is Do not have your hands, arms or any other
contained in the accumulator, so read the bodies placed between moving parts. For
following requirements and properly use the example, between work implement and cylinder,
accumulator. between machine and working implement.
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

The air valve of the accumulator shall be Oil

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.
Release the air before discarding the waste
accumulator.
 4-7
November 17, 2017 Basic Information
CLG835H Safety Precautions for Hydraulic System

At working temperature, the hydraulic oil tank is When installing and using the spare accessory,
hot and contains pressure. When opening oil please read related instructions, manuals and
filler cap of hydraulic oil tank, shut off the engine informations about the accessories.
and cool the filler cap down until it can be
Incorrect installation or purchase of accessories
opened by bare hands. Remove the tank cover
will not only cause safety issues, but also have
slowly to release the pressure of hydraulic oil
the negative effect on service life and operation
tank so as to prevent from being scalded by hot
of the machine.
oil.
Do not use the accessories unauthorized by
Release pressure of the system before
LiuGong. Using unauthorized accessories will
disassembling all pipes, connector, or relevant
cause safety issues, do harm on the normal
parts.
operation of machine and influence its service
life.
Pipeline, Pipe and Hose
It is forbidden to make any refit on the
Do not warp or knock the high-pressure pipeline, accessories without permissions; otherwise you
and do not install the abnormally warped or shall bear the responsibility.
broken pipe or hose onto the machine.
LiuGong Machinery Co., Ltd will not be
Repair the loose or damaged pipe and hose of responsible for the injury, accident and damage
fuel and lubricant pipeline and hydraulic system of machine due to using unauthorized
in time. Leakage will cause fire hazard, and if accessories.
repair or replacement is necessary, please
contact the authorized dealer by LiuGong
Machinery Co., Ltd.
If following problems occur, it shall be replaced.
● 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.
4-8
Basic Information November 17, 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 machine hydraulic system is as follows:
Work hydraulic system

3
5

P28H00844

1. Bucket cylinder 6. Steering pump

2. Proportional pressure-reducing valve 7. Boom cylinder
3. Hydraulic oil tank
4. Pilot valve
5. Working pump
 4-9
November 17, 2017 Basic Information
CLG835H Overviews of Hydraulic System

Steering hydraulic system

1 3

P28H00845

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

4-10
Basic Information November 17, 2017
Overviews of Hydraulic System CLG835H

Brake system

4
P28H00846

1. Brake valve 5. Brake valve assembly

2. Gear pump 6. Accumulator assembly
3. Brake cylinder 7. High-pressure oil filter
4. Charge valve
 4-11
November 17, 2017 Basic Information
CLG835H Technical Parameters of Hydraulic System

Technical Parameters of Hydraulic System

Main technical parameters of hydraulic system

Theoretical value
Items Unit
ZF158 Gearbox

Type Dual-pump converging hydraulic system

Working pressure of the system Mpa 18
Pilot working pressure Mpa 3.5
Displacement of working pump ml/r 52.2
Work
Rated speed of the working pump r/min 2200
hydraulic
system Proportional pressure-reducing
Pilot dual (triple) valve stem mood
valve
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)
Type Articulation frame and full hydraulic steering system
Working pressure of the system Mpa 17.2
Displacement of steering pump ml/r 52.2
Steering
Rated speed of the steering pump r/min 2200
hydraulic
system Metering pump ml/r 800
Steering angle ° 40°± 1°
Steering cylinder (cylinder number
mm\in 2-φ70×420
-- cylinder bore × stroke)

Service Type Dual-circuit full-hydraulic wet brake

brake system System oil pressure Mpa 4.8± 0.4
Parking & Type Push-button hydraulic brake
emergency
brake system System oil pressure Mpa 12.8

Working Hydraulic oil L 106

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 November 17, 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

Notice: The removed standard parts should be placed with relevant material together to
avoid being mixed.
 4-13
November 17, 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

S/N LiuGong No. Tool description Figures Purpose

1 SP130702 Pry bar For assembling auxiliary tools

For assembling dust ring of cylinder

2 SP129313 Rubber hammer
head

Tooling for
For compressing dust ring of
3 SP130917 compressing dust
cylinder head
ring

For assembling the O-ring of piston

4 SP130915 Guide sleeve
rod

For assembling cylinder head

5 SP130700 Guide sleeve
assembly onto piston rod
4-14
Basic Information November 17, 2017
Special Tools and Tooling for Hydraulic Maintenance CLG835H

List of special tools and tooling for boom and bucket cylinder

S/N LiuGong No. Tool description Figures Purpose

For aligning flange bolt hole with

6 SP129308 Positioning tool
cylinder head trough hole

For aligning flange bolt hole with

7 SP130698 Dowel pin
cylinder head trough hole

8 SP133205 Blower gun For pre-tightening bolt

9 SP129309 Socket For tightening bolt

10 SP130929 Steel wire scissors For snap ring of cylinder head

 4-15
November 17, 2017 Basic Information
CLG835H Special Tools and Tooling for Hydraulic Maintenance

List of special tools and tooling for steering cylinder

S/N LiuGong No. Tool description Figures Purpose

Tooling for press For pressing and fitting the friction

1 SP130702
fitting of friction ring ring onto piston

Tooling for
2 SP129313 compressing friction For compressing the friction ring
ring

For assembling cylinder head

3 SP130917 Guide sleeve
assembly onto piston rod

For assembling the O-ring of piston

4 SP130915 Guide sleeve
rod

Tooling for press For assembling the bushing onto

5 SP130700
fitting of bushing cylinder block

For supporting the cylinder block

Cylinder block
6 SP129308 and pressing the bushing to the
support
cylinder block
4-16
Basic Information November 17, 2017
Special Tools and Tooling for Hydraulic Maintenance CLG835H

List of special tools and tooling for steering cylinder

S/N LiuGong No. Tool description Figures Purpose

For detecting the size of bushing

7 SP130698 Bushing detection which is assembled onto the
cylinder block

8 SP133205 Blower gun For tightening the nylon locknut

For pressing the piston rod into the

9 SP129309 Copper bar
cylinder block

For pre-tightening the cylinder head

10 SP130929 Hook spanner
assembly

For locking the cylinder head

11 SP129306 Socket
assembly
 4-17
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

Structure Function Principle

Work Hydraulic System

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 work hydraulic system is as follows:
Layout drawing of work hydraulic system

3
5

P28H00844

1. Bucket cylinder 5. Working cylinder

2. Proportional pressure-reducing valve 6. Steering bump
3. Hydraulic oil tank 7. Boom cylinder
4. Pilot valve
4-18
Structure Function Principle November 17, 2017
Work Hydraulic System CLG835H

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
neutral position, and variable plunger pump Structure
is at minimum displacement position, the
variable pump hardly has oil to output (only The hydraulic oil tank is side-sited type, which is
the minimum displacement required to keep located on the rear frame in the middle of a
self-running), oil passages of the control machine, the right side of a cab. The main
valve connected to both of big and small function is to store the hydraulic oil required for
cavities of the boom cylinder and bucket work cycle of the hydraulic system and
cylinder are sealed, and boom and bucket precipitate the pollutant of oil in hydraulic tank,
are kept in original position. separate the air from oil and cool the hydraulic
2. Operate the boom reversing valve controlled oil. A return oil filter has been set in the oil tank to
by the pilot valve to lift, lower or float the filter the pollutant in oil lines of the hydraulic
boom and manipulate the bucket tilting system so as to guarantee the cleanliness of
reversing valve controlled by the pilot valve to hydraulic oil. Structural diagram of hydraulic oil
tilt the bucket forward or backward. There is tank is as follows:
an automatic leveling device of bucket Structural diagram of hydraulic oil tank
installed on bucket hydraulic cylinder.
5
3. Big and small cavities double-acting safety
valves are installed in oil lines of the control 1
valve connected with big and small cavities of
the bucket cylinder to protect the big and
small cavities of the bucket cylinder from 9
overload and fill oil and play the role of
stabilizing system work and protecting the
relevant elements of the system. 6

Technical Parameters of Work System

2
Items Parameters 7
System pressure 18±0.3MPa
System flow 210L/min@2200r/min 3
Steering cylinder big 8
chamber overload valve 20±0.3MPa
pressure
Steering cylinder small 4
chamber overload valve 14±0.3MPa
pressure P28H00848
Pressure of main safety
18±0.3MPa 1. Oil return chamber and 6. Oil filler, oil filter
valve oil return filter element and breather
2. Baffle 7. Sight glass
3. Washing port 8. Oil suction port
4. Oil drain hole 9. Oil return flange
5. Ventilated oil conduit
 4-19
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

In which, the oil return chamber is used to Working Pump

temporarily store the hydraulic oil that returns
from the system to effectively reduce the back- Main Technical Parameters
flow velocity so as to avoid bubbles in the
hydraulic oil tank resulted from too fast oil return. Items Parameters Remarks
The oil return filter mainly filters the oil returning
to the hydraulic oil tank to prevent pollutant from Rated pressure 20MPa
entering into the system through the oil tank to Displacement 52.2mm/r
cause pollution. The baffle is used to form
Direction of rotation Left rotation
isolation circulation for cold and hot oil in the oil
tank to prevent oil shake from generating large Rated speed 2200rpm
quantities of bubbles and isolate oil suction port Anti-wear
Operating fluid 46#
from oil return port to ensure gas separates out hydraulic oil
of hydraulic oil return. Washing port is used to
clean the dirt in the oil tank. Oil drain hole is used Structure and working principle of plunger
to drain fluid out of oil tank when replace oil or pump
clean oil tank. Oil suction port is used to supply
oil for hydraulic pump. The ventilated oil conduit Outline diagram and working principle of plunger
is used for exhalation of a breather and to lead pump
the oil vapor exhaled by the breather to
underbody. Hydraulic oil is filled from the oil filler
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
sucks air from atmosphere to fill the air space
when the air pressure in oil tank is negative and
that exhaust extra air to realize the protection
function when the air pressure in oil tank is out of
P18H00038
limit. Oil level gauge is used to observe the oil
level of oil tank. Oil suction port is used to supply
oil for hydraulic pump. The gear pump works using the meshing
movement of a pair of gears and causing volume
changes in the suction and draining cavities. It is
the suction port with a closed volume always in a
growing state, and it is the outlet with a closed
volume always in a reducing state. Generally, the
side with larger port is the suction port, and the
side with smaller port is the outlet.
4-20
Structure Function Principle November 17, 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) 125mm Cylinder bore (mm\in) 140\5.51
Rod diameter (mm\in) 70mm Rod diameter (mm\in) 70
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
 4-21
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

Control valve

Main Technical Parameters

Service
Items Parameters Remarks
conditions
Rated flow (L/min\ US gpm) 220 / /
Setting pressure of main safety valve (MPa\psi) 18 / /
Pressure of safety valve of bucket cylinder small
14 / /
cavity (Mpa\ psi)
Pressure of safety valve of bucket cylinder big cavity
20 / /
(Mpa\ psi)
Operating fluid Anti-wear hydraulic oil HM46/HV46 /

Structure and Working Principle of Control Valve

Outline structure diagram of control valve

P28H00849
4-22
Structure Function Principle November 17, 2017
Work Hydraulic System CLG835H

Structure of control valve

1 2 3 4 6 8 10 11 12 13 14 15 16 17 18 19 20 21
5 7 9

P28H00850

1. Cover 8. Spring 15.Screw

2. Spring seat 9. O ring 16.Control valve rod
3. Spring 10.Valve body 17.Valve stem
4. Screw-hex socket 11.O ring 18.O ring
5. Spring 12.Cover 19.Cover
6. Positioner sleeve 13.O ring 20.Safety valve
7. Positioner sleeve 14.Plug 21.Plug
 4-23
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

Hydraulic schematic diagram of control valve

P28H00851

Working principle

There is boom valve rod and bucket valve rod in the banked direction control valve as the bucket valve
rod has three positions of neutral position, upward tilting and downward tilting and the boom valve rod
has four positions of neutral, lifting, lowering and floating. P is the oil inlet and T is the oil return port, A1
and B1 are connected respectively with bucket cylinder big and small cavities, A2 and B2 are connected
respectively with boom cylinder big and small cavities.
1. Neutral position: see above hydraulic circuit schematic, when the bucket valve rod and boom valve
rod are in neutral position, the oil of working pump communicates with oil return tank at T port
through oil inlet P.
4-24
Structure Function Principle November 17, 2017
Work Hydraulic System CLG835H

2. Tilting upward and downward of bucket: move the bucket valve rod rightwards, oil from the working
pump opens the check valve and enters A1 cavity and then bucket cylinder big cavity to tilt the
bucket upward, as the oil in small cavity returns through B1 cavity; also, move the bucket valve rod
leftwards, oil from the working pump opens the check valve and enters B1 cavity and then the bucket
cylinder small cavity to tilt the bucket downward, but the oil in big cavity returns through A1.
Hydraulic schematic diagram of control valve bucket block

P28H00853
 4-25
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

3. Lifting, lowering and floating of boom: move the boom valve rod rightwards, the oil from the working
pump opens the check valve and enters A2 cavity and then the boom cylinder big cavity to lift the
boom, meanwhile oil in small cavity returns through B2 cavity; also, move the boom valve rod
leftwards, oil from the working pump opens the check valve and enters the B2 cavity and then boom
cylinder small cavity to lower the boom, meanwhile oil in big cavity returns through A2 cavity; when
the boom valve rod is at the lowering position, moving it leftwards will come into floating position, the
oil inlet P and big and small cavities of cylinder communicate with oil return and stay at low pressure
and thus the cylinder is at free floating state under the weight of work implement and the ground
force.
Hydraulic schematic diagram of control valve boom block

P28H00853

4. Functions of overload valve and oil refilling valve: when the bucket is interfered by exterior impact or
other mechanism, the overload valve opens for protection. The oil refilling valve fills oil to prevent
cylinder cavity from becoming empty.
4-26
Structure Function Principle November 17, 2017
Work Hydraulic System CLG835H

Pilot Valve
Schematic diagram of pilot valve
Main Technical Parameters

Service
Parameter Remar
Items condition
s ks
s
Working
2.5 / /
pressure (MPa)
Maximum
4.48 / /
pressure (MPa)
Flow (L/min) 7.6-19 / /
Anti-wear P28H00909
Operating fluid HM46/HV46 /
hydraulic oil
Outline diagram of pilot valve
Structure and working principle of pilot valve

The pilot valve shall be installed on the handrail

assembly in the cab and its position can be
adjusted forwards and backwards with the
handrail assembly. The standard configuration of
the model is triplex pilot valve (boom and bucket
way are hydraulically controlled and multi-
functional way is electrically controlled), which
consists of boom operating way, bucket
operating way and multi-functional way. The
boom operating way includes two metering valve
groups, which are respectively used for raise,
lowering and floating lowering of the boom. The
P28H00910
bucket tilting operating way includes two
metering valve groups, which are respectively
used for bucket tilting back and dumping of the
bucket. Multi-functional operating way includes
two metering valve groups, which can be used to
realize actions of multi-functional cylinder, for
example, quick coupler, grapple device and other
attachments. With controlling the handle of pilot
operating valve, the action of each valve group in
boom operating way, bucket operating way and
multi-functional way can be controlled. In
addition, in all metering valves, the displacement
of the spool is in proportional relation with the
operating angle displacement of the handle. The
larger the operating angle of the handle is, the
faster the action speed of the work implement is.
Schematic diagram and outline diagram of pilot
valve are as follows:
 4-27
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

Pilot Supply Oil Valve

Main Technical Parameters

Items Parameters Service conditions Remarks

Setting pressure (MPa) 3.5±0.2 / /
Relief valve opening pressure (MPa) 4.5±0.2MPa / /
Accumulator charge pressure (MPa) 1.0
Rated flow (L/min) 5 / /
Check valve inner leakage (mL/min) ≤8
Operating fluid Anti-wear hydraulic oil HM46/HV46
Hydrauic oil working temperature -20°C~80°C
Accumulator pre-charge pressure 1.0MPa Nitrogen gas

Working principle

1. The pilot oil valve is installed in the handrail box at the right side of the rear frame. It is to supply
stable low-pressure small-flow oil sources for the metering pump and the pilot valve and control the
on-off of all oil lines of the flow amplifying valve of the steering system and the control valve of the
working system via the metering pump and the pilot valve so as to realize the steering and working
function of the loader.
2. When the loader works normally, the oil inlet receives the oil from the steering pump and supplies oil
for the metering pump and the pilot valve through the check valve after decompression by the
pressure reducing valve (set pressure as 3.5MPa) and the accumulator simultaneously works for
storing hydraulic energy.
3. When the loader stops working or shuts down abruptly, the accumulator will carry out energy
conversion to release hydraulic energy so that it can still supply the pilot valve with oil for a certain
time.
4. The relief valve is used to control system pressure and it is normally closed. When system pressure
is higher than the set pressure of 4.5MPa, the spool opens to unload so as to prevent the system
elements from being damaged. Principle diagram and outside diagram of pilot oil valve are as
follows:
4-28
Structure Function Principle November 17, 2017
Work Hydraulic System CLG835H

Schematic diagram of pilot supply oil valve

Oil outlet
4
2

To oil tank
3

1
Oil inlet P28H00908

1. Pressure reducing valve 2. Relief valve 3. Check valve 4. Accumulator

outline of pilot supply oil valve

4
Port PV
To port P of metering pump
To oil inlet of pilot
cut-off valve

3 Port T
To return oil
flange

2 Port P1 (P2)
To oil outlet of
pilot oil filter
1

P28H00907

1. Pressure reducing valve 2. Relief valve 3. Check valve 4. Accumulator

 4-29
November 17, 2017 Structure Function Principle
CLG835H Work Hydraulic System

Oil Filter

The oil filter is installed in the interior of right side of rear frame and it is mainly used to filter oil.

Main Technical Parameters

Items Parameters Service conditions Remarks

By-pass valve opening
0.4MPa / /
pressure
Rated pressure 3.5MPa / /
Rated flow 10L/min / /
Filter accuracy 10μm
Operating fluid Anti-wear hydraulic oil HM46/HV46

outline of oil filter

P28H00906

Oil Filter--Change

The high-pressure oil filter element is replaced at the interval of 2000 hours and the replacement
procedures are as follows: screw the old filter element out of the bottom of the high-pressure oil filter
assembly, and then screw the new oil filter into the high-pressure oil filter assembly.

Pay attention to the arrow direction of the oil filter and do not connect the oil inlet and outlet hose
in a wrong way while replacing the oil filter.
4-30
Structure Function Principle November 17, 2017
Steering Hydraulic System CLG835H

Steering Hydraulic System

Components and Position

Steering hydraulic system is used to control the vehicle traveling direction, for this configuration, the
steering hydraulic system is a variable load sensing hydraulic system, which is mainly composed of
variable plunger pump, shuttle valve, priority valve, metering pump, steering cylinder and other pipeline
accessories. This system can realize steering priority function.
Steering priority refers that oil from the plunger pump will be supplied to steering system with priority and
the surplus oil will be supplied to the work hydraulic system, which is realized by the priority valve.
Priority valve, actually a floating spool, adjusts the flow of oil supply to steering system through sensing
the load pressure of the steering system. The oil flow supplied to the steering system will adapt to the
steering load and velocity.
Component layout

P28H00862

1. Steering pump 2. Metering pump 3. Pilot valve 4. Steering cylinder

 4-31
November 17, 2017 Structure Function Principle
CLG835H Steering Hydraulic System

Technical Parameters of Steering System Steering Pump

Items Parameters Main Technical Parameters

System pressure 17.2±0.3MPa
Items Parameters Remarks
System flow 128L/min@2200r/min
Pressure of main safety Rated pressure 20Mpa
17.2±0.3MPa
valve Rated displacement 52.2mm/r
Steering angle 40°±1° Direction of
Direction of rotation Left rotation
rotation
Rated speed 2200rpm
Anti-wear
Operating fluid #46
hydraulic oil

Structure and Working Principle of

Steering Pump

The gear pump works using the meshing

movement of a pair of gears and causing volume
changes in the suction and draining cavities. It is
the suction port with a closed volume always in a
growing state, and it is the outlet with a closed
volume always in a reducing state. Generally, the
side with larger port is the suction port, and the
side with smaller port is the outlet.
Schematic of metering pump

P28H00405
4-32
Structure Function Principle November 17, 2017
Steering Hydraulic System CLG835H

Metering Pump Schematic of metering pump

Main Technical Parameters

Item Parameters Remarks

Rated displacement 800ml/r
Amplification ratio 2
Max pressure of the
17.2MPa(2494psi)
system
Max back pressure 2.1Mpa(304.5psi)
Contamination degree
of recommended ISO18/13
hydraulic oil
Anti-wear
Operating fluid HM46/HV46
hydraulic oil

Structure and Working Principle P28H00533

Outline structure diagram of metering pump Working principle:

Metering pump is used to control the steering

T cylinder to realize left-right turning.
1. When the steering wheel is not turned,
metering pump is in neutral position, LS port
L is connected with T port, and L, R ports are
cut off.
LS 2. When turning steering wheel to right (left),
pressure oil of P port will be connected with R
(L) port to control the action of steering
R
cylinder to realize right (left) steering.
3. The pressure oil of LS port is fed back to LS
P port of variable pump.
(1) For power steering, pressure oil flows into
stator and rotor pair in certain proportion
(flow amplifying function) through spool and
valve bushing pair to push rotor to rotate with
P28H00532
steering wheel and oil from plunger pump
flows into left cavity or right cavity of steering
cylinder to realize steering.
(2) For manual steering, the stator and rotor pair
of metering pump will play the role of oil
pump to press the oil in one cavity of steering
cylinder to another cavity. Oil cylinder piston
rod will push the wheel to realize steering.
 4-33
November 17, 2017 Structure Function Principle
CLG835H Steering Hydraulic System

Priority Valve

Main Technical Parameters

Items Parameters Service conditions Remarks

Flux 150L/min
Pressure of safety valve 17.2Mpa
Operating fluid Anti-wear hydraulic oil HM46/HV46

Structure and Working Principle of Components

The priority valve is installed on the inner side of left web plate of rear frame and close to hinge position.
Hydraulic oil from the plunger pump enters into metering pump via priority valve and then flows into
steering cylinder to realize left-right turning. The priority valve realizes the steering priority function.
Schematic of priority valve

P18H00032 P18H00032

Working principle: during single steering, P port of metering pump communicates with L (or R) port, the
channel from LS to T is closed and the channel from LS to L (or R) is open. LS oil pressure acts on left
side of priority valve spool so that the spool moves rightwards, the opening of CF channel increases and
the opening of EF channel decreases. This is steering priority.
Outline diagram of priority valve

P28H00411
4-34
Structure Function Principle November 17, 2017
Steering Hydraulic System CLG835H

Steering Cylinder

Main Technical Parameters

Items Parameters Remarks

Cylinder 70 mm (2.76 In)
Rod diameter 40mm (1.57 In)
Stroke 420mm (16.53 In)
Minimum mounting distance 728mm (28.66 In)

Structure and Working Principle of Steering Cylinder

Steering cylinder, which is installed at the articulated joint of front & rear frame and cylinder, is the
actuator of steering hydraulic system. It realizes the left-right steering by pushing the front and rear
frame of left-right steering cylinder piston rod.

Structure of steering cylinder

Overall structure diagram of steering cylinder

1 2

P28H00495

1. Oil port of big cavity 2. Oil port of small cavity

 4-35
November 17, 2017 Structure Function Principle
CLG835H Brake system

Brake system

Components and Position

Brake system consists of service brake system, emergency & parking brake system. Service brake
system is used in speed control and parking in general traveling. Emergency & parking brake system is
used for brake after parking, or emergency brake in case of service brake system failure.
Service brake system consists of brake pump, brake valve, charge valve, accumulator, wet brake (in the
axle), pressure switch and pipeline. Emergency & parking brake system consists of parking brake
accumulator, brake cylinder, brake valve block and pipeline.

This is a full-hydraulic brake system and its features are as follows:

1. Using wet-type wheel brake: the system circuit is fully closed so as to avoid the influence of external
uncertain factors (for example: sand invasion and oily friction disc) on braking performance. Using
oil-immersed cooling method by which the friction plate is immersed in oil to avoid reduction of
braking performance caused by heat fading of friction material due to high temperature of friction
plate, at the same time, to reduce the requirement for brake oil.
2. Using full-hydraulic brake system: cancel air line and simplify the system so as to avoid the corrosion
of pipeline and brake components caused by water in the air line system, and the reliability and
response speed of the system are improved.
3. Using dual-circuit brake: front and rear axle brake lines are independent so as to make them safer
and more reliable
Component layout drawing of full-hydraulic brake system as follows:

1 2

3 4 5 6 7 P28H00863

1. Brake valve 4. Brake cylinder 6. Brake valve assembly

2. Gear pump 5. High-pressure oil filter 7. Charge valve
3. Accumulator assembly
4-36
Structure Function Principle November 17, 2017
Brake system CLG835H

Technical Parameters of Brake System When applying the parking brake, emergency &
parking brake system controls the brake valve
Items Parameters block assembly using the parking brake solenoid
valve switch in the cab to make the parking brake
Dual-circuit full-hydraulic wet
Service brake system accumulator release pressure oil which controls
brake
the brake cylinder to realize emergency &
Electronically controlled full parking brake function. In addition, the pressure
Parking brake system
hydraulic brake
control switch in electrical system can also
Pressure of brake realize the machine brake.
17.2±0.3MPa
pump relief valve
Output pressure of Power cut-off function (i.e. function of brake
4.8±0.35MPa and spontaneous out-of-gear): when the shift
brake valve
control lever is in forward or backward I & II
System flow 36L/min@2200r/min
position and the clutch on/off switch is closed
(i.e. push button lamp is on) during driving, once
Working Principles of Brake System apply the foot brake, electric control box sends a
command to the shift control valve to engage the
Working principle of full-hydraulic brake: the
transmission in N position and cut off power.
system pressure is kept by accumulator
When the shift control lever is in forward or
assembly and each brake circuit is equipped with
backward I & II position and the clutch on/off
accumulator independently. When oil pressure in
switch is disconnected (i.e. push button lamp is
the accumulator is lower than the setting
off) during driving, once the brake is applied, the
minimum working pressure of the system (the
power will not be cut off.
pressure is 13.5MPa), the charge valve feeds the
pressure oil of brake pump (brake pump and Clutch on/off switch is a switch with self-locking
cooling pump form tandem pump and share one function, refer to the electrical system in the
pump body) filtered and outputted by oil filter into manual for detail of using method.
the accumulator. When oil pressure in the
The "function of brake and spontaneous out-of-
accumulator reaches the setting maximum
gear" can work only in forward or backward I & II
working pressure (the pressure is 16MPa), the
position. In order to guarantee safe driving, when
charge valve stops supplying oil for the
load is in high-speed position, once the brake is
accumulator of brake system. The brake pump is
applied, the electric control box will not sends the
unloaded by connecting S port of charge valve
command of cutting off power no matter whether
with oil tank. At the time of braking, depress the
the clutch on/off switch is closed or
brake valve pedal, high pressure oil stored in the
disconnected, which is determined by driving
accumulator of service brake circuit enters into
properties of the loader.
the axle via the service brake valve so as to push
the brake piston in the axle, the piston compacts
the wet-type friction plate and half shaft of wet-
type brake axle to realize the service brake of the
machine. After releasing the brake pedal and When the shift control lever is in forward or
removing brake, oil in the axle returns to oil tank backward I & II position during driving, do not
via the brake valve. disconnect the clutch on/off switch
easily,otherwise, the brake and power train
system may be damaged. When the machine
is in operation at the upslope or downslope
of rough road and the brake is applied, the
function can be selected in order to ensure
safe driving.
 4-37
November 17, 2017 Structure Function Principle
CLG835H Brake system

Emergency brake button and clutch on/off switch locked. During operation, if the parking &
emergency brake circuit is faulty, resulting in oil
pressure in the accumulator BR3 lower than
11MPa\1595psi, the emergency brake low
2 pressure alarm light flashes. At this time, stop
1 operation and park the vehicle for inspection.
During inspection, stop the machine on level
ground, pull the emergency brake button and
chock the wheels with blocks to prevent the
P18H00037 machine from moving.
1. Emergency brake button If the service brake low pressure alarm fails and
2. Clutch on/off switch the system is faulty, which results in oil pressure
At short time of starting the machine, the service in the accumulator of service brake circuit lower
brake low pressure alarm light flashes and the than 7MPa\1015psi, the clutch on/off switch of
alarm buzzer sounds. Because oil pressure in emergency brake in the system cuts off the
the accumulator of service brake circuit is still power automatically to engage the transmission
lower than the alarm pressure (11MPa\1595psi) in N position. Simultaneously, the solenoid valve
at this time, and the alarm will stop automatically is powered off, hydraulic oil in the parking brake
as pressure in the accumulator is higher than the cylinder flows back to oil tank via emergency
alarm pressure. Press down the emergency brake solenoid valve so that the parking brake is
brake button only after the alarm stops. During locked and the emergency parking of loader is
operation, if the system is faulty, resulting in oil achieved.
pressure in the accumulator of service brake
circuit lower than 11MPa\1595psi, the service
brake low pressure alarm light flashes and the
alarm buzzer sounds. At this time, stop operation Unless in emergency, do not apply parking &
and park the vehicle for inspection. During emergency brake when the machine is
inspection, stop the machine on level ground and running. Applying parking & emergency
pull the emergency brake button. brake in normal operation will cause serious
When press down the emergency brake button, damage to the brake and power train system.
the solenoid valve is powered on, valve port is
open, the pressure of oil outlet is
16MPa\2320psi, high pressure stored in the
accumulator of parking & emergency brake
circuit enters into parking brake cylinder via
emergency brake solenoid valve to release the
parking brake. At the moment of pressing down
the emergency brake button, the parking &
emergency brake low pressure alarm light
flashes. Because oil pressure in the parking
brake circuit is still lower than the alarm pressure
(11MPa\ 1595psi) at this time. The machine can
be started only when the emergency brake low
pressure alarm light is off. When pull the
emergency brake button, the solenoid valve is
powered off, hydraulic oil in the parking brake
cylinder flows back to oil tank via emergency
brake solenoid valve and the parking brake is
4-38
Structure Function Principle November 17, 2017
Brake system CLG835H

Brake Pump The gear pump works by using the meshing

movement of a pair of gears and causing volume
Main Technical Parameters changes in the suction and discharge chambers.
It is the suction port with a closed volume always
Service in a growing state, and it is the outlet with a
Items Parameters closed volume always in an ever-reduced state.
conditions
Generally, the side with larger port is the suction
Theoretical
displacement (ml/r\cc/ 15\2175 / port, and the side with smaller port is the outlet.
r) Overall structure of brake pump
Rated speed (r/min) 2200 /
1
Maximum speed (r/
2500 /
min)
Rated pressure
18\2610 /
(Mpa\psi)
Maximum
25\3625
pressure(Mpa\psi)
Volume efficiency 0.92 /
Anti-wear HM46/
Operating fluid 2 3
hydraulic oil HV46 P28H00904
Direction of rotation Left rotation / 1. Oil outlet (for oil entering into high-pressure oil filter)
2. Safety valve of brake system
Structure and Working Principle of Brake 3. Oil inlet (to oil outlet steel tube of tank)
Pump

The brake pump is a gear pump and located

under cab and installed on the left power take-off
of the gearbox and tightened by stud and nut. It
is driven by engine via hydraulic torque converter
and gearbox to supply oil for brake hydraulic
system.
Gear pump working principle schematic

P28H00405
 4-39
November 17, 2017 Structure Function Principle
CLG835H Brake system

EXploded view of brake pump (cooling pump and brake pump form tandem pump)

19
17 18
1
14 13
15 16 9
12 24
8 2
11 25

23
20
22 27
21 28
10 3
4
6
26

5
7

P28H00905

1. Front housing 11.Internal circlip 21.Seal ring of side plate

2. Pump body 12.Outboard ball bearing 22.Seal ring of side plate
3. Pump body 13.Skeleton oil seal 23.Stud bolt
4. Drive gear 14.Washer 24.Nut
5. Drive gear 15.Snap ring 25.Washer
6. Driven gear 16.Snap ring 26.Relief valve
7. Driven gear 17.Roller bearing 27.Plug
8. Connecting shaft 18.Oil blocking screw 28.Washer
9. Connecting shaft 19.Cylindrical pin
10.Lateral plate 20.O-ring
4-40
Structure Function Principle November 17, 2017
Brake system CLG835H

Internal maintenance instructions of brake pump

1. Maintenance of brake pump: brake pump is the power source of brake hydraulic system, and its vol-
ume efficiency will influence the speed and efficiency of actuator directly. It is not recommended to
remove or install the brake pump by non-professionals as it is a precise hydraulic element, and the
broken pump shall be returned to the manufacturer and repaired by professionals; after repair, brake
pump shall perform the test of airtightness and volume efficiency in order to guarantee its perfor-
mance and normal application.
2. Installation requirements for brake pump:
(1) You shall understand fully about rotating direction of brake pump and its compliance with the require-
ments of the entire machine before installation of the brake pump.
(2) Inlet and outlet port of brake pump shall be kept clean without dirts, and its surface shall have no inju-
ries so as to guarantee the sealing effect of O-ring.
(3) Before assembling the brake pump, check whether the mounting hole depth of gearbox spline is
larger than the pump's shaft extension length or not, in order to prevent from culmination phenome-
non, pump burnt out. Installation of spline shaft and spline housing shall be free without stuck.
3. Precautions for maintenance of brake pump:
(1) Apply a moderate force during assembly and disassembly of brake pump, and rude operation is not
allowed; user shall not open the brake pump without manufacturer's consent, otherwise they cannot
guarantee their product performance.
(2) Pay attention to maintenance of brake pump during operation, replace the hydraulic oil and check all
bolts at connections for looseness according to the maintenance manual.
(3) Oil inlet and outlet of brake pump shall be installed firmly and sealing device shall be secured, other-
wise it may cause oil leakage or air suction and affect the pump's performance.
(4) It is not allowed to operate the brake pump under maximum pressure, maximum speed or over-
loaded circumstances, otherwise, it may influence the service life.
(5) Oil temperature is required to be kept lower than 80 °C/176°F, otherwise it may affect the viscosity of
hydraulic oil and also accelerate the oxidation of fluid.
 4-41
November 17, 2017 Structure Function Principle
CLG835H Brake system

Brake Valve

Main Technical Parameters

Service
Items Parameters Remarks
conditions
Maximum allowed system pressure 20.7±0.35MPa \ \
Maximum brake pressure 4.8±0.35MPa \ \
Pedal force under maximum pressure (about) 230N \ \
Pedal stroke (about) 18° \ \
Operating fluid Anti-wear hydraulic oil HM46/HV46 \

Adjustment of maximum brake pressure

If the maximum brake pressure value of dual-circuit brake valve is 4.8±0.35MPa and wrong, it can be
adjusted by increasing or decreasing the gasket 12 shown in below..

as the structure of dual-circuit brake valve is complex and the requirement for assembly and
adjustment is high, the removal & installation and adjustment can not be conducted by non-
professionals without authorization. Before the dual-circuit brake valve is delivered, its pressure
value has been adjusted. If fault occurs or the maximum brake pressure value is wrong, please
contact its factory or dealer.
4-42
Structure Function Principle November 17, 2017
Brake system CLG835H

Structure and working principle of brake valve

Brake valve (also called foot brake valve) is located on left floor of cab and its pedal can be controlled by
left foot. Brake valve, which realizes the sensitive follow-up control during the brake and release process
of service brake system, is one of the main parts of brake system.
Outline diagram of brake valve

P18H00059 P18H00059
 4-43
November 17, 2017 Structure Function Principle
CLG835H Brake system

Structure drawing of brake valve

P18H00060P18H00060

1. Spring 9. X-ring
2. Valve body 10.Y-ring
3. Lower spool 11.Reset spring
4. Valve body 12.Adjusting shim
5. Upper spool 13.Balance spring
6. Steel ball 14.Piston
7. Spring holder 15.Roller
8. Balance spring 16.Step

Hydraulic schematic of brake valve

Rear axle Front axle

P18H00061 P18H00061
4-44
Structure Function Principle November 17, 2017
Brake system CLG835H

Main structure of brake valve is as shown above 2. With the brake valve pedal depressed, apply
picture, P2 port and P1 port are connected with certain force to balance spring 8 & 13 by
accumulator BR1 & BR2 respectively, A2 port piston 14 to push spool 5 & 3 to move
and A1 port are connected with wheel brake of downwards, A1 port and A2 port is
front and rear axle. disconnected with T port, and then P1 port is
connected with A1 port, P2 port is connected
1. When the brake valve pedal is released,
with A2 port, high pressure oil stored in
spool 5 & 3 are pushed to maximum position
accumulator BR1 &BR2 enters into the wheel
under the effect of spring 1, P1 port and P2
brake of front and rear axle to apply brake, at
port are disconnected with A1 port and A2
the same time, the brake switch acts and the
port respectively, A1 port and A2 port are
brake light is on. Two circuits of dual-circuit
connected with T port and thus the machine
are independent from each other, as one
is under non-brake state.
brake circuit is faulty, the other circuit can still
work normally.

Tank Port
Brake Port Tank Port
Pressure Port Brake Port
Pressure Port

Brake Port
Pressure Port Brake Port
Pressure Port
P18H00062
P18H00063
 4-45
November 17, 2017 Structure Function Principle
CLG835H Brake system

3. Under brake, the proportional relation of 4. If it is necessary to remove and clean brake
output oil pressure of brake valve with valve, do not clean seal ring, valve and other
operating force applied on the brake pedal is rubber parts using brake fluid, kerosene and
realized by balance spring 8 & 13. When the other fluids which can corrode the rubber
pedal force is fixed, the pressure applied on parts, they can only be wiped by blowing or
the balance spring is also a fixed value. After clean cloth. Apply 3# lithium lubricating
P1 port and P2 port opening, pressure oil grease on the moving parts, such as valve
enters into C cavity and D cavity of the spool and piston after being cleaned;
lower cavity. As the force which is applied on
the spool by oil pressure of the spool lower
cavity exceeds the tension force of balance
spring, the balance spring is compressed and
the spool moves upward until P1 and P2 are
closed, at this time, the force applied on the
spool by oil pressure is balanced with the
pressure applied on the balance spring
applied by the pedal and the oil pressure
outputted by brake valve is at a certain value.
When the pressure applied on the balance
spring by the pedal rises, the spool moves
downwards and P1 port and P2 port are open
again. When oil pressure of the spool lower
cavity rises up to a certain value, the force
applied on the spool is balanced with the
pressure applied on the balance spring by
the pedal, P1 port and P2 port are closed
again, the oil pressure outputted is kept at a
certain value which is higher than previous
one. That is, the oil pressure outputted by
brake valve is in in proportion to the
compression and deformation of the balance
spring and also to the stroke of brake pedal.

Precautions for use and maintenance of

brake valve

1. Be sure the connecting pipeline is clean,

without any impurities;
2. Periodically check the connection and
fastening condition of all parts and tighten
timely if there is looseness;
3. Periodically check the working condition of
pedal: whether it is stuck when depressing
the pedal and whether it can return rapidly at
the time release;
4-46
Structure Function Principle November 17, 2017
Brake system CLG835H

Charge Valve

Main Technical Parameters

Items Parameters Service conditions Remarks

Shut-off pressure of charge
15.9±0.35MPa \ \
valve
Connecting pressure of
12.8±0.35MPa \ \
charge valve
Charging speed 10.2±1.9L/min \ \
Operating fluid Anti-wear hydraulic oil HM46/HV46 \

If the maximum charging pressure of the charge valve is not in compliance with the setting value
(15.9±0.35MPa) before the delivery of the complete machine, adjustments shall be made as follows:
1. Make sure that all external pipelines of dual-circuit charge valve are connected correctly;
2. Connect accurate pressure gauge at SW port;
3. Start the machine, it is permitted for the charge valve starting working after 1 minute around, stop oil
supply as the pressure shown on the pressure gauge continues to increase.
4. Remove the plug 8 and O-ring 9 shown in the Figure below, turn the nut 10 slowly until the maximum
reading of the pressure gauge up to 15.9±0.35MPa. The pressure can be set in the accurate position
only by adjusting the nut 10 several times.

As the structure of dual-circuit charge valve is complex and the requirement for assembly and
adjustment is high, the removal & installation and adjustment can not be conducted by non-
professionals without authorization. Before the dual-circuit charge valve is delivered, its
pressure value has been adjusted. If fault occurs or charging pressure value is wrong, please
contact its factory or dealer.
 4-47
November 17, 2017 Structure Function Principle
CLG835H Brake system

Exploded view of the charge valve pressure adjustment

P18H00120
4-48
Structure Function Principle November 17, 2017
Brake system CLG835H

Structure and working principle of charge valve

Charge valve, located in left housing of rear frame, is used to charge the accumulator according to the
pressure of brake system.
Structure diagram of charge valve

P18H00121

1. Rod 11.Spool 21.Spring

2. Spring 12.Seal ring 22.Spring
3. Seal ring 13.Steel ball 23.Spool
4. Spool 14.Rod 24.Seal ring
5. Valve body 15.Nut 25.Valve seat
6. Nut 16.Screw rod 26.Seal ring
7. Spring 17.Spring 27.Valve seat
8. Rod 18.Spool 28.Spool
9. Steel ball 19.Valve seat 29.Spring
10.Seal ring 20.Filter element
 4-49
November 17, 2017 Structure Function Principle
CLG835H Brake system

Hydraulic schematic of charge valve

4 7

6 5

1
2

P28H00364

1. Priority valve (main spool) 4. Shuttle valve one 6. Check valve

2. Relief valve 5. Filter element 7. Shuttle valve two
3. Pilot spool

The priority valve 1 is used to supply oil for brake system preferentially and unload after meeting
requirements for the accumulator of brake system; the relief valve 2 is used for limiting the maximum
pressure of the charge valve import; the pilot valve spool is used for setting the pressure for connecting
and shutting off charge valve; The shuttle valve 4 & 7 are used to protect brake circuit A1 & A2 from
interference with each other.
Hydraulic schematic diagram of charge valve is shown in Figure above. P port is connected with pump,
A1 & A2 ports are connecting with the accumulator for service brake, SW port is connected with P port of
brake valve block, and then connected with parking brake accumulator, T port is connected to oil tank
and O port is connected to oil tank.
When the pressure of working oil port of charge valve is lower than the connecting pressure of charge
valve (12.8±0.35MPa), the spring 21 pushes the rod 14 to move upwards to close P port, W cavity is
connected with H cavity; the spool 4 moves downwards under the effect of spring 2 to reduce the
opening of P port and O port, one branch of oil from the pump enters into G cavity via small hole and the
other branch props up the check valve spool 18 and enters into W cavity via spool 20 to push the spool
23 & 28 and open check valves F1 & F2 and starts charging the accumulator which reduces pressure of
SW port. When the pressure of oil outlet SW of charge valve is higher than the pressure of shut-off
pressure of charge valve (15.9±0.35MPa), the force of W cavity oil pressure and spring 7 is higher than
the common force of spring 21, the spool 11 moves downwards to prop up the valve under the spool 11,
oil of H cavity enters into oil tank, the pressure decreases, at this time, the pressure of G cavity is higher
than common force of spring 2 and oil in H cavity, the spool 4 moves upwards, P port is connected with
O port, charging is stopped, all of oil from the pump returns to oil tank via the O port. Recharging the
accumulator as the pressure of accumulator is lower than that of connecting pressure of charge valve.
4-50
Structure Function Principle November 17, 2017
Brake system CLG835H

Oil line diagram in charging state

1
2
11
3 10

5
6
12

4 7
P28H00298

1. Check valve 5. Fliter 9. Top dead center testing steel ball

2. Chamber 1 6. Spring 10. Polit fliter
3. Spring 7. Shuttle valve 2 11. Bottom dead center testing steel ball
4. Chamber 2 8. Shuttle valve1 12. Mail valve

P18H00124
 4-51
November 17, 2017 Structure Function Principle
CLG835H Brake system

Oil line diagram in bypass state

1
10

2 11

3 9
4

5 12

6 7
P28H00297

1. Check valve 5. Main valve core 9. Top dead center testing steel ball
2. Chamber 6. Chamber 2 10. Check valve base
3. Spring 7. Shuttle valve 2 11.Bottom dead center testing steel ball
4. Shaft snap ring 8. Shuttle valve 1 12.Spring

P18H00126
4-52
Structure Function Principle November 17, 2017
Brake system CLG835H

Structure principle

Bladder type structure is adopted for the

accumulator, as shown in Figure below.
The pressure change of SW port has the Structure diagram of diaphragm type
priority to that of A1 & A2, the pressure of SW accumulator
port, through dual check valve, is the
pressure of A1 & A2 port, therefore, the
pressure of A1 & A2 port decreases, so dose 1
the pressure of SW port.
2
Dual check valves F1 & F2 are used to
guarantee two brake circuits are not interference
with each other. When one of circuits fails, the
pressure decreases, the valve (F1 or F1)
corresponding to the port with higher pressure is 3
closed under the effect of hydraulic force. Make
sure that the brake circuit with zerofailure still 4
realize braking function. At this time, the failed
circuit is connected with the charge valve, the 5
pressure of SW port decreases, low pressure
1. Inflating port / hex locking screw 4. valve seat
alarm switch of service brake acts, the machine
2. Pressure vessel 5. Fluid side port
shall be stopped immediately for inspection.
3. Diaphragm P18H00049

Accumulator Assembly Diaphragm type accumulator is used to store

pressure oil for braking and hold pressure of
The accumulator assembly, which is located in system. The operating principle is to isolate the
the housing at left side of complete machine and fluid under pressure from the air volume
is fixed on rear frame, mainly consists of service chamber with pre-set pressure in the
brake accumulator and parking brake accumulator with diaphragm and store them in
accumulator, i.e. service brake accumulator BR1 sealing housing. It absorbs and releases fluid for
(rear axle), service brake accumulator BR2 (front braking due to change of pressure. When the
axle) and parking brake accumulator BR3 in brake pump is operating, it inputs the
order from front to back. pressurized fluid into the accumulator via charge
valve to store energy, at this time, air in the air
chamber is compressed so that the pressure of
liquid is equal to air pressure to achieve energy
storage. Nitrogen charged into the accumulator
is non-flammable.

The accumulator housing may be hot so as to

cause burn.
 4-53
November 17, 2017 Structure Function Principle
CLG835H Brake system

Accumulator charging parameter 6. After reaching the specified pressure, turn off
the switch of the nitrogen cylinder, and then
Items
Parame-
Items Parameters
the switch on gas charge tool.
ters
7. Remove gas charge tool.
Gas charging Below 20°C\
1L\ 8. If the accumulator leaks (apply oil onto head
Rated pressure of accu- 68°F
0.26US
capacity mulator BR1 & 5.5MPa\ of the accumulator and check it for bubbles, if
gal
BR2 797.5psi any, the accumulator leaks), knock down gas
Gas charging Below 20°C\ charge valve in the accumulator lightly using
Rated
pressure
31.5MPa pressure of accu- 68°F 9.2MPa\ hammer or small screwdriver to make it move
mulator BR3 1334psi downwards and then return to its original
Pre- Charging pres- position so that its sealing surface contacts
charging Nitrogen sure of accumu- 12.8~15.9MPa completely.
gas lator BR1 & BR2
9. Install the protective cap of accumulator gas
Charging pres-
Working Hydraulic
sure of accumu- 15.9 MPa
charge valve.
medium oil
lator BR3 10. Conduct gas charging for the other two
accumulators according to above
Gas charging method of accumulator procedures.
1. Stop the machine, but do not turn off the Gas charge of accumulator
electric lock. Depress the brake continuously
for more than 20 times, and then press and
release the button of manual solenoid valve
for more than 20 times, drain high-pressure
oil in the accumulator. Then, unscrew the
plug of oil outlet at lower end of the
accumulator slowly. At this time, there is
residual pressure oil in the accumulator. Note
that the residual pressure oil shall not splash
onto person.
2. Remove the protective cap of gas charge
valve from upper end of one accumulator.
P18H00050
3. Connect as shown in Figure Below.
4. Turn on the switch of the nitrogen cylinder, Precautions for safety use of accumulator
after reading of the pressure gauge is stable, 1. The accumulator shall be checked before
turn on the switch on gas charge tool, that is, charge of nitrogen. It is prohibited to charge
prop up the gas charge valve in the the accumulator with gas if the accumulator
accumulator and conduct gas charging. does not have a nameplate, or the words on
5. As pressure may reach the limit the nameplate are missed so that its type can
instantaneously, turn off the switch of not be identified, or if the steel seal marks are
nitrogen cylinder, check whether the pressure incomplete or cannot be read clearly, or if
reaches limit after reading of pressure gauge there is defect with the housing and therefore
is stable. If insufficient, recharging it. If the safe use cannot be ensured.
pressure is too high, conduct bleeding using 2. The accumulator can only be filled with
the bleeding plug on the gas charge tool and nitrogen other than oxygen, compressed air
reduce the pressure to a proper value. or other flammable air to avoid explosion.
4-54
Structure Function Principle November 17, 2017
Brake system CLG835H

3. Slowly charge the nitrogen into the When the system reaches the working pressure,
accumulator so as to avoid the breakage of and the control knob of emergency & parking
the rubber bag. brake is pressed down, the pressure oil flows
into the left chamber of brake cylinder through
4. The accumulator shall be installed vertically
solenoid valve to compress the spring, push the
with the valve facing upwards. The
spring seat and piston to right side and the
accumulator shall be stably fixed on the
parking brake lever so as to release the brake
bracket without being welded.
and drive the vehicle. When the oil pressure of
5. Before removal of the accumulator, drain the accumulator in the circuit of service brake is
pressure oil, release nitrogen in accumulator lower than 7MPa\1015psi, the cut-off switch of
using gas charge tool, and then remove emergency brake acts to cut off the power of
parts. solenoid valve. The hydraulic oil in the parking
brake cylinder returns to oil tank via manual
Maintenance of accumulator solenoid valve. Force from spring pushes the
spring seat and piston left side and pulls the
Check directly gas charging pressure in
parking brake lever to lock the brake, meanwhile,
accumulator using gas charge tool. After the
transmission shifts to the neutral position to
machine is delivered, check the pressure in
achieve the emergency parking of loader.
plastic bag once a week; after a month, check it
once a month, after half a year, check it once The machine is equipped with parking brake
every three months; after one year, check it once which is released by hydraulic pressure based
half a year. Regular inspection is beneficial for on spring action (working of brake cylinder). If
keeping the accumulator in best service the engine, hydraulic system or the brake system
conditions, finding the leakage early and fails, the machine is braked and unable to drive.
conducting repair in time. When the machine fails to drive and needs to be
towed, the pin shaft in the brake cylinder as
Brake Cylinder shown below is removed, tow the machine after
the parking brake is released.
The brake cylinder, as key actuation component Structure diagram of brake cylinder
for emergency & parking brake system, is
installed on the left side of front end of 1 2 3 4 5 6
transmission housing.

Structural composition and working principle

of brake cylinder

The structure of brake cylinder is shown as

below, its working pressure is
15.9MPa\2305.5psi. The disengagement and
engagement of emergency & parking brake are
available with brake cylinder whose lever is
coupled with cam handle. When the system has
no oil pressure or the control knob of emergency
& parking brake is pulled up, no pressure oil
enters the left chamber of brake cylinder. The
1. Tank body assembly 3. Piston 5. Spring
spring seat and piston are always pushed to the 2. Seal ring 4. Spring holder 6. Pin
left side by force from spring, pull the parking
brake lever to engage it, thus to achieve the
brake performance.
 4-55
November 17, 2017 Structure Function Principle
CLG835H Brake system

Main parameters of brake cylinder 4. Keep the service brake state and check
whether machine will move.
Service
Items Parameters
conditions
Fully release the
5.2MPa \
pressure
If the machine moves during inspection, it
Maximal spring may cause personal injury.
6422N \
force
Rated capacity 42ml \ Exhaust of brake system
Working pressure 15.9MPa
Anti-wear Bleeding position at front/rear axle
Operating fluid HM46/HV46
hydraulic oil

Check the performance of service brake

Before checking the performance of service

brake, you shall inspect the performance of Exhaust hole
parking brake so as to guarantee parking
safety and the effects of emergency brake.

1. Adjust the tire pressure of machine to the P18H00053

specified value, and lay down the bucket
levelly at approx. 300mm\ 11.8in from the 1. Stop the machine on a level and straight
ground. And confirm the machine have the road.
performance of good service brake.
2. Turn the shift lever to the neutral position,
2. Start the engine, and drive the machine start up the engine and let it run at idle
toward and on the 25% slope (14°2') and, the speed, activate the parking brake switch;
road surface shall be flat and dry. switch off the low-pressure alarm lights for
service brake and for parking brake, stall the
engine and then activate the electric lock.
3. Put a transparent hose around the exhaust
nozzle of the left/right wheel brake of front
drive axle and the other end of the hose into
the oil pan.
4. It needs the coordination of two persons, one
is to loosen the exhaust nozzle to observe
P18H00052
the exhaust situation; the other depresses
the pedal firmly after stepping on it several
times continuously until the the liquid column
3. Depress the service brake pedal, stop the
without bubbles is discharged, tighten the
machine and place the shift control lever to
exhaust nozzle.
neutral position, and engine won't cut-out.
5. Repeat these steps to discharge the gas from
the rear axle.
4-56
Structure Function Principle November 17, 2017
Hydraulic Cooling System CLG835H

6. After the gas in the front/rear axles is Hydraulic Cooling System

discharged, continuously pull up and press
down the switch of parking brake for 3-4
times, and discharge the gas out of parking Components and Position
brake.
This machine is equipped with separate
7. Take care to and slowly loosen the drain plug hydraulic fan motor cooling system, which
under the energy accumulator until there are acquires oil, water temperature signals of torque
oil liquid and bubbles out of thread, Tighten converter and temperature signal of air-air inter-
the plug when no babbles emerge. cooler, and control the speed of fan with
program. This not only meets needs for system
cooling, but also achieves the purpose of energy
saving. The system consists of cooling pump,
Since there is high pressure oil stored in the motor, solenoid directional valve and other pipes
wheel brake, special care must be taken (refer to the maintenance manual of electrical
when bleeding. It is not allowed to loosen system for electrical controls).
fully the bleeding valve. Keep the eyes and
System's features:
body away from the bleeding valve in order to
avoid injuries caused by spraying oil liquid. 1. Electric adjustment, by controlling pressure
drop △ P of the oil through fan motor, adjusts
Check for the performance of parking the speed of fan;
brake
2. The proportional relief valve integrates the
reversing valve, when the relief valve is
closed normally, it guarantees the fan works
at full speed in the case of no electrical
You shall frequently inspect the performance signal;
of parking brake so as to guarantee parking 3. The fan is driven in reverse direction to make
safety and effect of emergency brake. fan work reversely, dredging the impurities
Guarantee parking safety and effect of deposited on the radiator;
secondary brake.
4. Plunger motor with low noise and long
service life;
1. Adjust the tire pressure of machine to the
specified value, and lay down the bucket
levelly at approx. 300mm\11.8in from the
ground. And confirm the machine have the
performance of good service brake.
2. Start the engine and load 5 tons weight and
align the machine at 15% slope (8° 32') and
the pavement shall be flat and dry.
3. Pull the parking brake button, stop the
machine and place the shift control lever to
neutral position, and the engine is not stalled.
 4-57
November 17, 2017 Structure Function Principle
CLG835H Hydraulic Cooling System

The schematic and component layout drawing of this machine cooling system are as follows:
Schematic of the hydraulic cooling system

P28H00868
4-58
Structure Function Principle November 17, 2017
Hydraulic Cooling System CLG835H

Layout drawing of hydraulic cooling system

2
1

P28H00869

1. Cooling pump 2. Motor & solenoid directional valve

 4-59
November 17, 2017 Structure Function Principle
CLG835H Hydraulic Cooling System

Technical parameters of hydraulic cooling system

Items Parameters
System pressure About 16±0.3MPa@1700rpm (fan speed)
System flow 55L/min@2200r/min

Working principle of hydraulic cooling system

Oil line of fan rotation clockwise

P28H00870

Working principle:

When the solenoid directional valve is not energized, under action of spring force, it works in lower
position. One branch of high-press oil from cooling pump flows into the right oil port of cooling motor via
solenoid directional valve. The left Port oil of cooling motor returns to oil tank via the solenoid directional
valve to achieve clockwise rotation of fan.
4-60
Structure Function Principle November 17, 2017
Hydraulic Cooling System CLG835H

Principle of fan reverse rotation

P28H00871

Working principle:

When the solenoid directional valve is energized, under action of spring force, it works to the upper
position. One branch of high-press oil from cooling pump flows into the left oil port of cooling motor via
solenoid directional valve. The right port oil of cooling motor returns to oil tank via the solenoid directional
valve to achieve reverse rotation of fan.
In addition, the electric control system acquires the temp signal from air-air inter-cooler, oil and water
temp signals from torque converter, to control the opening of proportional relief valve, so that the
pressure difference between inlet and outlet of cooling motor, further to control motor flow and fan speed.
 4-61
November 17, 2017 Structure Function Principle
CLG835H Hydraulic Cooling System

Cooling Pump

Main Technical Parameters

Items Parameters Service conditions Remarks

Theoretical displacement 25ml/r / /
Rated speed 2200r/min / /
Max. speed 2350r/min
Rated pressure 16MPa / /
Max. pressure 21MPa
Volume efficiency 0.92 / /
Operating fluid Anti-wear hydraulic oil HM46/HV46 /
Direction of rotation Left rotation / /

Structure and Working Principle of

Cooling Pump Outline of cooling pump

Cooling pump is a gear type, installed on

flywheel at left side of engine. It provides the 1
cooling system with oil at the same speed as the
engine works.
Gear Pump Working Principle Schematic

P28H00875

P28H00405

The gear pump works by using the meshing

movement of a pair of gears and causing volume
changes in the suction and discharge chambers.
It is the suction port with a closed volume always
in a growing state, and it is the outlet with a
closed volume always in an ever-reduced state.
Generally, the side with larger port is the suction
port, and the side with smaller port is the outlet.
P28H00876

1. Oil outlet (to fan motor)

2. Oil inlet (to suction oil hose)
4-62
Structure Function Principle November 17, 2017
Hydraulic Cooling System CLG835H

Maintenance Instruction for Cooling 2. Pay attention to maintenance of cooling

Pump pump during operation, replace the hydraulic
oil and check all bolts at connections for
Maintenance of cooling pump: looseness according to the maintenance
manual.
the cooling pump is the power source of brake
hydraulic system, and its volume efficiency will 3. Oil inlet and outlet of cooling pump shall be
affect the speed and work efficiency of actuator installed firmly and sealing device shall be
directly. It is not recommended to remove or secured, otherwise it may cause oil leakage
install the cooling pump by non-professionals as or air suction and affect the brake pump's
it is a precise hydraulic element, and the broken performance.
brake pump shall be returned to the 4. It is not allowed to operate the cooling pump
manufacturer and repaired by professionals; under maximum pressure, maximum speed
after repair, cooling pump shall perform the test or overloaded circumstances, otherwise, it
of airtightness and volume efficiency in order to may affect the service life.
guarantee its performance and normal
application. 5. Oil temperature is required to be kept lower
than 80°C, otherwise it may affect the
Installation requirements for brake pump: viscosity of hydraulic oil and also accelerate
the oxidation of fluid.
1. You shall understand fully about rotating
direction of cooling pump as per the
requirements of the complete machine before
installation of the cooling pump.
2. There is no debris at the inlet and outlet of
radiator pump, and no damage on the flat
surface of inlet and outlet so as to ensure the
sealing performance of O-ring.
3. Before assembling the cooling pump, check
whether the mounting hole depth of engine
spline is larger than the pump's shaft
extension length or not, in order to prevent
from culmination phenomenon, pump burnt
out. Installation of spline shaft and spline
housing shall be free without stuck.

Precautions for maintenance of cooling

pump:

1. Apply a moderate force during assembly and

disassembly of cooling pump, and rude
operation is not allowed; user shall not open
the brake pump without manufacturer's
consent, otherwise they cannot guarantee
their product performance.
 4-63
November 17, 2017 Structure Function Principle
CLG835H Hydraulic Cooling System

Cooling Motor

Main Technical Parameters

Items Parameters Service conditions Remarks

Theoretical displacement 23.76ml/r / /
500r/min
Min. / max. speed / Fan-set speed 1700r/min
2500r/min
Rated / max. pressure 17Mpa/21Mpa / /
Volume efficiency 0.92 / /
Operating fluid Anti-wear hydraulic oil HM46/HV46 /
Direction of rotation Turnable in both directions / /

Structure and Working Principle of Outline of cooling motor

Cooling Motor

The cooling motor, as an actuator of system, is

used to pull the fan to rotate, so that the
hydraulic pressure from cooling pump is
converted into mechanical energy of fan. The
motor used by this system is a swash plate and
axial plunger type, which features high level of
withstanding pressure, long service life and low
noise and so on. Overall structure of motor:
Outline of cooling motor

2
3
P28H00874

1. Oil return port 3. Housing oil return port

2. Oil inlet

P28H00873
4-64
Structure Function Principle November 17, 2017
Hydraulic Cooling System CLG835H

Sectional drawing of cooling motor

2
5 12

6 4

9
17 1
28 26 24
25 32 16 14
23 11 31
33
3
8 27
20 18 7 29
13 21 19
30

10

22
15 P28H00872

1. Bushing 10.Gear 19.Seal ring 28.Shaft

2. Plug 11.Roller bearing 20.Roller bearing 29.Relief valve group
3. Electromagnetic control parts 12.Bolt 21.Bearing 30.Guide ring
4. Valve spool 13.Lock nut 22.Circlip 31.Drive shaft
5. Solenoid valve control parts 14.Washer 23.Circlip 32.Pin
6. Motor housing 15.Gasket 24.Shaft seal ring 33.Relief valve group
7. Motor (lower)end face 16.Shaft seal ring 25.Wedge
8. Motor (upper)end face 17.Seal ring 26.Motor housing
9. Gear 18.Washer 27.Relief valve group
 4-65
November 17, 2017 Testing and Adjustment
CLG835H Work Hydraulic System Test

Testing and Adjustment

Work Hydraulic System Test

Pressure Release of Work Hydraulic System

Sudden movement of vehicle or release of oil pressure may cause injury to the persons around
the vehicle.
Perform the following procedures to avoid the possible injury:

Figures Operation instructions

1. Park the vehicle on flat and level ground,
transfer vehicles and workers working around,
place the work implements on the ground, and
pad the wheel and install the lock device of
steering frame;

P18H00066

P18H00067

2. Only operators other than other persons are

allowed to work around vehicle;
3. Pull up the emergency brake handle to apply
parking brake;
4-66
Testing and Adjustment November 17, 2017
Work Hydraulic System Test CLG835H

Figures Operation instructions

4. Turn the starting switch to "OFF" position

P18H00069
5. Operate the control lever of the work
implement the floating lowering & lifting of
boom and dumping and tilting back of bucket.
Release pressure of work hydraulic system;

Pressure Test of Work Hydraulic System

Work hydraulic system for this model has set fast-connection pressure measuring connector or pressure
measuring plug at all key points of circuits for the convenience to detect hydraulic system pressure and
to understand the working condition and detection and maintenance of the fault on the hydraulic system.
The followings are the detailed explanations and the instructions of these pressure measuring points.

When installing testing instruments for hydraulic system, perform the pressure detection and
adjustment and the pressure release of hydraulic system. The pressure detection and adjustment
shall be performed by professionals; non-professionals need consult from the professionals and
adjust strictly in accordance with instructions from the professionals, or adjustment is
prohibited.
 4-67
November 17, 2017 Testing and Adjustment
CLG835H Work Hydraulic System Test

Measuring point positions of work hydraulic system

Layout of the pressure measuring point position of the work hydraulic system

3
1

3 2

P28H00859

Description of measuring points of work hydraulic system

Pressure Description of Theoretical

Port
measuring pressure pressure Brief introduction for test
dimension
points measuring points MPa(psi)
Pressure The pressure measuring point is installed with
Pressure at the
measuring 18 (2610) M14×1.5-6H pressure measuring connector which can connect
working pump port
point 1 directly with the pressure gauge for measurement.
Remove the plug, install the pressure measuring
Pressure connector 44C0022 and O-ring 12V0497 to take
Pressure of boom
measuring 18 (2610) M14×1.5-6H the test; after test, remove the pressure measuring
cylinder big cavity
point 2 connector and the O-ring and re-assemble the
original plug.
Remove the plug, install the pressure measuring
Pressure Pressure of boom connector 44C0022 and O-ring 12V0497 to take
measuring cylinder small 18 (2610) M14×1.5-6H the test; after test, remove the pressure measuring
point 3 cavity connector and the O-ring and re-assemble the
original plug.
Remove the plug, install the pressure measuring
Pressure connector 44C0022 and O-ring 12V0497 to take
Pressure of bucket
measuring 20 (2900) M14×1.5-6H the test; after test, remove the pressure measuring
cylinder big cavity
point 4 connector and the O-ring and re-assemble the
original plug.
4-68
Testing and Adjustment November 17, 2017
Work Hydraulic System Test CLG835H

Inspection and adjustment for pressure of work hydraulic system

Test method

Tools required
Tool(s) Part description Standard Quantity

1 Measuring range of the pressure gauge 25MPa/3625psi 1

2 Pressure measuring connector 44C0022 1
3 O-ring 12V049 1

Figures Operation instructions

1. Connect the pressure gauge at pressure
measuring point 1 (as shown in figure);

1
P28H00860
2. Disassemble the plug at the position of
pressure measuring point 4, and install the
pressure measuring connector 44C0022 and
O-ring 12V049; connect the pressure gauge;
3. Start the machine with large throttle and
operate the bucket control lever to tilt back the
bucket with very slow speed till suppression;
pay attention to the value on the pressure
gauge of measuring point 4 during operation;
4 P28H00529
4. During step 3, when bucket is suppressed, the
value on pressure gauge of pressure
measuring point 1 & 4 shall be 18±0.3MPa
(2610±43.5psi) constantly

Generally, the pressure at oil outlet of working pump can be tested directly; at suppression, if the
pressure reaches 18±0.3MPa (2610±43.5psi), the pressure of the work hydraulic system is
considered to meet the requirements.
 4-69
November 17, 2017 Testing and Adjustment
CLG835H Work Hydraulic System Test

Work system pressure adjustment:

If value of pressure measuring point 1 is incorrect, adjust working pressure of the control valve main
safety valve (see adjustment steps of the control valve main safety valve for specific adjustment) to
make it reach 18 ± 0.3 MPa (2610±43.5psi).

Pressure test and adjustment of the control valve main safety valve
Control valve main safety valve location diagram

P28H00861

1. Main safety valve

Adjusting step:

If the pressure is nonconforming, adjust the control valve main safety valve by the following steps:
● Unscrew 1 main safety valve locknut.
● Rotate the adjusting stud for pressure adjustment (the adjusting stud rotates clockwise for pressure
increase and counterclockwise for pressure decrease).
● After adjust the stud, tighten the locknut.
● Test the pressure value according to the pressure test steps of work system.
Repeat the above operations till reaching the correct system pressure.
4-70
Testing and Adjustment November 17, 2017
Work Hydraulic System Test CLG835H

Pressure inspection and adjustment of bucket big cavity overload valve

Control valve bucket overload valve diagram

2 3

P28H00861

2. Bucket big cavity overload valve 3. Bucket small cavity overload valve

Test method

Tools required
Tool(s) Part description Standard Quantity
1 Measuring range of the pressure gauge 25MPa(3625psi) 1
2 Pressure measuring connector 44C0022 1
3 O-ring 12V049 1
 4-71
November 17, 2017 Testing and Adjustment
CLG835H Work Hydraulic System Test

Figures Operation instructions

1. Disassemble the plug at the position of
pressure measuring point 4, and install the
pressure measuring connector 44C0022 and
O-ring 12V049; connect the pressure gauge;
2. Start the machine and lift the boom to the
maximum position (when diesel engine and
hydraulic oil is under normal operating
temperature, the diesel engine will be in idle
running);
3. Operate the bucket control lever to make it in
the bucket tilting back position so that the
bucket will rotate to the maximum bucket tilting
back position;
4 P28H00529
4. The lever returns to the neutral position;
5. Operate the boom control lever to make it in
boom lowering position to lower the boom;
check the pressure gauge at the same time;
6. When taking step 5, the maximum pressure
value of pressure gauge at pressure measuring
point 2 shall be 20±0.3MPa (2900±43.5psi).

Adjusting step:

If the pressure is nonconforming, adjust the control valve bucket big cavity overload valve by the
following steps:
● Unscrew the locknut.
● Rotate the adjusting stud for pressure adjustment (the adjusting stud rotates clockwise for pressure
increase and counterclockwise for pressure decrease).
● After adjustment, tighten the locknut.
Repeat the operation above to check the adjusting pressure for incorrectness.
4-72
Testing and Adjustment November 17, 2017
Work Hydraulic System Test CLG835H

Pressure Inspection and Adjustment of Bucket Small Cavity Overload Valve

Refer to control valve bucket overload valve diagram.

Test method

Tools required
Tool(s) Part description Standard Quantity
1 Measuring range of the pressure gauge 25MPa(3625psi) 1
2 Pressure measuring connector 44C0022 1
3 O-ring 12V049 1

Figures Operation instructions

1. Install the test flange 04A2519 at the position
of pressure measuring point 1, and install the
pressure measuring connector 44C0022 and
O-ring 12V049; connect the pressure gauge;
2. Start the machine, and operate the boom
control lever to lift boom to horizontal position
(when the diesel engine and hydraulic oil are
1 under normal operating temperature, the diesel
engine will be in idle running);
3. Operate the bucket control lever to make the
bucket in maximum dumping position;
4. The control lever returns to the neutral position;
5. Operate the boom control lever to make it in
P28H00530 boom lifting position to lift the boom; check the
pressure gauge at the same time;
6. When taking step 5, the maximum pressure
value of pressure gauge at pressure measuring
point 1 shall be 14±0.3MPa (2030±43.5psi).

Adjusting step:

If the pressure is nonconforming, adjust the control valve bucket small cavity overload valve by the
following steps:
● Unscrew the locknut.
● Rotate the adjusting stud for pressure adjustment (the adjusting stud rotates clockwise for pressure
increase and counterclockwise for pressure decrease).
● After adjustment, tighten the locknut.
Repeat the operation above to check the adjusting pressure for incorrectness.
 4-73
November 17, 2017 Testing and Adjustment
CLG835H Work Hydraulic System Test

Boom Cylinder Test

Temperature of test oil: 50±5°C

P18H00106

Test items Test method Criterion

Adjust the pressure of test system to make the
tested hydraulic cylinder start without load
The hydraulic cylinder operates smoothly without
Commissioning condition, and conduct full stroke reciprocating
being stuck.
motion for more than 3 times to exhaust the air
from the hydraulic cylinder.
Stop the tested hydraulic cylinder piston at both
ends of stroke respectively (single-acting
External leakage and damaged parts are not
Pressure test hydraulic cylinder stopped at the limit position of
allowed.
stroke), then apply 1.5 times rated pressure of oil
to the working cavity and keep for 10s.
Supply oil to the working cavity of tested
Internal leakage hydraulic cylinder, then increase the pressure to
Internal leakage ≤0.28ml/min
test the working pressure, measure the oil leakage at
port of small cavity for 2min.
Make the tested hydraulic cylinder piston stop at
Stroke test the limit positions at both ends of stroke 727mm~729mm
respectively, then measure its stroke length.
4-74
Testing and Adjustment November 17, 2017
Work Hydraulic System Test CLG835H

Bucket Cylinder Test

Temperature of test oil: 50±5°C

P18H00106

Test items Test method Criterion

Adjust the pressure of test system to make the
tested hydraulic cylinder start without load
The hydraulic cylinder operates smoothly without
Commissioning condition, and conduct full stroke reciprocating
being stuck.
motion for more than 3 times to exhaust the air
from the hydraulic cylinder.
Stop the tested hydraulic cylinder piston at both
ends of stroke respectively (single-acting
External leakage and damaged parts are not
Pressure test hydraulic cylinder stopped at the limit position of
allowed.
stroke), then apply 1.5 times rated pressure of
oil to the working cavity and keep for 10s.
Supply oil to the working cavity of tested
Internal hydraulic cylinder, then increase the pressure to
Internal leakage ≤0.30ml/min
leakage test the working pressure, measure the oil leakage
at port of small cavity for 2min.
Make the tested hydraulic cylinder piston stop at
Stroke test the limit positions at both ends of stroke 519mm~521mm
respectively, then measure its stroke length.
 4-75
November 17, 2017 Testing and Adjustment
CLG835H Steering Hydraulic System Test

Steering Hydraulic System Test

Loader steering hydraulic system has set fast-connection pressure measuring connector or pressure
measuring plug at all key points of circuits for the convenience of detecting hydraulic system pressure
and understanding the detection and maintenance of the steering condition and fault of the hydraulic
system. The followings are the detailed explanation and the instructions of these pressure measuring
points.

When installing testing instruments for hydraulic system, perform the pressure detection and
adjustment, pressure release “mounting location and functional structure of hydraulic oil
tank”should be operated. The pressure detection and adjustment shall be performed by
professionals; non-professionals need consult from the professionals and adjust strictly in
accordance with instructions from the professionals, or adjustment is prohibited.

Measuring Point Position of Steering Hydraulic System

Layout of all measuring point position of steering hydraulic system

2
1

P28H00496

1. Right steering measuring point 2. Left steering measuring point

4-76
Testing and Adjustment November 17, 2017
Steering Hydraulic System Test CLG835H

Description of Measuring Points Of Steering Hydraulic System

Description
Pressure
of pressure Theoretical Port
measuring Testing steps
measuring pressure dimension
points
points
Remove the plug, install the pressure measuring
Pressure Right steering
17.2 MPa connector 44C0022 and O-ring 12V0497 to take the
measuring measuring M14×1.5-6H
(2494psi) test; after test, remove the pressure measuring
point 1 point
connector and re-assemble the original plug.
Remove the plug, install the pressure measuring
Pressure Left steering
17.2 MPa connector 44C0022 and O-ring 12V0497 to take the
measuring measuring M14×1.5-6H
(2494psi) test; after test, remove the pressure measuring
point 2 point
connector and re-assemble the original plug.

Pressure Testing and Adjustment of Steering Hydraulic System

Testing method

Tools required
Tool(s) Part description Standard Quantity
1 Measuring range of the pressure gauge 25MPa/3625psi 1

Figures Operation instructions

1. Install the pressure gauge in the pressure
measuring point shown in the Figure; (pressure
gauge (range 25MPa/3625psi))

P28H00814
 4-77
November 17, 2017 Testing and Adjustment
CLG835H Steering Hydraulic System Test

Figures Operation instructions

2. Start machine and operate the steering wheel
to make machine turn to maximum steering
angle slowly and suppress the steering.

P18H00110

P18H00111
3. During the process of step 2 suppress steering,
the pressure value of pressure gauge at
pressure measuring point shall be
17.2±0.3MPa (2494±43.5psi) constantly.

P18H00112
4-78
Testing and Adjustment November 17, 2017
Steering Hydraulic System Test CLG835H

Steering Cylinder Test

Temperature of test oil: 50±5°C

P18H00113

Test items Test method Criterion

Adjust the pressure of test system to make the tested
hydraulic cylinder start without load condition, and conduct full The hydraulic cylinder operates
Commissioning
stroke reciprocating motion for more than 3 times to exhaust smoothly without being stuck.
the air from the hydraulic cylinder.
Stop the tested hydraulic cylinder piston at both ends of stroke
respectively (single-acting hydraulic cylinder stopped at the External leakage and damaged parts
Pressure test
limit position of stroke), then apply 1.5 times rated pressure of are not allowed.
oil to the working cavity and keep for 10s.
Supply oil to the working cavity of tested hydraulic cylinder,
Internal
then increase the pressure to the working pressure, measure Internal leakage ≤0.13ml/min
leakage test
the oil leakage at port of small cavity for 2min.

Make the tested hydraulic cylinder piston stop at the limit

Stroke test positions at both ends of stroke respectively, then measure its 419mm~421mm
stroke length.
 4-79
November 17, 2017 Testing and Adjustment
CLG835H Brake System Test

Brake System Test

When installing testing instruments for brake system, the system pressure shall be released
The following pressure testing and adjustment shall be performed by professionals; non-
professionals shall consult from the professionals and adjust in strict accordance with
instructions from the professionals, or adjustment is prohibited.

Pressure Measuring Points Layout of Brake System

Brake system measuring points diagram

1
3

P28H00919

1. Front axle brake oil pressure output 2. Rear axle brake oil pressure output 3. Service brake accumulator oil
from foot brake valve from foot brake valve pressure

Description of Pressure Measuring Points of Brake System

Pressure mea- Description of pres- Theoretical Interface

Test specification
suring point sure measuring point pressure value dimension
Pressure It can be measured directly by
Foot brake valve
measuring 4.8±0.4Mpa R1/8×26 connecting the pressure gauge to the
output pressure
point 1 & 2 pressure measuring connector.
Pressure It can be measured directly by
Foot brake valve 24° cone
measuring 12.8-15.9Mpa connecting the pressure gauge to the
output pressure M18×1.5 -6g
point 3 pressure measuring connector.
4-80
Testing and Adjustment November 17, 2017
Brake System Test CLG835H

Brake Valve Test

Testing tools

One pressure gauge with range of 10MPa and one hydraulic stand.

Testing procedure

P port of brake valve is connected with power source of hydraulic stand, A port of brake valve is
connected onto the brake (the pressure gauge (10MPa) is connected onto oil line between P port of
brake valve and the brake), and T port of the brake valve is connected with the oil tank of hydraulic
stand. Start the hydraulic stand, depress the brake valve pedal to the maximum travel after refilling the
accumulator in the hydraulic stand, check whether the testing data of the pressure gauge is within the
range of setting pressure of brake valve: 48.3±3.5 Bar and whether the brake valve is normal.

Users can not remove and install the internal parts of brake valve on their own without
authorization of manufacturer LiuGong, otherwise, LiuGong will not be liable for the service of
quality assurance.
 4-81
November 17, 2017 Testing and Adjustment
CLG835H Brake System Test

Charge Valve Test

Testing tools

One pressure gauge with range of 20MPa and one hydraulic stand.

Testing procedure

Connect the charge valve into the hydraulic system in hydraulic stand. Connect the pressure gauge
20MPa between A1 & A2 oil ports of charge valve and the connecting oil pipes of its corresponding
accumulator. Start the hydraulic stand, check whether reading of the pressure gauge reaches range of
155.1±3.5bar and whether the upper charging pressure of the charge valve is correct; depress the brake
valve pedal to release pressure of the accumulator, release the brake valve pedal after reading of
pressure gauge decreases to 125.8±3.5bar. The lower charging pressure of the charge valve is correct
as reading of the pressure gauge increases to 155.1±3.5bar continuously.

Users can not remove and install the internal parts of charge valve on their own without
authorization of manufacturer LiuGong, otherwise, LiuGong will not be liable for the service of
quality assurance.
4-82
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal and Installation

Work Hydraulic System
Removal and Installation of Hydraulic Oil Tank Assembly

Removal for Hydraulic Oil Tank Assembly

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13#, 15#, 17#, 22#, 24#, 30#, 36#, 41# 8
2 Sling Set 1
3 Shielding film Roll 1
4 Oil collecting basin Piece 1
Other information
Weight of oil tank 111kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
 4-83
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Removal steps

Figures Operation instructions

1. Loosen the plug at the top of hydraulic oil tank
respirator and press the bleed screw in it to
bleed the air;

P18H00121
2. Find the drain plug at bottom of left oil tank at
rear frame, and then wipe clean the
circumference of drain plug;
3. Place a clean oil basin below the drain plug for
collecting the hydraulic oil; screw off the drain
plug;

Tools: Oil basin, open-end wrench 30#

P18H00122
4. After the hydraulic oil in the hydraulic oil tank is
drained, hang the lug welded on both sides of
the hydraulic oil tank with a lifting rope;

Tools: Lifting rope

P18H00123
4-84
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Figures Operation instructions

5. Loosen the oil suction hose clamp of the gear
pump located at lower part of back of oil tank,
remove the oil suction hose and mask the oil
ports; remove the oil suction hose joint of
secondary steering pump (option) and mask oil
ports.
Tools: Open-end wrench 8#, 36#

P18H00124

6. Remove the oil return hose located at upper

1 2 5 part of back of oil tank, mask oil ports;
3 4 6

Tools: Open-end wrench: 13#, 17#, 22#, 24#, 32#,

7
36#, 41#

P18H00125

7. Unscrew out the 8 fastening bolts on both

edges of the hydraulic oil tank side;

Tools: Open-end wrench 15#

P18H00126

8. Lift the hydraulic oil tank slowly away; note that

the lifting process must be smooth, it is not
allowed to damage the other areas of the
Machine;
Tools: 2T \4410lb traveling crane, lifting rope
 4-85
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Installation for Hydraulic Oil Tank Assembly

Figures Operation instructions

1. Check the oil tank for impurities, if any, it
should be cleaned before installation
2. Install one end of oil suction hose to the oil
suction steel pipe with clamp and install the
steel pipe to the oil suction of oil tank.

P18H00127

3. Hang the oil tank with traveling crane and

install the other end of suction hose to the oil
suction steel pipe of pump, meanwhile pre-
tighten the mounting bolt of oil tank, and tighten
the oil suction hose clamp.

Tools: Open-end wrench 8#, 36#

P28H00918

4. Connect hoses to the oil ports of oil tank

according to the connection in the removal
steps
4-86
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal of Working Pump Assembly

Removal of Working Pump

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 16#, 18# 2
2 Inner hexagon spanner 8# 1
3 Shielding film 1
4 Oil collecting basin 1
5 Sling 1
Other information
Weight of working pump 26kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
 4-87
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Removal steps

Figures Operation instructions

1. Park the complete vehicle and remove the seat
by referring to the section of Removal and
Installation of Cab Seat.
2. Remove 4 captive bolts (1) of the seat
mounting bracket. Remove the bracket.
3. Remove 8 mounting bolts (2) of bottom plate.
1 Remove the bottom plate.

P28H00406

P28H00407
4. Remove the flange mounting bolt (3) of the oil
inlet pipe joint at left of the pump, remove the
oil pipe, mask the oil port and make mark on
the oil pipe.

P28H00450
4-88
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Figures Operation instructions

5. Remove the wire harness connector (4) at right
of the pump and unplug the wire harness.
6. Remove the flange mounting hex bolt (5) of the
oil outlet pipe joint at right of the pump, remove
5 4 the oil pipe, mask the oil port and make mark
on the oil pipe.

P28H00451
7. Remove mounting bolt (6) of the pump, lift out
the working pump, mask the oil port and place
it at a clean and safe place.

P28H00452
 4-89
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Installation of the Working Pump

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Check the pump for damage, rusting and if
qualified, hang the pump to the mounting
position and install the bolt (6) to the
transmission, tighten the mounting bolt of the
pump with torque 120±15Nm.

P28H00452

2. Install the flange mounting bolt (3) of the oil

inlet pipe joint at left of the pump with tightening
torque 90±12Nm.
3. Connect the wire harness connector (4) at right
3 4 of the pump.

P28H00451
4. Install the flange mounting hex bolt (5) of the oil
outlet pipe joint at right of the pump with
tightening torque 90±12Nm.

P28H00450
4-90
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Figures Operation instructions

5. Install the plate and seat frame.

P28H00407

P28H00406
 4-91
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Removal and Installation of Boom Cylinder

Removal of Boom Cylinder

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13#, 16#, 18#, 27# 4
2 Copper bar 1
3 Shielding film 1
4 Oil collecting basin 1
5 Sling 1
Other information
Weight of boom cylinder 101kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
4-92
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Park the machine in horizontal hard ground →lay flat the bucket →pull the hand brake →shut
down→release the pressure in the boom cylinder

Removal steps (take the left boom cylinder as an example, and the removal steps of the right
boom cylinder are the same as those of the left boom cylinder):

Figures Operation instructions

1. Place an oil collecting container under the
bottom of vehicle to prevent hydraulic oil from
polluting ground;
2. Sleeve the lifting rope conforming to safety
requirements on the boom cylinder and hang
the boom cylinder with a traveling crane.
3. Loosen the hose clamp bolt connected with the
steel tube below the boom cylinder big and
small cavities, remove the hose assembly and
mask the hose joint.
P18H00141

4. Remove the fastening bolt of the rear pin shaft

of the boom cylinder and knock out the pin
shaft with a copper bar.
CAUTION: The boom shall be supported
firmly before removing the oil cylinder to
prevent the boom from falling.

P28H00509

5. Remove the bolt tightening the front pin shaft of

the boom and knock out the pin shaft with a
copper bar;
6. Lift out the boom cylinder from the frame and
place it on a level ground;
CAUTION: The boom shall be supported
firmly before removing the oil cylinder to
prevent the boom from falling.

P28H00510
 4-93
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Figures Operation instructions

7. Remove steel tube clamp of the boom cylinder
big and small cavities and place it together with
the removed bolts and nuts;
P18H00142

8. Remove the fastening bolt of the steel tube of

the boom cylinder big and small cavities and
remove the steel tube; check whether the O-
ring is aged or damaged and replace it in time,
mask the oil ports of steel tube.
P18H00143
9. Mask the boom cylinder big and small cavities
oil ports to avoid pollution.

Installation of Boom Cylinder

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install the steel tube of the boom cylinder big
and small cavities to the cylinder and tighten 8
mounting bolts with the tightening torque
52±6Nm.
2. Install the steel tube clamp, fastening bolts,
shims, nuts with the tightening torque:
26±4Nm.
3. Lift and place the cylinder to the proper position
with proper sling
4. Align the pin hole of boom cylinder piston rod
connecting fork with that of boom, and then
insert the pin shaft into the pin hole, tighten
mounting bolt of pin shaft with torque
310±45Nm.

P28H00510
4-94
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Figures Operation instructions

5. Install rear pin shaft of boom cylinder, and
tighten mounting bolt of pin shaft with torque
90±12Nm.

P28H00509

6. Connect the hoses of boom cylinder big and

small cavity, tighten the clamp bolt to 72±6Nm.

P18H00147

7. Start the machine, and run it at idle speed,

slowly lift and lower the boom cylinder for 3-5
times to bleed the air in the cylinder and line.
8. Fill lubricant for pin shaft.
9. Check whether the hydraulic oil level is normal,
and if not, please fill the hydraulic oil to the
specified level.
 4-95
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Disassembly and Assembly of The Boom Cylinder

Disassembly of Boom Cylinder

Exploded view of boom cylinder

19
20 18
21 17
11
16
11
10

15
4
6
5
6
7
22 3

23
12
13
14
9
1
2
22 14
P28H00902

1. Cushion 6. Support ring 11.Support ring 16.Seal ring 21.Washer

2. Cover 7. O-ring 12.Cushion 17.Seal ring 22.Rubber ring
3. Locknut 8. Piston rod 13.Cover 18.Dust ring 23.Shaft bushing
4. Piston 9. Cylinder block 14.Bolt 19.Snap ring
5. Seal ring 10.Cylinder head 15.O-ring 20.Bolt
4-96
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Disassembly procedures of boom cylinder

Figures Operation instructions

1. Pull out one notch of the piston rod (when the
wrench and the rod do not interfere with each
other), then screw off the connecting bolt 20
from the cylinder head 10 with wrench.
Note: Tightening torque for bolt 20: 150±20
N.m;

P28H00883 Tool: Open-end wrench: 30mm.

2. Pull out the piston rod 8 from the oil cylinder
block 9 and remove the piston locknut 3 with
wrench; remove the piston and the cylinder
head.
Note: Tightening torque: 1400±100 N.m;

P28H00884

3. Remove the support ring (6) at both ends of

5
piston 4 along the support ring notch, stretch
the seal ring (5) with straight screwdriver to a
6
deformed state and remove it, then remove the
O-ring. (Removal of seal ring 5 is destructive).
6

Tool: Straight screwdriver

P28H00885
 4-97
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Disassembly procedures of boom cylinder

Figures Operation instructions

4. Remove the O-ring (15), support ring (11), seal
15 ring (16) and (17), dust ring (18) and retainer
(19) from the cylinder head 10.
17
11

18

16 19

P28H00886
5. Remove rubber ring (22) and bushing (23) from
the cylinder head.

22

23 P28H00887
4-98
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal and Installation of Bucket Cylinder

Removal of Bucket Cylinder

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 13#, 15# 2

2 Copper bar 1
3 Shielding film 1
4 Oil collecting basin 1
5 Sling 1

Other information
Weight of bucket cylinder 105.5kg

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.

Place the machine in horizontal hard ground →lay flat the bucket →pull the hand brake →shut
down→release the pressure in the rotating bucket cylinder
 4-99
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

See the section of Machine Placement for parking the machine.

Figures Operation instructions

1. Place an oil collecting container under the
bottom of vehicle to prevent hydraulic oil from
polluting ground;
2. Remove the bucket pin lubrication line; remove
the harness line of front frame;
3. Hold the bucket cylinder with lifting rope and
traveling crane;
4. Loosen the hose clamp bolt connected with the
bucket cylinder small cavity oil port, and
remove the hose assembly and shield the hose
joint.

P28H00512

5. Loosen the hose clamp bolt connected with the

steel tube of the bucket cylinder big cavity oil
port and remove the hose assembly and shield
hose joint.

P18H00178
6. Remove the fastening bolt of the front and rear
pin shaft of the bucket cylinder and knock out
the pin shaft with a copper bar;

P18H00179

7. Lift out the bucket cylinder from the frame to

place it on a level ground.
8. Remove the fixing clamp and fastening bolt of
steel tube of the bucket cylinder big cavity and
remove the steel tube; check whether the O-
ring is aged or damaged and replace it in time,
mask the oil ports of steel tube.
P18H00180

9. Mask the oil ports of the bucket cylinder big

and small cavity to avoid pollution.
4-100
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Installation of Bucket Cylinder

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install the steel tube of bucket cylinder big
cavity and tighten the bolt to 52±6Nm; install
the steel tube clamp and tighten the bolt to
52±6Nm;

P18H00181
Check whether the O-ring is aged or damaged
and replace it in time
2. Hang the bucket cylinder to the mounting
position with sling.
3. Install the rear pin of bucket cylinder, and
tighten the pin shaft mounting bolt to 90±12Nm.
4. Install the front pin of bucket cylinder, and
tighten the pin shaft mounting bolt to 90±12Nm.
P18H00182

5. Connect the hoses of bucket cylinder big and

small cavity, tighten the clamp bolt to 52±6Nm

P18H00183

P18H00184
 4-101
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Figures Operation instructions

6. Install the proximity switch wire harness line of
bucket cylinder.

P18H00185

7. Install the centralized lubrication system joint.

P18H00186

8. Start the machine, and run it at idle speed,

slowly deploy and retract the bucket for 3-5
times to bleed the air in the cylinder and line.
9. Check whether the hydraulic oil level is
qualified, and if not, please fill the hydraulic oil
to the specified level
4-102
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Disassembly and Assembly of Bucket Cylinder

Disassembly of Bucket Cylinder

Exploded view of bucket cylinder

19
10

18
21 16 19
22 15
14
13
12
13

20
22
22
17
11 8
7
3 5
7
1 6
2 4

23
24 25
9
19

26
19 P28H00900

1. Cushion 7. Support ring 12.Seal ring 17.Cylinder head 22.Washer

2. Cover 8. Piston 13.Support ring 18.Shaft bushing 23.Cushion
3. Bolt 9. Cylinder block 14.Seal ring 19.Rubber ring 24.Cover
4. Locknut 10.Piston rod 15.Dust ring 20.Bolt 25.Bolt
5. Seal ring 11.O-ring 16.Snap ring 21.Bolt 26.Shaft bushing
6. O-ring
 4-103
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Removal procedures of bucket cylinder

Figures Operation instructions

1. Pull out one notch of the piston rod (when the
wrench and the rod do not interfere with each
other), then screw off the connecting bolt 20
from the cylinder head 17 with wrench;
Note: Tightening torque for bolt 20: 150±20N.m;

Tool: Open-end wrench 30mm

P28H00888
2. Pull out the piston rod 10 from the oil cylinder
block 9 and remove the piston locknut 4 with
torque wrench; remove the piston and the
cylinder head;
Note: Tightening torque for locknut 4: 1400±100
P28H00889 N.m.

3. Remove the support ring (7) at both ends of

5
piston 8 along the support ring notch, stretch
the seal ring (5) with straight screwdriver to a
7
deformed state and remove it, then remove the
O-ring. (Removal of seal ring 5 is destructive).
7

Tool: Straight screwdriver

P28H00885
4-104
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal procedures of bucket cylinder

Figures Operation instructions

4. Remove the O-ring (11), support ring (13), seal
11 ring (12) and (14), dust ring (15) and retainer
(16) from the cylinder head.
14
13

15

12 16

P28H00886
5. Remove rubber ring (19) and bushing (26) from
the cylinder head.

26

19 P28H00887
 4-105
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Removal and Installation of Control Valve Assembly

Removal of Control Valve Assembly

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13#, #16#, 18# 3
2 Inner hexagon spanner 8# 1
3 Wire cutter 1
4 Shielding film 1
5 Oil collecting basin 1
Other information
Weight of control valve 48kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
4-106
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal steps:

Figures Operation instructions

1. Lift the boom and jack up the boom cylinder with
its support.
2. Operate the handle for unloading the boom
cylinder and the bucket cylinder.

P28H00419

3. Remove 4 mounting bolts of the cover plate.

Remove the cover plate.

P28H00420

4. Remove 4 pilot oil pipes and correctly make

corresponding marks. Wrap the oil pipes and
control valve corresponding to the pilot oil ports
with clean plastic bags.

1
P28H00858
 4-107
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Figures Operation instructions

5. Remove the control valve oil inlet pipe (1), move
away the oil pipe, make marks and mask the oil
ports.
6. Remove the control valve oil return pipe (2),
move away the oil pipe and mask the oil ports.

2
1
P28H00854
7. Remove oil pipes (3) and (4) from the control
valve to bucket cylinder big and small cavities,
move away the oil pipes, mask the oil ports and
make marks.

P28H00855

8. Remove the tubes (5) and (6) from the control

valve to the boom cylinder big and small
cavities.

6
5

P28H00856
4-108
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Figures Operation instructions

9. Remove the retaining nut (7) of the control valve
and take out the control valve. Place it at a clean
and safe place.

7
P28H00857

Installation of Control Valve Assembly

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
installation. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install the captive bolt (7) of control valve.
2. Install the hoses from the control valve to the
boom cylinder big and small cavities.

7
P28H00857
 4-109
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Figures Operation instructions

3. Install the oil inlet pipe (3) and oil return pipe (4)
the control valve.
4. Install the oil pipes (5) and (6) from the control
valve to the bucket cylinder big and small
cavities.

6
5

P28H00856

P28H00855
5. Install the control valve oil inlet pipe (1).
6. Install the control valve oil return pipe (2).

2
1
P28H00854
7. Respectively connect 4 pilot pipes (1) with the
corresponding oil ports according to the marks.

1
P28H00858
4-110
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal and Installation of Pilot Valve Assembly

Removal of Pilot Valve Assembly

Tools required
Tool(s) Part description Standard Quantity
1 Open-end wrench 10#, 13#, 17#, 21#, 24# 5

Figures Operation instructions

1. Before removal, release the system pressure,
place the boom at the lowest position, and lay
the bucket on the ground.
2. Turn the pilot shut-off valve to the off-position
(vertical position).

CAUTION: When turning the handle to the

vertical position, the work implement will not
work when the driver operates the pilot lever.
Thus it can prevent accidents caused by mis-
ON operation of the work implement control lever.

3. Remove the cover plate of the handrail

assembly.
OFF

P28H00911
4. Unscrew the retaining nuts around the pilot
shut-off valve, remove the pilot shut-off valve
with joint and hose assembly from the U-base,
and place them well to spare.
5. Unscrew off 4 fastening bolts of the pilot valve
mounting board.

Tool: Open-end wrench 10#, 21#

P28H00912
 4-111
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Figures Operation instructions

6. Unscrew the bolts from the mounting board of
the clamps of pilot valve hoses on the rear right
side of the driver seat.

Tool: Open-end wrench 13#

P28H00913

7. Remove the pilot valve, mounting board, pilot

shut-off valve, hose assembly and hose joint
together from the cover hole of the hose clamp
mounting board, and place them to the bottom
of the cab.
8. Please mark the hose assembly connected to
the pilot valve and pilot shut-off valve
C respectively with: "Q_oil inlet of shut-off valve",
P "P_oil inlet of pilot valve", "T_return oil of pilot
B valve", "A_port A of pilot valve", "B_port B of
pilot valve", "C_port C of pilot valve", "D_port D
of pilot valve", the marks should be firm.
9. Remove the above hose assembly; mask oil
ports;

T
D Tool: Open-end wrench 17#, 24#
A Q
P28H00914
10. Remove the pilot valve from the bottom of the
cab and place it on the ground; shield the oil
ports.

Installation of Pilot Valve Assembly

Install the pilot valve assembly in reverse order of the removal steps of pilot valve assembly.
4-112
Removal and Installation November 17, 2017
Work Hydraulic System CLG835H

Removal and Installation of Pilot Oil Valve Assembly

Removal of Pilot Oil Valve Assembly

Figures Operation instructions

1. Respectively mark symbols "P1 port", "T port",
"PV port” on all the hose assemblies connected
with the pilot oil valve; the symbols shall be
firm.

PV
T

P1

P28H00915
2. Removal of 3 hoses: After screwing out the
hose by 1-2 circles with the open-end wrench,
knock down the joint position with the wrench
to completely relieve pressure of hydraulic oil,
screw out the hose, and shield the oil port.
Tools: Open-end wrench 17#, 24#
3. Screw off two bolts which fix the mounting plate
of the pilot oil valve mounting assembly on the
vehicle frame.
4. Take the pilot oil valve mounting assembly out
of the handrail box and shield the oil port.

P28H00915

Installation of Pilot Oil Valve Assembly

Install the pilot oil valve assembly in reverse order of the removal steps, in which, the assembling part of
hose shall be connected with 3 joints of the pilot oil valve according to the hose symbols without
connection in a wrong way.
 4-113
November 17, 2017 Removal and Installation
CLG835H Work Hydraulic System

Removal and Installation of Oil Filter

Removal of Oil Filter

Figures Operation instructions

1. Respectively mark the symbol "oil inlet 1" , "oil
outlet 2” on hose assemblies at both ends of oil
filter; the symbols shall be firm;

P28H00916
2. Removal of hose: after screwing out the hose
by 1-2 circles with the open-end wrench, knock
down the joint position with the wrench to
completely relieve pressure of hydraulic oil,
screw out the hose, and shield the oil port;
Tool: Open-end wrench 24#
3. Screw off the 2 fastening bolts of the high-
pressure oil filter mounting assembly;
4. Take out the high-pressure oil filter mounting
assembly and shield the oil port.

P28H00916

Installation of Oil Filter

Install the oil filter in reverse order of the removal steps. When assembling, make sure that the arrow
direction of oil filter is consistent with oil lines. Assembling part of hose shall be connected with the 2
joints of high-pressure oil filter according to the hose symbols without connection in a wrong way.
4-114
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Steering Hydraulic System

Removal and Installation of Steering Pump Assembly

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 16#, 18# 2
2 Inner hexagon spanner 1
3 Shielding film 1
4 Oil collecting basin 1
5 Sling 1

Other information
Weight of the steering pump 26kg

Removal of Steering Pump Assembly

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
 4-115
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Figures Operation instructions

1. Park the complete vehicle and remove the seat
by referring to the section of Removal and
Installation of Cab Seat.
2. Remove 4 captive bolts (1) of the seat
mounting bracket. Remove the bracket.

P28H00406
3. Remove 8 mounting bolts (2) of bottom plate.
Remove the bottom plate.

P28H00407

P28H00450
4-116
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Figures Operation instructions

4. Remove the flange mounting bolt (3) of the oil
inlet pipe joint of the pump, remove the oil pipe,
mask the oil port and make mark on the oil
pipe.

P28H00408
5. Remove the flange mounting hex bolt (4) of the
oil outlet pipe joint of the pump, remove the oil
pipe, mask the oil port and make mark on the
4 5 oil pipe.
6. Remove the wire harness connector (5) on the
steering pump and unplug the wire harness.
7. Remove mounting bolt (6) of the pump, lift out
6 the steering pump, mask the oil port and place
it at a clean and safe place.

P28H00409
 4-117
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Installation of Steering Pump Assembly

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install the mounting bolt (6) of pump.
2. Install the flange mounting bolt (4) of the oil
outlet pipe joint of the pump with tightening
4 5 torque 52±7N m.
3. Install the harness connector (5).

P28H00409

4. Install the flange mounting bolt (3) of the oil

inlet pipe joint of the pump with tightening
torque 90±12N m.

P28H00408
4-118
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Figures Operation instructions

5. Install 8 mounting bolts (2) of bottom plate.
6. Install 4 captive bolts (1) of the seat mounting
bracket.
7. Install the seat by referring to the section of
Removal and Installation of Seat.
2

P28H00407

P28H00406
 4-119
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Removal and Installation of Metering Pump

Removal of Metering Pump

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13#, 16#, 18#, 27#, 32# 5
2 Cross screwdriver 1
3 Shielding film 1
Other information
Weight of the metering pump 8.52kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
4-120
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Removal steps

Figures Operation instructions

1. Remove the hose joints from the metering
pump (After screwing out the hose by 1-2
circles with the wrench, knock the joint position
with the wrench to completely relieve pressure
of hydraulic oil, remove the hose), make marks
and mask the oil ports, remove the hose.

P28H00383
2. Remove the mounting screw of the steering
column trim cover and remove the trim cover.

P28H00384
3. Remove bolts fixing the metering pump on the
steering column. Remove the metering pump
and place it in a safe and clean space.

P28H00385
 4-121
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Installation of Metering Pump

Figures Operation instructions

4. Install the metering pump assembly on the
complete vehicle and tighten the mounting
bolts at bottom of the metering pump and
steering column.

CAUTION: When installing, make sure that

metering pump is concentric with steering
column and there shall be clearance in axial
direction to avoid jacking of spool. Check
whether it is turned flexibly after installation.

P28H00385
5. Install the mounting screw of the steering
column trim cover.

P28H00384

6. Install hose joints on the metering pump and

the tightening torque of bolt is 63±3Nm.

P28H00383
4-122
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Disassembly and Assembly of Metering Pump

Disassembly of Metering Pump

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13# 1
2 Inner hexagon spanner 1
3 Vise 1

Figures Operation instructions

1. Fix the metering pump on the vise.
2. Remove 7 bolts at the bottom.

P28H00386

P28H00387
 4-123
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Figures Operation instructions

3. Take out the part (1).
4. Take out the part (2).

P28H00388

P28H00389

P28H00390
4-124
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Figures Operation instructions

P28H00391

5. Loosen the metering pump, after adjustment,

fix the metering pump with vise.
6. Unscrew the captive bolt using the inner
hexagon spanner. Take down the cover plate.

P28H00392

P28H00393
 4-125
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Figures Operation instructions

7. Remove the metering pump from the vise. Take
out gasket group (3).
8. Take out the part (4).

P28H00394

P28H00395

P28H00396

P28H00397
4-126
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Assembly of Metering Pump

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install parts and components of the metering
pump in the reverse order of removal.
Tightening torque of bolt is: 52±7N m.

P28H00398

P28H00399

P28H00400
 4-127
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Figures Operation instructions

P28H00401

P28H00402

P28H00403

P28H00404
4-128
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Removal and Installation of Priority Valve

Removal of Priority Valve

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13#, 18#, 27#, 32#, 36# 5
2 Shielding film 1
3 Oil collecting basin 1
Other information
Weight of the priority valve 2.3kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.
 4-129
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Removal steps

Figures Operation instructions

1. Start the complete vehicle and turning the
vehicle right to the limit state. Place the oil
collecting basin under the vehicle.

P28H00412

2. Remove 5 oil port joints (1) from the priority

valve. Remove the oil pipe, make marks and
1 mask the oil ports.
3. Remove the mounting bolts (2) from the priority
2 valve. Remove the priority valve. Place it at a
clean and safe place.

P28H00413

P28H00414
4-130
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Installation of Priority Valve

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install 5 oil port joints of the priority valve.

P28H00415
2. Install the mounting bolts of the priority valve.

P28H00485
3. Install the joint hoses of the priority valve, the
tightening torque is 52±5Nm.

P28H00484
 4-131
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Disassembly and Assembly of the Priority Valve

Disassembly of the Priority Valve

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 24#, 27#, 32# 3

Figures Operation instructions

1. Screw off all joints on the valve.

P28H00415

P28H00416

2. Remove the spool plug, take out the spool,

spring, etc.

P28H00417
4-132
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Figures Operation instructions

P28H00418

Assembly of the Priority Valve

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Install the spring, spool and spool plug in
sequence.

P28H00418
2. Install 5 oil port joints of the priority valve.

P28H00415
 4-133
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Removal and Installation of Steering Cylinder

Removal of Steering Cylinder

Tools required
Tool(s) Part description Standard Quantity
1 Wrench 13#, 15#, 27# 3
2 Copper bar 1
3 Shielding film 1
4 Oil collecting basin 1
5 Sling 1
Other information
Weight of steering cylinder 23kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Hydraulic oil pressure and hot oil may cause personal injury or even death.
There may be residual hydraulic oil with pressure in the hydraulic system after the engine stops.
Release the residual pressure before repairing the hydraulic system, otherwise the serious
personal injury or even death may be caused.
Make sure that all the work implements have been lowered down and the hydraulic oil has cooled
before removing any component or pipe. The oil filter cover can not be removed until the engine
stopped and the filter cover is cool enough that can be touched by bare hand.

Place the machine in horizontal hard ground →lay flat the bucket →pull up the hand brake →shut
down→fix the front and rear frame by bumper
4-134
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Removal steps (Take right steering cylinder as example, and the removal steps of left steering
cylinder is the same)

Figures Operation instructions

1. Loosen and remove steering cylinder big cavity
hose and mask the oil ports;

P28H00535
2. Loosen the steering cylinder small cavity hose
joint by wrench and remove the hose joint by
gentle knockdown; mask the oil ports;

P18H00254
3. Remove the fastening bolt of rear pin shaft of
steering cylinder and knock out the pin shaft by
copper bar;

P18H00255
 4-135
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Figures Operation instructions

4. Tie the steering cylinder with lifting rope,
remove the fastening bolt of front pin shaft of
steering cylinder and knock the pin shaft out
with copper bar;

P18H00256
5. Lift the steering cylinder out of the frame using
traveling crane and place it on a level ground.
6. Mask the oil ports of the steering cylinder big
and small cavity to avoid pollution.

Installation of Steering Cylinder

Please keep clean. All components shall be cleaned thoroughly with cleaning solution prior to
assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all components. If the
components are worn or damaged, please replace them with new ones.

Figures Operation instructions

1. Hang the steering cylinder to the mounting
position with proper sling.
2. Install the front pin of steering cylinder and
tighten the pin shaft captive bolt to 90±10Nm.
3. Install the rear pin of steering cylinder and
tighten the pin shaft captive bolt to 90±10Nm.

P28H00536
4-136
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Figures Operation instructions

4. Connect the steering cylinder small cavity hose
and the tightening torque of hose joint is:
47±2Nm.
5. Connect the steering cylinder big cavity hose
joint.
6. Fill the hydraulic oil, start the machine and idle
it for 5min.
7. Turn slowly for at least 10 times and bleed the
air in the line.
P28H00535 8. Stop the machine and check it for leakage.
9. Check whether the hydraulic oil level is
qualified, and if not, please fill the hydraulic oil
to the specified level.

P18H00259
 4-137
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Disassembly and Assembly of Steering Cylinder

Disassembly of Steering Cylinder

Exploded view of steering cylinder

20 1 2 3 4 5 7 9 10 11 12 13 14 15 16 17 19 18
6 8

P28H00901

1. Bolt 6. O-ring 11.Seal ring 16.Dust ring

2. Cushion 7. Support ring 12.O-ring 17.Piston rod
3. Cover 8. Piston 13.Seal ring 18.Retainer
4. Nylon locknut 9. Cylinder block 14.O-ring 19.Radial knuckle bearing
5. Glyd ring 10.Support ring 15.Cylinder head 20.Retainer

Figures Operation instructions

1. Remove the oil cylinder head (15).
Note: Tightening torque for cylinder head 15:
380±20 N.m;

15

P28H00892
2. Pull out the piston rod (17) from cylinder block
4 9 and remove the piston nylon locknut (4).
Note: Tightening torque for locknut (4):
650±60N.m.

17
P28H00893
4-138
Removal and Installation November 17, 2017
Steering Hydraulic System CLG835H

Figures Operation instructions

3. Remove support ring (7) and Glyd ring (5) from
5
the piston (8).
7

P28H00894
4. Remove the piston (8) and push out the
17 cylinder head (15) from piston rod (17).
15
8

P28H00895

5. Remove the support ring (10), seal ring (11)

13 and (13), and dust ring (16) from the cylinder
11 16
head 15.
10

P28H00896
 4-139
November 17, 2017 Removal and Installation
CLG835H Steering Hydraulic System

Figures Operation instructions

6. Remove the O-ring (6) from the piston rod 17.
6

P28H00897

7. Remove the retainer (18) and the knuckle

19
bearing (19) from the piston rod 17.

18 P28H00898

8. Remove the retainer (20) and the knuckle

bearing (19) from the cylinder head.
19

20 P28H00899
4-140
Removal and Installation November 17, 2017
Brake System CLG835H

Brake System

Removal and Installation of Brake Pump

Refer to “Pressure Release of Hydraulic System” to release the pressure of service brake system
and parking brake system before removing the brake pump.

Since the brake pump is an integrated tandem pump with steering pump, its removal steps are same as
that of steering pump.

Removal and Installation of Brake Valve

Removal of Brake Valve

Refer to “Pressure Release of Hydraulic System” to release the pressure of service brake system
and parking brake system before removing the brake valve.

Figures Operation instruction

Remove the brake light switch or clutch on/off

A1 switch in the electrical system.
1. Mark 5 hoses connected with brake valve
respectively with "P1_charge valve",
A2 "P2_charge valve", "T_ pilot joint block", "A1_
rear axle" and "A2_ front axle" and note that
the markings shall be firm;

T 2. Remove the joints of 5 hoses and shield the oil

ports;

Tool: Open-end wrench 27#

P1

P2 P18H00064
 4-141
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

3. Unscrew the 4 bolts tightening the brake valve;

Tool: Open-end wrench 13#

P18H00065

4. Take out the brake valve from the bottom of

cab;
5. Shield the port of brake valve and store it in dry
and clean place.

P18H00066
4-142
Removal and Installation November 17, 2017
Brake System CLG835H

Installation of Brake Valve

Figures Operation instruction

1. Install the brake valve onto the cab floor from
the bottom, tighten the bolt. Tightening torque
of bolt: 52±6Nm;

Tool: Open-end wrench 13#

P18H00067

2. Tighten the joints of 5 hoses "P1_charge

valve", "P2_charge valve", "T _ pilot joint
block", "A1_ rear axle" and "A2 _ front axle".
Tightening torque: 51±8Nm
A1 3. Connect the brake light switch and clutch on/off
switch well in the electrical system by referring
A
to Electrical System Overhaul Manual.

Tool: Open-end wrench 24#

T

P1

P2
P18H00068
 4-143
November 17, 2017 Removal and Installation
CLG835H Brake System

Disassembly and Assembly of Brake Valve

Disassembly of Brake Valve

Figures Operation instruction

Place the brake valve on the inside of operation

platform.

Tool: Clean operation platform, 06-466-245 MICO

brake valve

P18H00069

1. Remove the inner circlip on one side of the

pedal using small straight screwdriver.

inner ޻গ㉝
circlip
Tool: Small straight screwdriver

P18H00070

2. Pull out the pin shaft by hand.

P18H00071
4-144
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

3. Remove the pedal.

P18H00072

4. Place the valve body on the vise.

Tool: Vise

5. Remove two hexagon connecting bolts from

the base using the socket wrench, record the
direction of the pedal base and the valve body
and remove the pedal base.

Tool: 5/16 Socket wrench

P18H00074

P18H00075
 4-145
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

6. Remove the toe clip by hand.

P18H00076

7. Pull out the piston in vertical direction by hand

P18H00077

8. Take out the internal spring and the gasket seat

P18H00078

CAUTION: record the number of gaskets.

P18H00079
4-146
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

9. Take out V-ring and seal ring from inner valve
body (caution: inner valve body and seal can
not be scratched)

P18H00080

P18H00081

P18H00082
 4-147
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

10. Take out the plug and spring from inner valve
body and remove O-ring from the plug.

Tool: 7/8 open-end wrench in in British system

P18H00083

P18H00084

P18H00085
4-148
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

11. Unscrew inner hexagon connecting bolts on
both sides using the inner hexagon spanner
and remove the plain washer.

Tool: 1/4 inner hexagon spanner

P18H00086

P18H00087

P18H00088

OO-ශാ
ring 12. Separate two valve bodies from each other and
remove two O-rings from valve bodies.

P18H00089
 4-149
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

13. Take out spools respectively from upper and
lower valve body and place them in order.

CAUTION: protect the spool and the inner

valve body from being damaged. Do not mix
spools and pay attention to their directions.

P18H00090

14. After completion of disassembly, check the

number of each component.

P18H00091
4-150
Removal and Installation November 17, 2017
Brake System CLG835H

Inspection and Cleaning of Brake Valve

Figures Operation instruction

1. Check whether the spool is worn.

P18H00092

P18H00093

2. Check whether all seal rings are damaged.

P18H00094
 4-151
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

P18H00095

P18H00096

3. Clean all seals and spools & valve holes using

clean lubricant and exterior surface of other
elements before installation.

P18H00097

P18H00098
4-152
Removal and Installation November 17, 2017
Brake System CLG835H

Assembly of Brake Valve

Figures Operation instruction

1. Install the O-ring between valve bodies.

P18H00099

2. Lubricate the upper spool using clean lubricant

and slide it into valve body cavity carefully, pay
attention to the direction of installation.

CAUTION: the spool shall be free for

sliding into valve cavity, replace new spools
and valve bodies if one of spools is damaged.

P18H00100

P18H00101
 4-153
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

3. Re-assemble two parts of valve bodies using
the connecting bolts of end cap and washer.
Torque: 29.8-33.9Nm.

CAUTION: make sure that valve bodies are

installed in correct order and the O-ring is
always in the groove during installation.

P18H00102 Tool: 1/4 inner hexagon torque wrench

P18H00103

4. Lubricate the spool using clean lubricant and

slide it into valve body cavity carefully, pay
attention to the direction of installation.

CAUTION: the spool shall be free for

sliding into valve cavity, replace new spools
and valve bodies if one of spools is damaged.

P18H00104

P18H00105
4-154
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

P18H00106

5. Install new O-ring on the end of plug, and the

spring and plug into valve body. Torque: 47.5-
54.2Nm.

Tool: 7/8 Open-end torque wrench

P18H00107

P18H00108
 4-155
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

6. Install new V-ring and seal ring into valve body
cavity carefully and pay attention to the order
and direction of installation.

CAUTION: the inner cavity of valve body

can not be scratched and damaged

P18H00109

P18H00110

7. Install the gasket, gasket seat and spring into

the valve body in sequence.

P18H00111

P18H00112
4-156
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

8. Install the piston。

P18H00113

9. Install new protective cover onto valve body

and piston.

P18H00114

10. Install the pedal base onto the valve body.

Torque: 24.4-29.8Nm.
11. Install the pedal.

Tool: 5/16 inner hexagon socket torque wrench

P18H00115

P18H00116
 4-157
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

P18H00117

P18H00118

12. After completion of assembly, check direction

of the pedal and whether parts are ready.

P18H00119
4-158
Removal and Installation November 17, 2017
Brake System CLG835H

Removal and Installation of Charge Valve

Removal of Charge Valve

Refer to “Pressure Release of Hydraulic System” to release the pressure of service brake system
and parking brake system before removing the charge valve.

Figures Operation instruction

1. Mark 4 hoses connected with charge valve
respectively with "P1_oil filter", "SW_ brake
T1 valve block", "P2_ brake valve A2", "P3_ brake
valve A1" and "P4_ accumulator BR2", "P5_
P1 T2
accumulator BR1" , "T1_ joint block", "T2_ joint
P2 block"and note that the markings shall be firm.
P3 2. Loosen the joint of 8 hoses; remove tee nut
SW
P4 end; shield the oil port.
P5
P18H00127 Tool: Open-end wrench 27#
3. Unscrew the 2 bolts tightening the charge
valve.

Tool: Open-end wrench 13#

P18H00128

4. Take the charge valve out of left housing;

5. Shield the joint of charge valve and store it in
dry and clean place.
 4-159
November 17, 2017 Removal and Installation
CLG835H Brake System

Installation of Charge Valve

Figures Operation instruction

1. Tighten bolts, install the charge valve onto the
box, tightening torque of bolts: 52±6Nm.

Tool: Open-end wrench 13#

P18H00129

2. Assemble 2 tees.
3. Assemble the joint of hoses "P1_oil filter",
T1 "SW_ brake valve block", "P2_ brake valve
T2 A2", "P3_ brake valve A1" and "P4_
P1 accumulator BR2", "P5_ accumulator BR1" ,
P2
"T1_ joint block", "T2_ joint block", tighten joints
P3 and their tightening torque: 51±8Nm.
SW
P4
P5 Tool: Open-end wrench 22#, 24#, 27#
P18H00130
4-160
Removal and Installation November 17, 2017
Brake System CLG835H

Disassembly and Assembly of Charge Valve

Disassembly of Charge Valve

Figures Operation instruction

P18H00131

Place the charge valve on the inside of operation

platform.

Tool: Clean operation platform, 06-463-432 MICO

charge valve

P18H00132

P18H00133
 4-161
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

1. Remove plug 1 using inner hexagon spanner.

Plug
ѓ๫1 1 Tool: 9/16 Inner hexagon

P18H00134

P18H00135

2. Remove plug 1 and O-ring and take out the

spring and ejector rod

Ejector
京ᵼ
rod

P18H00136
4-162
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

3. Remove plug 2 and O-ring.

Tool: 9/16 Inner hexagon

P18H00137

Plug22
ѓ๫

P18H00138

P18H00139
 4-163
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

4. Take the spool out of plug 1 (only can be taken
out from this end).

P18H00140

5. Loosen screw cap 3.

Screw
㷰ᑳ 3 cap 3

Tool: Monkey wrench

P18H00141

6. Unscrew plug assembly.

Plug
ѓ๫ᙱᡆassembly

Tool: 3/8 inner hexagon spanner

P18H00142

7. Take down the O-ring from plug assembly, take

gasket, spring, steel ball, O-ring of valve seat
and washer from valve body and remove filter
screen and washer.

P18H00143
4-164
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

8. Remove plug 4.

Tool: 5/16 inner hexagon spanner

Plug
ѓ๫ 44

P18H00144

9. Measure and record the depth from plug to

bottom of valve body accurately for installation,
Plug55
ѓ๫ and then remove plug 5.

Tool: 5/16 inner hexagon spanner

P18H00145

P18H00146
 4-165
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

10. Remove spring, ball retainer and ball (do not
mix two balls)

P18H00147

11. Remove plug 6 and O-ring.

Plug66
ѓ๫

P18H00148

12. Remove spring, ejector rod and ball.

P18H00149
4-166
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

13. Screw the plug 6, take the bushing and spool
out from valve body trough hole of plug 4 using
wood bar or plastic bar with diameter 6.35-
7.87mm and the bushing and spool can fall
from plug 6.

P18H00150

P18H00151
14. Remove plug 7 and O-ring.

Plug77
ѓ๫ Tool: Monkey wrench

P18H00152
 4-167
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

15. Take spring, poppet, shuttle valve bushing,
poppet and spring out from the valve body. A
special tool shall be made at the time of
removing the valve bushing.

P18H00153

P18H00154

P18H00155
4-168
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

16. Remove O-ring of shuttle valve bushing.

P18H00156

17. Remove relief valve, O-ring and support ring.

18. Remove plug 8.

Plug 8
ѓ๫8

P18H00157

19. The removal is completed.

P18H00159
 4-169
November 17, 2017 Removal and Installation
CLG835H Brake System

Check and Clean of Charge Valve

Figures Operation instruction

1. Check whether all rubber seal rings and spools
are damaged and conduct sufficient lubrication
with lubricant.

P18H00160

P18H00161

2. Clean filter element, relief valve and shuttle

valve bushing.

P18H00162
4-170
Removal and Installation November 17, 2017
Brake System CLG835H

Assembly of Charge Valve

Figures Operation instruction

Place all parts respectively and check the quantity

P18H00163

1. Install new O-ring on plug 2 and assemble plug

2 on valve body. Torque: 67.8-81.4Nm.

Tool: 9/16 inner hexagon spanner

P18H00164

2. Install new seal ring on spool and ensure that

the seal ring in the groove is not bent.

P18H00165
 4-171
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

3. Lubricate the spool sufficiently and install it into
the valve body

P18H00166

P18H00167

4. Install spring and ejector rod into the valve.

P18H00168
4-172
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

5. Install new O-ring on plug 1 and assemble it on
the valve body. Torque: 67.8-81.4Nm.

Tool: 9/16 inner hexagon spanner

P18H00169

P18H00170

6. Install new O-ring on bushing and assemble it

into the valve. Pay attention to the direction of
installation. Wood bar or plastic bar with
diameter 12.7mm shall be used for installation
of the bushing.

Tool: Nylon rod with diameter 12.7

P18H00171
 4-173
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

P18H00172

P18H00173

7. Install the spool into the valve and note that the
upper end of the spool shall be aligned with
plug 6.

P18H00174
4-174
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

8. Install steel ball onto the spool.

P18H00175

P18H00176

9. Place the ejector rod on the ball.

P18H00177
 4-175
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

10. Place the spring on the ejector rod.

P18H00178

11. Install O-ring on plug 6, and then install the

plug on the valve. Torque: 47.5-54.2Nm.

Tool: Torque wrench

P18H00179

P18H00180

P18H00181
4-176
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

12. Reverse the valve body, place plug 2 vertically
upwards, install the ball into valve body and
ensure that the ball is located at center of inner
hole bottom of the valve body.

P18H00182

P18H00183

13. Place the ball retainer into the valve body.

P18H00184
 4-177
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

14. Place the spring into the valve body.

P18H00185

15. Screw plug 5 on the valve body again

according to the depth recorded before
removal.

Tool: 5/16 inner hexagon spanner

P18H00186

P18H00187
4-178
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

16. Install O-ring on plug 4 and assemble it on the
valve body. Torque: 47.5-54.2Nm.

Tool: Torque wrench

P18H00188

P18H00189
17. Install new filter and snap ring into the valve
body.

P18H00190

18. Install gasket, new O-ring, valve seat, steel

ball, gasket, spring, and plug assembly into the
valve body. Torque: 24.4-29.8Nm.

P18H00191
 4-179
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

P18H00192

P18H00193

P18H00194
4-180
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

P18H00195

P18H00196

P18H00197
 4-181
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

19. Tighten screw cap 3 onto the plug assembly.
Torque: 43.5-51.5.

Tool: Torque wrench

P18H00198

P18H00199

20. Install new O-ring on shuttle valve bushing

P18H00200
4-182
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

21. Install the spring, poppet, shuttle valve
bushing, new poppet, spring into the valve
body.

P18H00201

P18H00202

P18H00203
 4-183
November 17, 2017 Removal and Installation
CLG835H Brake System

Figures Operation instruction

22. Install O-ring on plug 7 and assemble it on the
valve body. Torque: 67.8-81.4Nm

P18H00204

23. Install 2 new O-rings and support ring on relief

valve

P18H00205

24. Install relief valve on valve body. Torque: 47.5-

54.2Nm.

Tool: Torque wrench

P18H00206
4-184
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

25. Install plug 8 on the valve body.

P18H00207

Re-assembly of charge valve is completed

P18H00208
 4-185
November 17, 2017 Removal and Installation
CLG835H Brake System

Removal and Installation of Accumulators

Removal of Accumulators

Refer to “Pressure Release of Hydraulic System” to release the pressure of service brake system
and parking brake system before removing the accumulator.

Figures Operation instruction

Open door of left housing, remove four bolts of the

left housing roof plate:

BR3
1. Mark accumulators respectively as BR1, BR2
BR1
and BR3 and hoses connecting with their lower
BR2
parts as P1(hose of charge valve port A1), P2
(hose of charge valve port A2) and P3 (hose of
valve assembly port A), note that markings
shall be firm.
2. Remove hoses and joints under accumulators
and mask oil ports.

P1 Tools: Open-end wrench 10#, 22#, 24#

P3 P2

P28H00865
3. Remove 3 U-bolts from the accumulators.

Tools: Open-end wrench 13#

P28H00866
4-186
Removal and Installation November 17, 2017
Brake System CLG835H

Figures Operation instruction

4. Take the accumulators out of left housing;
5. Shield the joint of accumulator and store it in
dry and clean place.

P28H00867

Installation of Accumulators

Install the accumulators in reverse order of the removal steps of the accumulators.
 4-187
November 17, 2017 Removal and Installation
CLG835H Brake System

Removal and Installation of Brake Cylinder

Removal of Brake Cylinder

Refer to “Pressure Release of Hydraulic System” to release the pressure of service brake system
and parking brake system before removing the brake cylinder.

Figures Operation instruction

1. Remove the pin shaft between the brake cylin-
der and manual brake.

Tools: Open-end wrench 27#

P18H00215

2. Remove the hose from the brake cylinder, and

then loosen the nuts from the above end of
brake cylinder.

Tools: Open-end wrench 13#

P18H00216

3. Take out brake cylinder.

4. Shield the port of brake cylinder and store it in
dry and clean place.

Installation of Brake Cylinder

Install the brake cylinder in reverse order of the removal steps of the brake cylinder.
4-188
Removal and Installation November 17, 2017
Hydraulic Cooling System CLG835H

Hydraulic Cooling System

Removal and Installation of Cooling Pump

Removal of Cooling Pump

Figures Operation instruction

1. Mark hoses with "P1_oil inlet hose of brake
P2
pump", "P2_oil outlet hose of brake pump". The
markings shall be clear, firm, and not easy get
off.

Tool: Open-end wrench 15#

2. Unscrew "P1_oil inlet hose of brake pump",

"P2_oil outlet hose of brake pump". Unscrew
the hose connector, and take out the connector
after few slightly heat off. Masking oil ports
properly.
P1
Tool: Open-end wrench 27#, 36#, 50#
P28H00877
3. Remove brake pump fixing bolt, and place it
into clean container. Please avoid cashing or
bumping, and ensure personel safety.

Tool: Open-end wrench 15#

P28H00878

4. Remove pump port flange, connector. Please

avoid pollution by masking the pump port
properly.

Tool: Open-end wrench 13#

P28H00879
 4-189
November 17, 2017 Removal and Installation
CLG835H Hydraulic Cooling System

Installation of Cooling Pump

Ensure that the oil ports of the hose joints are connected correctly and ensure the cleanness of
hose lines and parts during removal and installation. Check O-rings for ageing and damage etc.
simultaneously and replace in time.

Figures Operation instruction

1. Install the oil suction port joint, oil outlet flange
P2
of the radiator pump with the tightening torque
of bolt 52±6Nm.
2. Hang the cooling pump to the mounting
position with proper sling.
3. Install the cooling pump, seal gasket to the
engine with the torque of bolt 120±10Nm.
4. Connect the P1_oil inlet hose with the
tightening torque of hose joint 135±20Nm.
5. Connect the P2_oil outlet hose with the
tightening torque of hose joint 330±50Nm.

P1

P28H00877

P28H00878

6. Fill the hydraulic oil, start the machine and idle

it for 5min to bleed the air in the line.
7. Stop the machine and check it for leakage.
8. Check the hydraulic oil level for normal, and if
not, please fill the hydraulic oil to the specified
level.
4-190
Removal and Installation November 17, 2017
Hydraulic Cooling System CLG835H

Disassembly and Assembly of Cooling Pump0

Disassembly of Cooling Pump

Figures Operation instruction

1. Fasten the front cover of the pump downward
to the workbench or vise, draw a straight line
(the line is for guidance during the process of
assembly) from the back cover to the pump
body and front cover with a marker. Measure
tightening torque with torque wrench
(tightening torque is 271N.m) and record it. Use
manual or pneumatic wrench to loosen the
fastening bolt.

P18H00410 Tools: Marker and torque wrench

2. Insert screwdriver slightly into port of pump

body, separate rear cover from pump body
forcibly (take care not to damage the joint
surface), and decide whether to replace parts
according to part replacement criterion; take
out the rear side plate subassembly from the
pump body (making marks) and check it
carefully to decide whether to replace parts
according to part replacement criterion.

P18H00411 Tools: Screw driver

3. Take the driving and driven gears from the

pump body, make the marks to avoid confusion
during the assembly. Decide whether to
replace spare parts in accordance with the
spare part replacement principle.

CAUTION: worn condition of gear

engagement surface, end surface and tooth
top.

P18H00412
 4-191
November 17, 2017 Removal and Installation
CLG835H Hydraulic Cooling System

Figures Operation instruction

4. Take out front side plate subassembly (side
plate shall be marked), check it carefully, and
decide whether to replace parts according to
part replacement criterion. Take out the
outboard bearing and decide whether to
replace the it according to part replacement
criterion, and the motor is provided with a
leakage oil plug; both of the oil drain hole are
provided with check valves (apply thread
sealant at the thread); see figure for details.
P18H00413

Check and Cleaning of Cooling Pump

Figures Operation instruction

Check the wear of gear engagement surface, end

surface and addendum, chamber sweeping of
pump body, matching of cylindrical pin, sealing
condition of square seal ring.

P18H00414
4-192
Removal and Installation November 17, 2017
Hydraulic Cooling System CLG835H

Assembly of Cooling Pump

Figures Operation instruction
1. Check the joints of the parts. Apply the flat oil
stone to the processed joints and grind higher.

P18H00415

2. Check the front oil drain passage and ensure

the smoothness of the oil drain.

CAUTION: Check the front cover of motor

for complete two check valves.

P18H00416

3. Eliminate high point and burr on the gear end

face with triangular oil stone.

P18H00417

4. Use washing detergent or diesel oil to washing

these parts, and use high-pressure air to dry
them.

P18H00418
 4-193
November 17, 2017 Removal and Installation
CLG835H Hydraulic Cooling System

Figures Operation instruction

5. Open the outboard bearing at both ends. Clean
the lubricant in the outboard bearing and blow it
dry with high pressure air. Apply molybdenum
disulfide grease evenly in the bearing and
install the bearing covers at both ends.
6. The large plane of the front cover faces
downward, and apply anaerobic sealant to the
excircle of oil seal, and then press it directly
into the front cover oil seal hole with special
tool (the lip is placed downward), press the
outboard bearing.
7. Turn the direction of front cover, make the big
plane of front cover upward, and press two
special tools for slide bearing into bearing hole
respectively; it requires that the oil groove of
slide bearing is assembled at 6 o’clock and 12
o’ clock position, and see assembly schematic
P18H00419 of oil groove of slide bearing for details.
8. Install the elastic snap ring for holes into the
backup ring slot.
If a new front cover is used, the assembly is the
same as above.
CAUTION: if the front cover oil drain hole
is double, it needs to block the oil drain hole of
the high pressure area with oil plug (apply
thread sealant at the thread).
9. Install the E-seal ring and the E-snap ring into
P28H00239 the side plate seal grooves respectively, and
apply a little molybdenum disulfide grease.
10. During the assembly, keep the straight line
marked across the front cover, the valve body
and the back cover in the same horizontal
position; pay attention to conducting the
assembly according to the mark position of the
gear side plate.
4-194
Removal and Installation November 17, 2017
Hydraulic Cooling System CLG835H

Removal and Installation of Cooling Motor

Removal of Cooling Motor

Figures Operation instructions

1. Remove fan guard and bracket by referring to
the Power System - Radiator Service Manual;
2. Respectively mark the hoses on the pump as:
oil inlet hose, oil return hose and housing oil
Oil return hose return hose. The identification should be clear,
firm and not fall off.
3. Remove the oil inlet hose, oil return hose and
housing oil return hose; loosen the T port hose
joint with wrench and remove the hose joint
Oil inlet hose
after gentle knockdown. Properly mask the
hose joints; unscrew the plate bolts of A port
hose and B port hose with wrench, place plate
and bolt and washer well after putting them
together and properly mask the hose joints.

Tools: Open-end wrench 24#, 32#, 36#

Housing oil
return hose
P28H00880

4. Remove the captive bolt and the locknut from

the motor, and hang them to the clean
container; avoid collisions to ensure the
personnel security during removal;

Tools: Open-end wrench 10#

P28H00880
 4-195
November 17, 2017 Removal and Installation
CLG835H Hydraulic Cooling System

Installation of Cooling Motor

Figures Operation instructions

1. Install the joint of housing oil return port, the
tightenig torque is: 110±17Nm.
2. Install the cooling motor onto the bracket, the
Oil return hose
bolt tightening torque is: 120±10Nm. Install the
fan, and screw two nuts, tightening torque is:
225±25Nm.
3. Connect T port hose, the tightening torque of
Oil inlet hose hose joint is: 51±8Nm.
4. Connect A port hose and B port hose, and
tighten the bolt with torque: 52±6Nm.
5. Install fan guard and bracket by referring to the
Power System - Radiator Service Manual.
6. Add hydraulic oil, start the machine and idling
for 5 minutes, and exhaust air in the pipelines.
Housing oil
return hose 7. Stop the machine, check for leakage.
P28H00880 8. Check the hydraulic oil level, and add hydraulic
oil to specified position if it is not enough.
4-196
Removal and Installation November 17, 2017
Hydraulic Cooling System CLG835H

Cooling Motor Test

Tachometer and pressure gage with range 25MPa.

1. Check whether the previously assembled hoses are tightened.
2. Turn the battery disconnect switch to “I” position.
3. Connect the pressure gage (with range 25MPa) to the oil outlet of the pump and paste label “Test the
speed” on the fan vane.

Position for connecting the pressure gage

(with range 25MPa)

Position for pressure adjustment

of the relief valve

P28H00920

4. Press the horn, start the machine, accelerate gradually the engine speed to the maximum and
observe the reading on the pressure gage and the speed reading of the tachometer, it is proper if the
pressure is 16MPa and the speed is about 1700. If the pressure dose not conform to the
requirement, adjust the pressure of the motor relief valve.
 4-197
November 17, 2017 Fault Diagnosis and Troubleshooting
CLG835H Troubleshooting of Metering Pump

Fault Diagnosis and Troubleshooting

Troubleshooting of Metering Pump

Troubleshooting
Faults Symptom Cause
methods
Check the joint surface and
Oil leakage in joint surface of parts Dirt in joint surface
clean it up
Oil leakage Oil leakage at front cover Shaft seal ring is damaged Replace the seal ring
Bolt (plug) is tightened with
Bolt (plug) leaks Tightening bolt (plug)
insufficient torque
Steering wheel is heavy when turned Check the oil pump and oil
Oil supply is insufficient
quickly supply line
Check whether the main
Steering wheel is light when turned
Main priority valve spool is stuck priority valve spool is
slowly
flexible
Cylinder crawling Bleed air in the system and
Foam in oil Air in steering system check oil pump inlet for air
Heavy steering leakage
Irregular noise
Check whether the steel ball
Heavy steering, no action on the Manual steering check valve
exists and whether it is
steering cylinder failure
chocked by impurities
No-load steering is light, heavy load Safety valve is chocked to leak Clean and check the safety
steering is heavy or safety valve spring fails valve in priority valve
Heavy steering High hydraulic oil viscosity
No steering back to neutral position Leaf spring failure Replace leaf spring
Pressure oscillation is significantly Pull pin bend or broken Replace the pull pin or
increased, even no steering Rupture at linkage shaft pin slot linkage shaft

Steering failure When you turn the steering wheel, it

Incorrect mutual alignment of
immediately rotates in the opposite Reassembly
linkage shaft and rotor
direction or swings from side to side
Priority valve is stuck, no oil at
No turning
port CF and port LS blocked
Steering column axially abuts
the spool to the bottom
Steering wheel When the pressure drop in the neutral High resistance of steering
does not position increases and steering wheel column Troubleshooting in
automatically stops turning, the metering pump is accordance with specific
return to the not unloaded (vehicle off tracking Leaf spring is broken conditions
neutral position occurs) The installation of steering
column is not concentric to that
of spool
No steering to No steering of steering cylinder to the
Increase the pressure of
the extreme extreme position, steering is heavy as Low pressure of safety valve
safety valve properly
position reflected
4-198
Fault Diagnosis and Troubleshooting November 17, 2017
Troubleshooting of Metering Pump CLG835H

Troubleshooting
Faults Symptom Cause
methods
During power steering, the cylinder
piston moves to the extreme position,
No manual the driver does not have obvious feel Large radial or axial clearance Replace the stator and rotor
steering of end point; during manual steering, of stator and rotor pair pair
the steering wheel rotates but the
cylinder is still
 4-199
November 17, 2017 Fault Diagnosis and Troubleshooting
CLG835H Common Troubleshooting for Brake System

Common Troubleshooting for Brake System

Due to the various reasons, we cannot list all of them, and only phenomena and possible causes for
common failures will be listed. If any question during using our product, please contact service provider
or dealer nearby.

When removing the hose and joint,confirm the residual pressure inside is totally eliminated
before operation.

S/N Fault features Reason Troubleshooting methods

1. Air in brake line 1. Bleed the brake line
2. Brake valve fault 2. Check the brake valve and
measure the pressure at port BR1,
BR2
Insufficient foot braking 3. Pump failure 3. Check the pump
1
force
4. Leakage in brake line 4. Check the brake line
5. Accumulator damaged 5. Check the pressure of the
accumulator
6. Wheel brake friction plate worn to limit 6. Replace the friction plate
1. Brake valve fault 1. Check the brake valve and
Incapable of putting into measure the pressure at port S3
2
gear 2. Pressure switch fault 2. Check the pressure switch under
the accumulator BR3
1. Brake valve fault 1. Check the brake valve and
No normal release of measure the pressure at port BR3
3
parking brake
2. Parking brake cylinder leakage 2. Replace cylinder oil seal parts
1. Large clearance between brake drum and 1. Readjust the clearance according
Insufficient parking brake shoe to the requirements of use
4
braking force
2. Oil on brake shoe 2. Clean up brake shoe
1. Air valve leakage 1. Check air valve, and supplement
nitrogen
5 Accumulator doesn't work
2. Rubber bag is broken, nitrogen leakage in 2. Remove and check the rubber bag
rubber bag or replace it
6 No inching braking Brake valve fault Check the pressure at port BR1, BR2
1. Insufficient system oil pressure in a short 1. Please wait
period of time for machine starting
Service or emergency
2. The machine has system failure and oil 2. Inspection after stopping machine
7 brake low pressure alarm
pressure drop during operation
light comes on
3. Air leakage in rubber bag of accumulator 3. Check the pressure of rubber bag
of accumulator
4-200
Fault Diagnosis and Troubleshooting November 17, 2017
Troubleshooting for Brake Pump CLG835H

Troubleshooting for Brake Pump

Fault features Reason Troubleshooting methods

Air enters the system Tighten all joints
Oil supply is insufficient Refill the oil to a proper level
Oil is cold Operating in a low speed
Oil suction tube is blocked Remove the blocking object
Oil pump is noisy Air filter in tank is blocked Clean or replace the air filter
Bad right alignment between pump and input
Check
shaft
Resonance is serious (resonance of pump
Check if mounting bolts of pipeline and
with peripheral components of oil tank and
components are tightened
pipeline)
Oil supply is insufficient Refill the oil to a proper level

Pump is slow at response or Setting pressure of relief valve is insufficient Readjust the pressure of relief valve
has no response Pump is worn or broken Repair or replace
Valve is worn or stuck or leaks Repair or replace
Adjust the pressure or replace the relief
Setting pressure of relief valve is too low
valve
Low viscosity of fluid Replace with recommended hydraulic oil
Oil temperature rises Oil is dirty Replace the hydraulic oil
Low oil level Refill hydraulic oil properly
Pump is worn or broken Repair or replace
Air enters the system through oil suction tube Tighten all joints
Low oil level Refill hydraulic oil properly
Oil foaming
Lip type seal ring (oil seal) of main revolving Replace the lip type seal ring (oil seal) of
shaft is worn or damaged main revolving shaft
Side plate is broken Replace side plate
The flow or pressure of pump
Relief valve fails Replace relief valve
is insufficient
Air enters the system Tighten all joints
Worn lip type seal ring (oil seal) of revolving
Oil still leaks after replacing shaft causes damage to the sealing area of Replace the drive gear shaft
the lip type seal (oil seal)of drive gear shaft
main revolving shaft
Seal ring is worn or damaged Replace the seal ring
 4-201
November 17, 2017 Fault Diagnosis and Troubleshooting
CLG835H Troubleshooting for Cooling Pump

Troubleshooting for Cooling Pump

Fault phenomenon of
Possible cause Handling method
oil pump
Air enters the system Tighten all joints
Oil supply is insufficient Refill the oil to a proper level
Oil is cold Operating in a low speed
Oil suction tube is blocked Remove the blocking object
Oil pump is noisy
Air filter in tank is blocked Clean or replace the air filter
Bad right alignment between pump and input
Check
shaft
Resonance is serious (resonance of pump with Check if mounting bolts of pipeline and
peripheral components of oil tank and pipeline) components are tightened
Oil supply is insufficient Refill the oil to a proper level

Pump is slow at response or Setting pressure of relief valve is insufficient Readjust the pressure of relief valve
has no response Pump is worn or broken Repair or replace
Valve is worn or stuck or leaks Repair or replace
Adjust the pressure or replace the relief
Setting pressure of relief valve is too low
valve
Replace with recommended hydraulic
Low viscosity of fluid
oil
Oil temperature rises
Oil is dirty Replace the hydraulic oil
Low oil level Refill hydraulic oil properly
Pump is worn or broken Repair or replace
Air enters the system through oil suction tube Tighten all joints
Low oil level Refill hydraulic oil properly
Oil foaming
Lip type seal (oil seal)of main revolving shaft is Replace the lip type seal (oil seal)of
worn or damaged main revolving shaft
Side plate is broken Replace side plate
The flow or pressure of
Relief valve fails Replace relief valve
pump is insufficient
Air enters the system Tighten all joints
Worn lip type seal (oil seal) of revolving shaft
Oil still leaks after replacing causes damage to the sealing area of drive gear Replace the drive gear shaft
the lip type seal (oil seal)of shaft
main revolving shaft
Seal ring is worn or damaged Replace the seal ring
4-202
Fault Diagnosis and Troubleshooting November 17, 2017
Troubleshooting for Cooling Pump CLG835H
 5-1
November 17, 2017 Air Conditioning System
CLG835H

Air Conditioning System

Basic Information ............................................................................................................5-3
Safety .....................................................................................................................................................5-3
Universal Tool, Tooling List....................................................................................................................5-3
Special Tool, Tooling List .......................................................................................................................5-3

Structure Function Principle ..........................................................................................5-4

Components and Position ......................................................................................................................5-4
System Technical Parameters ...............................................................................................................5-5
Description of Principle Diagram and Working Principle........................................................................5-5

Test and Adjustment .......................................................................................................5-8

A/C System Test ....................................................................................................................................5-8

Removal and Installation ..............................................................................................5-10

Main Components Introduction of A/C System ....................................................................................5-10
Removal and Installation of A/C Components .....................................................................................5-11
Removal and Installation of Compressor .........................................................................................5-11
Removal and Installation of Evaporator Mounting Assembly...........................................................5-17
Evaporator Assembly .......................................................................................................................5-22
Replacement of A/C Control Panel ..................................................................................................5-23
Inspection and Replacement of A/C Fuse........................................................................................5-23
Removal and Replacement of Reservoir .........................................................................................5-24
Removal and Installation of Condenser ...........................................................................................5-25
Removal and Installation of Pressure Switch...................................................................................5-26
Removal and Installation of Expansion Valve ..................................................................................5-27
Removal and Installation of Servo Electrical Motor of Air Inlet ........................................................5-28
Removal and Installation of Evaporator Blower ...............................................................................5-29
Removal and Installation of Solenoid Water Valve ..........................................................................5-30

Fault Diagnosis and Judgment ....................................................................................5-31

Classification of Common Faults..........................................................................................................5-31
Overhauling Method.............................................................................................................................5-31
Maintenance Method When Backlight of A/C Panel is Not On and the Button Does Not Work.......5-31
Maintenance Method When No Air Comes Out of Air Conditioner or Air Outlet Volume is Obviously
Smaller Than the Normal Volume ....................................................................................................5-32
Maintenance Method for Natural Air Comes Out When Heating is Switched On ............................5-38
5-2
Air Conditioning System November 17, 2017
CLG835H

System Maintenance .....................................................................................................5-39

A/C System Regular Maintenance .......................................................................................................5-39
Cleaning of Recirculating Air Strainer ..............................................................................................5-39
Cleaning of Fresh Air Strainer..........................................................................................................5-40
Adjustment of Compressor Belt ......................................................................................................5-41
A/C Refrigerant Filling Method .........................................................................................................5-43
 5-3
November 17, 2017 Basic Information
CLG835H Safety

Basic Information Universal Tool, Tooling List

Safety Specifications Main functions

It is used for removal and installation of
10# Open-end
captive bolts of the pipeline, joint box
Drain refrigerant in air conditioning system as wrench
and cover plate
required in “Refrigerant Release (Recycle) in Air
13# Open-end It is used for removal and installation of
Conditioning System” before removing wrench captive bolts (nuts) of the compressor
compressor, condenser, reservoir, pressure
It is used for removal and installation of
switch, air conditioner coils, etc. Seal up the 14# Open-end
hold-down nuts (screw rods) of tension
removed pipe joints through a reliable method to wrench
pulley
prevent moisture in the air from entering air
It is used for removal and installation of
conditioning system. 19# Open-end
air conditioning pipe joint in the
wrench
evaporator assembly
It is used for removal and installation of
21# Open-end
air conditioning pipe joint in the
wrench
If liquid refrigerant splashing into eyes may evaporator assembly
lead to blind; and spraying on the skin may 24# Open-end
It is used for removal and installation of
cause frostbite. In addition, the container for air conditioning pipe joint in the
wrench
storing refrigerant can neither be exposed to evaporator assembly
ambient temperature above 50°C or placed 27# Open-end It is used for removal and installation of
near a heat radiating device or object, nor be wrench water hose joint of the evaporator
exposed to direct sunlight. In this case, the Cross It is used for removal and installation of
temperature of the refrigerant easily rises to screwdriver evaporator mounting assembly
cause increase in pressure in the container. Ratchet It is used for removal and installation of
When the pressure reaches high enough, the wrench captive bolts of evaporator
container may have leakage explosion. It is used for removal and installation of
13# Socket
captive bolts of evaporator
The refrigerant itself is non-toxic, but it
cannot be in direct contact with open flames It is used for removal and installation of
Extended rod
or heated metal, otherwise toxic gases will be captive bolts of evaporator
produced. Plastic bag,
It is used for sealing up the pipe joints
tape
In order to avoid the injury from refrigerant,
Marking pen It is used for marking the removed joints
the goggles and gloves should be worn and
open fire or smoking is prohibited.
Special Tool, Tooling List

Specifications Main functions

It is used for the drainage and filling of
Manifold gauge
refrigerant
Vacuum pump It is used for the filling of refrigerant
5-4
Structure Function Principle November 17, 2017
Components and Position CLG835H

Structure Function Principle

Components and Position

(1) Compressor
Compressor is installed on the fan side of engine, at upper rear right side of the machine, and is
driven by engine through belt to operate.
(2) Evaporator assembly
A/C evaporator assembly of this machine is located on the right of seat, parts inside evaporator
assembly include expansion valve, air door and servo motor, blower unit, and pressure switch.
(3) Air duct assembly and inlet and outlet air vents
Air conditioner of this machine has 2 front vents, 2 rear vents, 4 defroster vents and 2 foot vents, and
vents are connected with evaporator via air duct assembly. Meanwhile, air duct assembly also com-
prises the fresh air vent, strainers and accessories. They are located in the front, side and rear deco-
rations of cab.
(4) Control panel
The A/C control panel lies on the right side of the cab's roof.
(5) Condenser reservoir assembly is located behind the radiator.
The compressor keeps rotating, and the above refrigeration process cycles continuously. The heat in
the car is taken away by refrigerant in the evaporator, so as to complete cooling and dehumidification
of the complete vehicle.

4
2 1

P28A00193
 5-5
November 17, 2017 Structure Function Principle
CLG835H System Technical Parameters

System Technical Parameters

Working medium Engine cooling water

Heating module
Heating capacity 5800W / 7.89PS
Refrigerant R134a
Air conditioner module Refrigerating capacity 5000W / 6.80PS
Refrigerant filling quantity 1100±30g / 2.43±0.07lb
Voltage 24V

Description of Principle Diagram and Working Principle

A/C of this machine is vapor compression type refrigeration A/C, and its working process and
principle are shown as follows:

(1) Compression process

Refrigerant absorbs heat in the evaporator and then changes into low-temperature and low-pressure
gaseous refrigerant, which is sucked into the compressor and compressed into high-temperature
high-pressure gaseous refrigerant, and then discharged into the condenser.
(2) Condensing process
After high-temperature and high-pressure gaseous refrigerant enters the condenser, the air, driven
by the engine radiator fan, is forced to pass across condenser surface and bring away heat of refrig-
erant. The refrigerant is condensed into medium-temperature and high-pressure liquid type.
(3) Throttling process
Medium-temperature and high-pressure liquid refrigerant is filtered by dryer and then throttled
through the expansion valve (refrigerant is sprayed from the pores of expansion valve and expanded
suddenly). It changes into low-temperature and low-pressure refrigerant mist to enter the evaporator.
(4) Evaporator process
Low-temperature and low-pressure liquid refrigerant formed by the throttling of expansion valve is
vaporized in the evaporator, and the air in the car is driven by the evaporator blower to flow through
the evaporator surface. The refrigerant absorbs the heat of air in the car to reduce the air tempera-
ture, and dissolve out condensate water. Refrigerant absorbing heat is evaporated into low-tempera-
ture and low-pressure gaseous refrigerant, which is sucked into the compressor and compressed
again, so that one refrigeration cycle is completed.
The compressor keeps rotating, and the above refrigeration process cycles continuously. The heat in
the car is taken away by refrigerant in the evaporator, so as to complete cooling and dehumidification
of the complete vehicle.
5-6
Structure Function Principle November 17, 2017
Description of Principle Diagram and Working Principle CLG835H

Schematic diagram for A/C system

High temperature & high pressure gas state Low temperature & low pressure gas state

Cooling Heat absorption

2 5
Low temperature
& low pressure lqid state

Medium temperature & high pressure liquid state 3

4

P28A00050

1. Compressor 3. Receiver dryer 5. Evaporator

2. Condenser 4. Expansion valve

Refer to the appendix schematic diagram in Chapter 9 for the A/C system electrical principle.
 5-7
November 17, 2017 Structure Function Principle
CLG835H Description of Principle Diagram and Working Principle

Transition harness of control panel to evaporator

Connectorview
Connector viewdirection
direction

Connect the control panel

Blade-type socket 5556-PT

Technical requirements
1.It needs to add wire number on the wire correspondingly;
2.Pull-out force fits ZB/T36003;
3.Dashed line shows the insulating tape wraps compactly,
and other protection jackets shall be wrapped discontinuously
with insulating tape;
4. Apply the AVSS wire to produce.

Connect the evaporator harness

Plastic connnector
Copper part

Wire
No.
Terminal1

Terminal2
Wire
length
Section
Red/ Black/ Blue/ Blue/
Color Red Black Brown gray White yellow Gray White black Gray Blue Yellow Green White green

P28A00116
5-8
Test and Adjustment November 17, 2017
A/C System Test CLG835H

Test and Adjustment Step 4

Check whether the refrigeration function is

A/C System Test normal according to the following steps

1. Check whether outlet air temperature of cab

is obviously lower than outside air
temperature. If not, the A/C system operates
abnormally.
It is suggested to check A/C system at
2. Observe the sight glass beside refrigerant
temperature above 28°C (82.4°F), since A/C
reservoir. In normal circumstances, no air
system may can not be started normally at
bubbles or only few air bubbles can be seen
too low air temperature.
through sight glass. If a large amount of air
The above steps are repeated to simply judge bubbles can be seen, or foam-like appears, it
whether A/C system works normally and is in means A/C system is out of order.
good conditions. If possible, it is more
3. Respectively touch the air inlet part near
accurate to connect the pressure gauge for
upper part of condenser and air outlet part
judgement. If it is obvious that A/C system
near lower part, as shown in the figure below.
operates abnormally, refer to section “Fault
In normal circumstances, the air inlet part
Diagnosis and Judgment” in this manual for
shall be hot to some extent, and the air outlet
treatment methods.
part shall be at a temperature close to air.
The temperature near air inlet is not high,
Step 1 which means the refrigerant is insufficient, or
compressor doesn't work normally; If the
Park the machine on a flat ground, and check it temperature in normal temperature zone is
to make sure the parking brake is applied. Start not obviously different from that in high
the engine, and let a companion depress the temperature zone, it means the condenser
accelerator, so as to make the engine operate at has poor cooling. Please clean up the dirt on
high idle speed. condenser surface.

Step 2
Zone of
high-temeature
Turn on the A/C switch, adjust the A/C to the
cooling mode, and control the air supply speed at
high speed by adjusting the air speed switch.
Select the minimum temperature.

Step 3 Zone of
proximalrom
temperature
Keep the A/C system operating steadily for 2
minutes. Observe the end face of A/C
compressor belt pulley. In normal circumstances,
the clutch shall be engaged, and the end face of P18A00004
belt pulley shall rotate along with belt. If the end
face of the pulley is still, it indicates that the
compressor is out of operation. Confirm the
operating state of the compressor, and then
perform the following steps.
 5-9
November 17, 2017 Test and Adjustment
CLG835H A/C System Test

4. Observe the sight glass beside refrigerant

reservoir, and touch lower end of reservoir. If
the lower end of reservoir is cold while
bubbles appear under the sight glass, it
means strainer inside the reservoir is
clogged. In normal circumstances, the
temperatures at all parts of refrigerant
reservoir are basically the same to that of
condenser outlet.
5. Touch air intake pipe fitting (the thicker one)
of compressor. If it is not cold, it means
refrigerant is insufficient or refrigerating
system is blocked or compressor valve plate
is damaged. Further inspection is needed.
6. If air cooler is switched on for about 20~50
minutes, air at the outlet is getting warmer, air
volume becomes smaller. The cooling
capacity and air volume return to normal
state when the cooler is switched off (but air
switch is ON) and then switched on 10~15
minutes later, it means defrosting sensor in
evaporator fails.
7. If the refrigeration is operated normally for
several minutes, and stops for several
minutes, and then restores to normal for
several minutes, so repeatedly, please
observe the operation condition of
compressor: If compressor operates in both
cases of refrigeration and no, refrigeration, it
means there is too much water in the system;
If compressor only operates in the condition
of refrigeration and does not operate in the
condition of no refrigeration, the reason may
be that the air temperature at that time is
lower than or close to set temperature, or
control panel is out of order.
8. If the refrigeration operates for several
seconds to tens of seconds, and stops for
several seconds to tens of seconds, so
repeatedly, it means there is too much
refrigerant or air is mixed in refrigerating
system, or the condenser is too dirty, the
system enters automatic protection mode
due to overhigh pressure, so that further
check and treatment are needed.
5-10
Removal and Installation November 17, 2017
Main Components Introduction of A/C System CLG835H

Removal and Installation 5. Expansion valve

The expansion valve is a throttling unit, used for

Main Components Introduction of throttling and step-down as well as flow
adjustment; meanwhile, it can also prevent wet
A/C System
compression, liquid impact and abnormal
overheating. The air conditioning of this machine
1. Compressor adopts the H-type thermal expansion valve.

The compressor is a core component of the air 6. A/C pipe

conditioning system. It is used to compress low-
temperature and low-pressure refrigerant vapor The connection lines of air conditioning system
into high-temperature and high-pressure include high-pressure pipes and low-pressure
refrigerant vapor. The compressor used for the pipes. Among them, compressor-to-condenser
system is a swash plate one. Model: 10P17, hose and reservoir-to-evaporator hose are high
displacement: 178cm³, and refrigerant oil brand: pressure hoses, and evaporator-to-compressor
PAG46. hose is low pressure hose.

2. Evaporator 7. Pressure switch

The evaporator is used to allow throttled low- The engagement and disengagement of
temperature and low-pressure refrigerant to compressor clutch are controlled by pressure of
absorb large heat from the surrounding air during pressure switch monitoring system to realize the
evaporation therein, so as to realize the purpose purpose of protecting refrigerating system. A
of cooling or dehumidification in the vehicle. The high/low-pressure combination switch is used in
evaporator of air conditioning system is a double this system, the upper limit of high pressure is
laminated type evaporator. 3.14 Mpa (455.3psi), and the lower limit of low
pressure is 0.196 Mpa (28.42psi).
3. Receiver dryer
8. A/C control panel
The receiver drier is a unit as required to ensure
the normal operation of compressor and It has the action of controlling the ventilation, air
refrigerating system. Its functions includes: 1. change, refrigeration, heating, defrosting and
storage, 2. filtration, 3. drying. other functions of air conditioning system.
Automatically switch on/off air conditioner or
4. Condenser heater through internal control program so as to
maintain temperature inside cab to be around
The condenser is a heat-exchange unit which setting temperature.
absorbs the heat of high-pressure overheated
refrigerant vapor from the compressor,
condenses into liquid type for over cool heat
exchanger. The air conditioner of the vehicle
adopts parallel-flow type condenser and others.
 5-11
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Removal and Installation of A/C Components

Removal and Installation of Compressor

Release (Recover) Refrigerant in A/C System

Only the release of refrigerant is described in this manual. It is recommended to use special equipment
to recover and reuse the refrigerant if available.
Incorrect release of refrigerant will cause adverse effect on A/C system, especially for the service life of
compressor.

Figures Operation instructions

1. Stop the machine or switch off the A/C system
for at least one hour, then close the negative
switch, and put up "DO NOT OPERATE"
G

warning decal.
IN
N
AR
W

er ot
!

op o n

e
at
d

:r
te
ra
pe
O

e:
at
D

P11000175
2. First close the high and low pressure valves at
the place of manifold gauge.

Tool: Manifold gauge

P28A00005

3. Close the valve of high and low pressure joints.

P28A00006
5-12
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Figures Operation instructions

4. Open the rear cover to sufficiently exposing
compressor and lines thereof.

P28A00118

5. Unscrew the plugs from the high and low-

pressure fillers of compressor, and connect the
high and low-pressure valves of manifold meter
respectively to the fillers of high and low-
pressure pipes. Open the joint valve after they
are connected properly.
Note: The one with thicker pipeline and thinner
interface is low pressure pipe; the one has thinner
pipeline and thicker interface is high pressure pipe.
This is error proof interface, it can't be connected
with wrong method.

P28A00194
 5-13
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Figures Operation instructions

6. Slowly loosen low pressure valve on manifold
gauge so as to make the refrigerant slowly
eject . Note the opening of control valve. Too
large flow rate may easily cause refrigerant oil
to be ejected out along with refrigerant. Control
the flow rate to the extent that no refrigerant oil
is ejected out (the refrigerant is released in a
gaseous state, and refrigerant oil is liquid. Align
the refrigerant outlet with one piece of white
paper, and observe whether there are liquid
droplets to be ejected out). After 10 minutes,
slowly open high pressure valve, and continue
to control flow rate to avoid refrigerant oil from
escaping. The whole process should keep 15-
P28A00121
30 minutes.

WARNING: It is forbidden to release

refrigerant from high pressure end at the
beginning, since at high pressure end it is easy
to cause the refrigerator oil to be ejected out
along with refrigerant.

P28A00122

7. Close the high and low pressure joint and

remove it.
5-14
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Remove Lines Connecting the Compressor and Compressor

If the interiors of compressor are damaged or the refrigerator oil gets gray or black, the fluid
reservoir must be replaced together with the compressor. Otherwise it will shorten the service
life of compressor.

Figures Removal and installation

1. Loosen M6 captive bolts of compressor line
with a wrench, and remove the line.

Tool: Open-end wrench 10#

P28A00194
2. Wrap two removed line connectors with clean
and unbroken plastic bags, tie them up with
adhesive tapes to prevent air and foreign mat-
ter from entering the line.
3. Disassemble the harness connector of com-
pressor clutch.
4. Remove belt as specified in Removal and
Installation of Belt and Tension Pulley. Loosen
the idler disassembly belt first.

Tools: Plastic bag, tape, open-end wrench 13#

P28A00176
 5-15
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Figures Removal and installation

5. Remove 4 M8 bolts fixing compressor, and
remove compressor.

P28A00177

Installation method:
1. Tighten 4 M8 captive bolts of A/C compressor
with torque spanner, and control the torque to
22~30Nm.
2. Install the belt as specified in Removal and
Installation of Belt and Tension Pulley of the
book.
3. Connect the compressor clutch connectors,
and fix the compressor line on the A/C com-
pressor with the bolts of M6X30-8.8.
Tools: Torque spanner, open-end wrench 10#

P28A00177
5-16
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Removal and Installation of Belt and Tension Pulley

Figures Operation instructions

1. Loosen the hold-down nut of tension pulley
with a wrench.
2. Loosen tension screw rod, and remove A/C
compressor belt.
3. Continue to loosen hold-down nut and tension
screw rod of tension pulley until it is
disengaged, and remove the tension pulley.

Tools: open-end wrench 13#, 10#, 14#

P28A00178

Installation method:

1. Tighten the tension pulley fixing nut and

tension screw rod of tension pulley with wrench
first, and fix the tension pulley at a position.
2. Install A/C compressor belt among tension
pulley, A/C compressor belt pulley and engine
belt pulley, and then adjust gradually tension
screw rod and tighten fixing nut to preliminarily
fix belt.
3. Adjust the belt tension according to the
Adjustment of Compressor Belt.

P28A00178
 5-17
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Removal and Installation of Evaporator Mounting Assembly

The following sequence of operations is used for removing evaporator assembly from cab
assembly. Most actual failures occur in certain components (such as fan, circuit, etc.) of
evaporator, so it is suggested to carry out selective removal, repair and replacement after these
failures are identified in accordance with this manual in order to avoid unnecessary operations.

Figures Removal and installation

1. Drain refrigerant in air conditioning system as
required in Release (Recover) Refrigerant in
Air Conditioning System.
2. Remove the cab-rh cover ( install flange bolt
whose bolt is M8).

Tool: #13 Open-end wrench

P18A00017

3. Remove the left evaporator fresh air filter

which is fixed by three butterfly bolts.

P18A00018
5-18
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Figures Removal and installation

4. Remove the pipelines under evaporator and
mark that with marker. Seal the connectors with
plastic bags and adhesive tape after removal,
1 3 in order to prevent foreign matter from entering
2
4 the line.

Tools: Open-end wrenches 19#, 21#, 24#, 27#;

plastic bags, marker and adhesive tape

5 6

1. Water drain pipe 5. The hose from

2. Warm water inlet pipeline evaporator to compressor
3. Warm water return pipeline 6. The hose from resevior
4. Water drain pipe bottle to evaporator
P18A00019

5. Open the cover plate of right shutter inside cab.

P18A00020
 5-19
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Figures Removal and installation

6. Remove two connectors, which connected with
evaporator and electrical system One connec-
tor lies behind the shutter of recirculating air fil-
ter element, and the other lies beside fresh air
filter.

P18A00021

P18A00022
5-20
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Figures Removal and installation

7. Remove 4 M8 mounting bolts, two of which are
in inner cab, another two are in the cab's right.

Tool: Open-end wrench 13#

P18A00023

P18A00024
 5-21
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Figures Removal and installation

8. Remove the the seal plate outside the evapora-
tor. (4 M6 bolts)

Tool: Open-end wrench 10#

P18A00025

9. Take out the entire evaporator from left to right,

and finish the removal.
Installation sequence is in reverse order of
removal sequence. The pipe connector torque
should be based on the tightening torque
requirements of the respective A/C pipe con-
nector.

P18A00026

Each Lower Part Location of Evaporator Assembly

During the actual use, the motor, circuit and other faults of evaporator assembly generally appear.
Therefore, please make an analysis on them and then disassemble the evaporator according to the
Fault Diagnosis in this manual. Each lower part location of evaporator assembly will be provided in the
following, so that it is easy to remove and install them.
5-22
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Evaporator Assembly

11

10

6
4
7

9
3
2
2
5 1 2

2
2

8
P18A00027

1. Damper motor 5. Temperature sensor 9. Strainer

2. Relay 6. Evaporator core 10.Heater core
3. Expansion valve 7. Temperature sensor 11.Evaporator blower
4. Housing 8. A/C harness
 5-23
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Replacement of A/C Control Panel

Figures Operation instructions

1. Remove the cover of control panel. (Cover is
buckled on decoration through plastic buckle
and can be directly plugged out.)

P18A00028

2. Remove four bolts fixing control panel.

3. Pull out the connector on the control panel and
then take off the control panel.

Tool: Cross screwdriver

P18A00029

Inspection and Replacement of A/C Fuse

When there is no display on A/C panel and A/C is inoperative after starting the machine, check whether
A/C fuse is burned out. Refer to the part of electric appliance in this manual for detail.
5-24
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Removal and Replacement of Reservoir

Figures Operation instructions

1. Open the rear cover.
2. Discharge the refrigerant in the A/C system as
required in Discharge (recover) the Refrigerant
out of A/C System.
3. Remove the captive bolt of the hose from
condenser to refrigerant reservoir, and the
captive bolt of the hose from refrigerant
reservoir to evaporator. Remove the pipe from
condenser to liquid reservoir, and the pipe from
liquid reservoir to evaporator. Seal up the
opening fittings with plastic bags and adhesive
tapes.

Tools: Wrench 10#, plastic bag, tape

P28A00179

4. Loosen the captive bolt on the refrigerant

reservoir bracket clamp. The refrigerant
reservoir can be removed.

P28A00180

Installation method:
1. Place liquid reservoir in the bracket, and
tighten the bolts on the bracket with a wrench.
2. Install the hose from condenser to liquid
reservoir and the hose from liquid reservoir to
evaporator onto the liquid reservoir, and control
the torque to 4~7Nm (3~5.2lbf·ft).

Tool: Wrench 10#

 5-25
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Removal and Installation of Condenser

Figures Operation instructions

1. Open the rear cover by operating the step 1-3
of Removal and Replacement of Reservoir.
2. Remove captive bolts of the hose from
compressor to condenser and the hose from
condenser to refrigerant reservoir, and seal up
the open joints with plastic bags and adhesive
tapes.

Tools: Wrench 10#, plastic bag, tape

P18A00031

3. Remove the captive bolts of condenser (4 in

total on left and right sides).

Tool: Wrench 13#

P18A00031
5-26
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Removal and Installation of Pressure Switch

Figures Operation instructions
1. Discharge the refrigerant in the A/C system as
required in Discharge (recover) the Refrigerant
out of A/C System.
2. Pull out connector of pressure switch.

P18A00032
3. Turn off the pressure switch.

Tool: Wrench 27#

The installation is in reverse order of removal

sequence.

P18A00032
 5-27
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Removal and Installation of Expansion Valve

Figures Operation instructions
1. Discharge the refrigerant in the A/C system as
required in Discharge (recover) the Refrigerant
out of A/C System.
2. Remove the bolt on the stop plate of the
expansion valve, remove the A/C hose and
seal up the open joints with plastic bags and
adhesive tapes.

Tools: Sleeve 8#, electric gun, 100mm link bar,

plastic bag, tape
P28A00182

3. Remove the mounting bolts of the expansion

valve, and then remove the expansion valve.

Tool: Internal hex wrench 4#

The installation is in reverse order of removal

sequence.

P28A00183
5-28
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Removal and Installation of Servo Electrical Motor of Air Inlet

Figures Operation instructions
1. Remove the decorative plate and fresh air
stainer on the right side of the cab.
2. Turn off the battery disconnect switch.

P28A00184

3. Remove two mounting bolts of the air inlet

electrical motor, and pull out the harness
connectors, then remove the electrical motor.

Tool: Cross screwdriver

The installation is in reverse order of removal

sequence.
P28A00185
 5-29
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of A/C Components

Removal and Installation of Evaporator Blower

Figures Operation instructions

1. Remove four mounting bolts on the right side
decorative plate of the cab, and then remove
the decorative plate.

Tool: Sleeve 10#, electric gun

P28A00186

2. Remove 11 mounting screws on the side cover

plate of the evaporator, and then remove the
side cover plate.
3. Turn off the battery disconnect switch, and pull
out the harness connectors of the evaporator
blower.

Tool: Cross screwdriver

P28A00187

4. Remove four mounting bolts of the evaporator

blower, and then remove the evaporator
blower.

Tool: Cross screwdriver

The installation is in reverse order of removal

sequence.
P28A00188
5-30
Removal and Installation November 17, 2017
Removal and Installation of A/C Components CLG835H

Removal and Installation of Solenoid Water Valve

Figures Operation instructions
1. Close two warm water valves, the valve handle
should be in vertical direction with the water
valve. Turn off the battery disconnect switch.

Tool: Cross screwdriver

P28A00189

P28A00190

2. Remove 4 mounting bolts on the right side seal

plate under the cab on the right side of the rear
frame, and then remove the right side seal
plate.

Tool: Wrench 13#

P28A00191

3. Remove two mounting bolts of the solenoid

water valve.
4. Move the solenoid water valve to proper
position, remove the water hose fixed clips on
two ends. Pull out the hose and seal up the
open joints with plastic bags and adhesive
tapes.
5. Pull out the harness connectors of the solenoid
water valve air duct, and then take out the
solenoid water valve.

Tool: Wrench 10#, straight screwdriver, plastic bag,

P28A00192 tape

The installation is in reverse order of removal

sequence.
 5-31
November 17, 2017 Fault Diagnosis and Judgment
CLG835H Classification of Common Faults

Fault Diagnosis and Judgment

Classification of Common Faults

Common faults of A/C system include:

1. The A/C panel neither displays nor functions.
2. No air comes out of A/C or air volume of A/C is small (in the case that the position is selected
correctly).
3. It generates heating or natural wind under cooling mode.
4. It generates natural wind under heating mode.

Overhauling Method

Maintenance Method When Backlight of A/C Panel is Not On and the Button Does Not
Work

Note: If the first item is normal, go to the second one, and the like.

Item Inspection items Description Troubleshooting methods

The A/C cannot be used until the Use the A/C when the machine is
1 Whether the machine is started
machine is started started
If fuse is burned, check whether
Replace and repair short circuit
2 Whether the A/C fuse is burned wiring and each load are short-
elements or parts
circuited
Whether connector XL8 is
connected properly Whether there are problems such
3 Whether the connectors at both as poor contact and exit of contact Repair the damaged parts
ends of control panel harness is pin
properly connected
Wire # 220 (gray) should be
earthed
If any abnormality occurs, it
Wire # 138 (orange) should be
indicates that the circuit of the
Pull out connector X18and check high level
4 machine is problematic. Refer to
each pin with a multimeter Wire # 800 (white) should be high
the part of electric appliance in this
level
manual for maintenance
Wire # 484 (white) should be
suspended

5 Replace the control panel

If failed to eliminate faults by the above steps, it means the harness of control panel or evaporator is out
of order, and refer to schematic diagram of A/C system for troubleshooting.
5-32
Fault Diagnosis and Judgment November 17, 2017
Overhauling Method CLG835H

Maintenance Method When No Air Comes Out of Air Conditioner or Air Outlet Volume
is Obviously Smaller Than the Normal Volume

Firstly, set air outlet volume to maximum, and listen whether there is a sound of blower operation.
If the blower is out of work, overhaul it according to the following procedures.

Blower unit is
not working.

Check
whether
the A/C fuse
is blown
No
Yes

Measure if
Check every connector clip
line and load of blower unit
for short is electrified
Yes No
circuit.

Yes No Check Select low, medium

whether the and high positions on
negative pole is corresponding panel,
grounding and respectively check
No
Yes whether pins #13, #14
Check whether
Wire or load the evaporator and #16 on control
repaired or blower impeller panel are live.
replaced The blower unit The negative wiring
is seized is faulty, replace it of blower unit is off Yes No

Yes No The relay or lines of

corresponding gear Control panel or its
on the evaporator circuit failure
Remove foreign The blower unit malfunctions.
materials is faulty, replace it

P18A00033
 5-33
November 17, 2017 Fault Diagnosis and Judgment
CLG835H Overhauling Method

If the blower operates normally, overhaul it according to the following procedures

Low air flow or

none air flow

Whether the return

air and fresh air
sensors are blocked
Yes seriously No

Check if
Clean or voltage of
replace the blower unit
relative is too low
Yes No
filters

The voltage of
complete machine
Check whether the is insufficient
condensed water drained or resistance of
from the a/c evaporator out of circuit board is
over large
vehicle drips slowly
or does not drip
Yes No

Switch off refrigeration, The blower

open doors and windows, unit is faulty
set air outlet volume in high position,
and observe for 5~-10 minutes to
see whether evaporator drains
water too quickly and air
volume is restored.

Yes No

The blower
unit is faulty
Whether air then is
too moist or low air
speed position
is used.

Yes No

Increase air Check whether

speed, and select defrosting
temperature
the temperature of sensor is damaged
slightly high position by measuring
(such as 26°C, resistance (see
cold enough is ok.) attached table).

Yes No
P18A00034

Replace control
Replacement panel P18A00034
5-34
Fault Diagnosis and Judgment November 17, 2017
Overhauling Method CLG835H

Maintenance method when warm air or natural air comes out when refrigeration is switched on

Heating or natural
air blowing under
cooling mode

Check
compressor
running
conditions
Compressor The compressor
runs normally is not working.

Turn off
the water valve
connecting the warm
water pipe on the
engine, check for
Yes malfunctions No Measure whether
the connector of
compressor clutch
has electricity
Yes No
Solenoid water valve Check the
is stuck in the open refrigerant from
position, or circuit sight glass
problems cause the
solenoid valve start
to be powered. No air bubble can be
seen from the fluid in Lots of bubbles
spection mirror or only a in sight glass Check
small amount can be seen whether Check the
there is the ground control panel
Replace the solenoid connection of Pin #18 for
water valve or check compressor electricity
the circuit Connect the manifold Check follow the housing
meter, measure pressures item 1 in the table
at high and low pressure
ends, and compare them
with normal pressure (see Yes No
table attached hereinafter). Yes No
Check follow
the item 2 in the table The refrigeration relay
on the evaporator
The electromagnetic Check
or its related lines
clutch coil is tripping whether
Repair and malfunctions
off and replace the two wires of pins
make it
clutch or No.6 and No.8 on
earthed well
the compressor control panel are
conducted.

No
Yes

Check whether the

Check the defrost pressure switch is
sensor for break circuit or breakover/connected
short circuit
Yes No
Yes No

Check the
Pressure switch high pressure of
wiring fault refrigerant
Defrost sensor or its Control panel fault
circuit failure

ψ 0. 196 Mpa ϊ 0.23 Mpa

Few refrigerant or Pressure switch or its

none refrigerant circuit failure
P18A00035
 5-35
November 17, 2017 Fault Diagnosis and Judgment
CLG835H Overhauling Method

Troubleshooting
Item Fault conditions Judged reasons
methods
Air bubbles persistently exist in sight glass, 1. Refrigerant leakage.
compressor air intake hose joint is not cold 2. Insufficient refrigerant Check and repair the leakage
enough and even warm, the upper end and lower filling amount. parts, and refill refrigerant by
1
end of refrigerant reservoir do not have referring to refrigerant
temperature difference, and temperature is higher refilling method
than or equal to ambient temperature
Compare the high and low pressures of A/C
system when it is operating, and compare them
with normal pressures (see table attached
hereinafter)
1. Normally refrigerate for several
minutes, stop refrigerating for several There is too much water
minutes, and normally refrigerate for Replace the reservoir,
several minutes…repeat like this. in refrigerating system
vacuum pumping for more
2. Compressor is operating and causes ice blockage
than 1 h, and refill refrigerant
continuously. in expansion valve
3. The pressure at the beginning of again according to the
(orifice is frozen due to
refrigeration is normal, and pressures section “A/C Refrigerant
water accumulation to
at low pressure side and high Filling Method” in this manual
pressure side when refrigeration block orifice)
stops are obviously low.
1. Touch compressor air intake hose 1. Switch on refrigeration for
joint (thicker joint) by hand to feel no about 1 minute and switch
cold. off refrigeration for about
Pressure of low pressure side and
high pressure side are both low

2. There are no big differences in 3~5 minutes with doors

temperature of the high temperature and windows open under
zone and the low temperature zone high engine speed (engine
2 of a condenser. can be at idle speed but air
3. The temperature of each part of volume shall be in highest
refrigerant reservoir is basically the position), then step on
The interior of accelerator to refrigerate
same to that of condenser outlet and
close to ambient temperature. refrigerating system is for about 1 minute…repeat
very dirty, and the like this for three times so
expansion valve orifice is that contamination and
blockage may be
blocked by dirts eliminated.
2. If the above methods are
ineffective, clean or
replace expansion valve; If
gray black or brown black
color appears in sight
glass, please make sure to
replace refrigerant
reservoir.
Replace the expansion valve.
The expansion valve If gray black or brownish
control head leaks air black color appears in sight
making the valve hole glass, please make sure to
smaller automatically replace refrigerant reservoir
altogether.
5-36
Fault Diagnosis and Judgment November 17, 2017
Overhauling Method CLG835H

Troubleshooting
Item Fault conditions Judged reasons
methods
1. Touch compressor air intake hose
joint (thicker joint) by hand to feel no
cold.
2. There are no big differences in
temperature of the high temperature
zone and the low temperature zone Line between sight glass
of a condenser. outlet and compressor air
3. The temperature of each part of intake port is blocked or
refrigerant reservoir is basically the crushed by foreign matter Remove blocked pipelines,
same to that of condenser outlet and blow out foreign matters or
close to ambient temperature.
4. There is obvious temperature release the one being
Pressure of low pressure side and

difference at both ends of the pressed to flat; If gray black

high pressure side are both low

blocked part. or brownish black color

appears in sight glass,
1. Touch compressor air intake hose
joint (thicker joint) by hand to feel no please make sure to replace
cold. refrigerant reservoir.
2. There are no big differences in Line between condenser
temperature of the high temperature outlet and sight glass
zone and the low temperature zone
of a condenser. inlet is blocked by foreign
3. There is obvious temperature matter
difference at both ends of the
blocked part.
4. Bubble is visible in sight glass.
1. Touch compressor air intake hose
joint (thicker joint) by hand to feel no
cold.
2. There are no big differences in
temperature of the high temperature Filter of refrigerant
Replace the refrigerant
zone and the low temperature zone reservoir is blocked by
of a condenser. reservoir
dirt
3. Bubble is visible in sight glass.
4. The bottom of the refrigerant
reservoir is cold and even has
condensing dew.
 5-37
November 17, 2017 Fault Diagnosis and Judgment
CLG835H Overhauling Method

Troubleshooting
Item Fault conditions Judged reasons
methods
1. Bubble is visible in sight glass.
2. Touch compressor air intake hose
joint (thicker joint) by hand to feel no
cold. Detect leakage, repair and fill
3. The upper end and lower end of Less refrigerant
refrigerant
reservoir do not have temperature
difference, and temperature is higher
than or equal to ambient
temperature.
1. Observe sight glass in the case of
compressor operation, and no air
bubble in sight glass within 5~10
seconds after refrigeration is
Pressures of low pressure side and
high pressure side are both high

switched off. Release or recycle some

2. Temperature in the condenser Redundant refrigerant
normal temperature zone almost has refrigerant
no difference with ambient
temperature.
3. The condenser high temperature
zone is hotter than normal situation.
1. There are bubbles in sight glass in Discharge the refrigerant,
the case of compressor operation. The refrigerating system vacuumize, and fill refrigerant
2. The pointer of high pressure gauge has non-condensing gas again according to the
vibrates sharply and frequently.
such as air section “A/C Refrigerant
Filling Method” in this manual
High temperature zone of condenser is
hotter than that in normal circumstance,
Dirty surface of the Clean the surface of the
and normal temperature zone of
condenser condenser
condenser is hotter than that in normal
circumstance.
1. There is too much condensing dew Expansion valve has too
on surface of low pressure pipe, and large opening degree or
middle housing of condenser is not Clean or replace expansion
hot or cold and even has condensing is stuck in large opening
valve
dew. degree position by
2. There are bubbles in sight glass. foreign matter
1. The air intake hose joint of Compressor air suction
but pressure of low pressure side is low
Pressure of low pressure side is high,

compressor is under normal valve block is damaged

temperature or warm. or cylinder body, piston or Replace the compressor
2. The pointer of low pressure gauge
swings. piston ring leaks air due
to wear
1. The compressor exhaust pipe joint is
hotter than usual.
2. The pointer of high pressure gauge
vibrates sharply.
The exhaust valve plate
of compressor is Replace the compressor
damaged
5-38
Fault Diagnosis and Judgment November 17, 2017
Overhauling Method CLG835H

Maintenance Method for Natural Air Comes Out When Heating is Switched On
Note: Please check warm water valve on engine has been opened, and engine coolant temperature has
been far above air temperature first. Or it is common to have no warm wind, it is not a malfunction.

Natural air blowing

under heating mode

Turn on and
turn off the heater,
touch the solenoid water
valve for
Yes operation No

Measure and warm air

connector of waterpipe for
solenoid water valve. It blocking or flating
shall be live at one end and bending
and be grounded
Yes No
at the other.

Solenoid water
valve fault, replace
solenoid water valve Measure
connector of
solenoid water valve.
It shall be live at one
Yes end and be grounded No
at the other.

Solenoid water valve

fault, replace solenoid
water valve
Check the output
of the control panel
pin 11 for high voltage
Yes No

Heating relay error Control panel fault,

or its circuit failure control panel
P18A00036
 5-39
November 17, 2017 System Maintenance
CLG835H A/C System Regular Maintenance

System Maintenance

A/C System Regular Maintenance

Cleaning of Recirculating Air Strainer

Figures Operation instructions

1. Open the shutter on the right of inner cab's
plate.

P18A00037

2. Screw off the two butterfly bolts of the filter, and

then remove the recirculating air strainer.
3. Blow off dust from air outlet surface to air inlet
surface of recirculating air strainer with
compressed air.

P18A00038
5-40
System Maintenance November 17, 2017
A/C System Regular Maintenance CLG835H

Cleaning of Fresh Air Strainer

Figures Operation instructions

1. Remove the shutters on the right of the cab's
cover.

P18A00039
2. Unscrew the three butterfly bolts fixing the new
air filter of A/C.

P18A00040
 5-41
November 17, 2017 System Maintenance
CLG835H A/C System Regular Maintenance

Figures Operation instructions

3. Remove the fresh air strainer
4. Blow off dust from air outlet surface to air inlet
surface of fresh air strainer with compressed
air. (The arrow in the Figure is the air intake
direction)

P28A00084

Adjustment of Compressor Belt

Figures Operation instructions

1. When a load W=1.5Kg (3.3lb) is applied to
perpendicular belt edge at neutral point of
tangential edge between belt and two belt
pulleys (A/C compressor belt pulley and belt
pulley on engine) by hand, the deflection f of
belt shall be 5±1mm (0.2±0.04In).
If belt deformation is too large or too small, it
means belt has inappropriate tension and needs to
be adjusted.

P28A00181
5-42
System Maintenance November 17, 2017
A/C System Regular Maintenance CLG835H

Figures Operation instructions

2. Loosen the captive bolts of idler.

Tool: Wrench 14#

P28A00181
3. Tighten tension bolt, and belt becomes taut;
While loosen tension bolt, the belt becomes
loose. Constantly adjust tension bolt, and test
belt deformation until belt tension becomes
appropriate.

Tool: Wrench 14#

P28A00181
4. Tighten the fixing nuts of idler.

Tool: Wrench 14#

P28A00181
 5-43
November 17, 2017 System Maintenance
CLG835H A/C System Regular Maintenance

A/C Refrigerant Filling Method

Even though there is only little water in A/C system, water vapor at low temperature part may be
frozen to cause refrigerant circulation blockage or compressor valve corrosion, etc. Therefore,
when refrigerant is refilled after parts are replaced or A/C system is reinstalled in machine,
strictly vacuumize and maintain pressure to check leakages and continue to refill refrigerant after
system airtightness is confirmed to be good.
Because A/C system is not an absolutely airtight system, the problem of deficient refrigerant may occur
after it is used for a period of time. At the moment, if refrigerant in the system is confirmed not to be
completely lost, start the operation of refilling refrigerant according to the section “A/C Refrigerant Filling
Method” in this manual.

Figures Operation instructions

1. Connect manifold gauge and A/C filler
according to the sequence specified in Release
1 2 (Recover) Refrigerant in Air Conditioning
System, and make sure there is no refrigerant
in the system.

3 4

1. Low pressure gauge

2. High pressure gauge
3. Low pressure valve(LO)
4. High pressure valve(HI)
P28A00044

2. Connect the hose connecting port A on the

manifold gauge to vacuum pump.

Tools: Vacuum pump, manifold meter

P28A00045
5-44
System Maintenance November 17, 2017
A/C System Regular Maintenance CLG835H

Figures Operation instructions

3. Start vacuum pump to vacuumize for 5
minutes, and make sure indications of high and
low pressure gauges are about -750 mm Hg or
-0.1 MPa (14.5psi).
Note: In general, high pressure gauge and its
connectors are red, and low pressure gauge and
its connectors are blue.
4. First close high pressure valve (HI) and low
pressure valve (LO) of line pressure testing
device, and then turn off vacuum pump.
5. Wait for 5 minutes in this status, and observe
that the reading of low pressure gauge shall
P28A00046
have no change. If the pressure is picked up, it
indicates there is a leakage in the system.
Check and repair leaking areas, and repeat the
steps 3-5.

The steps 6-8 below are operations for the portable

canned refrigerant is used. It may change as the
packaging type of refrigerant changes. Please
confirm that the refrigerant container is properly
connected to the manifold gauge.
6. Install the plug clock to refrigerant container.
7. Connect the hose at connecting point A of
manifold gauge to the interface mounted on
screw plug of refrigerant container.

P28A00047
8. Rotate handle of screw plug clockwise so that
pintle injector punctures refrigerant container,
and then rotate screw plug handle
counterclockwise so that the pintle injector
exits.

P28A00048
 5-45
November 17, 2017 System Maintenance
CLG835H A/C System Regular Maintenance

Figures Operation instructions

9. Loosen nut on manifold gauge connecting
refrigerant receiver connecting hose, drain air
in the filling hose by using refrigerant pressure,
and tighten nut immediately after listening
"Hissing" sound.

P28A00049

10. Open high pressure valve (4) so that refrigerant

enters high pressure side of A/C system.
1 2
11. Observe high pressure gauge, and close high
pressure valve (4) until pressures does not rise
any more.

CAUTION: At the moment, make sure that

high pressure valve has been closed, or else
subsequent operations may cause damages to
compressor.
3 4

1. Low pressure gauge

2. High pressure gauge
3. Low pressure valve(LO)
4. High pressure valve(HI)
P28A00044

12. Start the engine to idle state and open the cab's
door and window. And turn on the A/C to
cooling mode. Adjust to the maximum wind.
13. Open low pressure valve (3), depress
accelerator with the aid of a companion,
maintain the accelerator to be 80% or so, and
observe high pressure gauge and sight glasses
until the pressure reaches an appropriate value
(refer to attached table). And there is no bubble
in sight glass.
14. First turn off all the valves, then remove the
inflating unit.
5-46
System Maintenance November 17, 2017
A/C System Regular Maintenance CLG835H

The table below gives reference values about corresponding relation between pressure and
temperature. Because the actual working pressure of A/C system is related to compressor speed,
sunlight intensity, evaporator air volume and other factors, data in the table below is only for reference:

Indicating range of the high Indicating range of the low

Ambient temperature
pressure gauge pressure gauge
Celsius degree Fahrenheit
(°C) degree (°F) Kg.f/cm2 psi Kg.f/cm2 psi

15.5 59.9 8.4-10.5 121.8-152.3 1.57-1.9 22.8-27.6

21.1 70 10.5-12.6 152.3-182.7 1.57-1.9 22.8-27.6
26.2 79.2 12.6-14 182.7-203 1.67-2.1 24.2-30. 5
32.2 90 14-15.5 203-224.8 1.67-2.1 24.2-30. 5
35 95 15.5-16.5 224.8-239.3 1.77-2.1 25.7-30. 5
37.7 99.9 16.1-17.5 233.5-253.8 1.77-2.1 25.7-30.45
40.5 104.9 17.5-19.3 253.8-279.9 1.9-2.4 27.6-34.8
43.3 109.9 18.2-21.8 263.9-316.1 1.9-2.6 27.6-37.7
 6-1
November 17, 2017 Driver's Cab and Covering Parts
CLG835H

Driver's Cab and Covering Parts

Structure Function Principle ..........................................................................................6-3
Driver Cab System .................................................................................................................................6-3
Engine Hood ..........................................................................................................................................6-3
Engine Hood Assembly......................................................................................................................6-3
Opening and Closing of Engine Hood................................................................................................6-5
Lifting Mechanism of Engine Hood Torsion Bar.....................................................................................6-7

Removal and Installation ..............................................................................................6-11

Installation Requirements for Shock Cushion of Cab...........................................................................6-11
Removal and Installation of Cab ..........................................................................................................6-11
Disassembly Order of Cab Lifting ....................................................................................................6-11
Removal of Air Conditioning Components in Cab............................................................................6-11
Disassembly of Hydraulic Components in Cab ................................................................................6-11
Disassembly of Power Components in Cab.....................................................................................6-17
Replacement and Installation for Lifting Rings of Head Cover.........................................................6-21
Removal of Shock Cushion..............................................................................................................6-21
Lift ....................................................................................................................................................6-22
Removal of the Seat ............................................................................................................................6-22
Removal of the Seat.........................................................................................................................6-24
Removal of Console.............................................................................................................................6-27
Removal of Decoration ........................................................................................................................6-31
Removal of the Rear Right Positioning Lock Trim Cover in the Cab ...............................................6-31
Removal of Left Decoration of Cab ..................................................................................................6-32
Removal of Right Decoration of Cab................................................................................................6-34
Removal of Decoration of Rear Plate...............................................................................................6-35
Removal of Decoration and Platform and Attachment .....................................................................6-37
Top Decorations of Cab ...................................................................................................................6-38
Assemble the Glass of Cab .................................................................................................................6-39
Installation of the Left Door Lock in Cab ..............................................................................................6-42
Removal and Installation of Engine Hood ............................................................................................6-45
Removal and Installation of the Engine Hood Torque Mechanism ......................................................6-52
6-2
Driver's Cab and Covering Parts November 17, 2017
CLG835H
 6-3
November 17, 2017 Structure Function Principle
CLG835H Driver Cab System

Structure Function Principle

Driver Cab System

The cab system mainly consists of cab assembly, steering column assembly, driver seat assembly,
protective cover console, console assembly and rear view mirror assembly. Among which some parts of
hydraulic system, electrical system and air conditioning system are assembled on cab assembly.

Engine Hood

Engine Hood Assembly

Overview of engine hood assembly

The engine hood mainly consists of two parts: one part is that can open round the engine hood hinge;
and the other part is that fixed on the frame and radiator. The engine hood is front-hinged. The lifting
mechanism mainly includes air spring and torsion spring. The maximum opening angle of engine hood is
about 50°.

Hood

P18C00001
6-4
Structure Function Principle November 17, 2017
Engine Hood CLG835H

Main components of engine hood

P28S00228

1. Bolt 14.Bolt 27.Plate

2. Side plate-LH 15.Nut 28.Bushing
3. Bushing 16.Rope 29.Washer
4. Rod as 17.Torsion spring 30.Mounting plate
5. Bracket 18.Angle block 31.Bolt
6. Bracket 19.Bushing 32.Nut
7. Side plate-RH 20.Bracket 33.Pin
8. Plate 21.Bracket 34.Washer
9. Rear cover 22.Side plate-RH 35.Rubber plate
10.Bolt 23.Push rod 36.Supporting seat
11.Lock 24.Plate 37.Push rod
12.Torsion spring 25.Shaft 38.Bracket
13.Angle block 26.Side plate-LH
 6-5
November 17, 2017 Structure Function Principle
CLG835H Engine Hood

Precautions on removal and installation:

1. The operator for special equipments shall have corresponding operation certificate.
2. The measuring equipment and tools shall be provided with inspection certificates from metrological
service;
3. Because many other related components on the complete machine are concerned during the
removal and installation of each component, removed components (especially standard parts) shall
be reasonably placed to avoid wrong installation, neglected installation, part missing, etc. during
reassembly.
4. If the removal and installation of other components on the complete machine are concerned in the
removal and installation of each component, tools are referred to the tool list for the removal and
installation of other components 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.

Opening and Closing of Engine Hood

Opening of engine hood

Reference picture Operation step

1. Open the lock on both sides of engine rear
hood by hand.

P18C00003

2. Grab and lift the bottom handrail of rear hood

P18C00004
6-6
Structure Function Principle November 17, 2017
Engine Hood CLG835H

Reference picture Operation step

3. After the hood rises automatically, hold the
rope at the hood bottom with hand to control
the hood opening speed until it opens com-
pletely.

P18C00005

Closing of engine hood

Reference picture Operation step

1. Grab and pull down the rope until the hood bot-
tom matches with the counterweight.

P18C00006

2. Tighten the locks on the both sides.

P18C00007
 6-7
November 17, 2017 Structure Function Principle
CLG835H Engine Hood

Lifting Mechanism of Engine

Hood Torsion Bar

1. Overview-components and position

The components and position of lifting mecha-

nism of engine hood torsion bar used in com-
plete machine are as shown in the figure below
and mainly composed of rear cover, bracket and
torsion spring. The torsion bar-assist type turn-
over mechanism involved in the mechanism is
able to solve effectively the problem of difficult
closing caused by large turning torque during the
turning of torsion bar turnover mechanism, and
the provided torsion bar-assist type turnover
mechanism includes the base and the turning 9 P18C00009
parts hinged on the base. The base is provided
with torsion bar, which is mutual parallel to the 1. Rear cover 6. Torsion spring - left
2. Bracket 7. Bracket
center of rotation of mentioned turning parts with 3. Plate 8. Push rod
its one end permanently connected to the base, 4. Push rod 9. Rod as
while the other end rotates relative to base and 5. Torsion spring - right
permanently connected to lever arm; moreover, it
includes link, one end of which is hinged with 2. Overview - part working principle
lever arm, while the other end hinged with turn-
ing parts. The base, lever arm, link and turning When the torsion bar-assist type turnover mech-
parts in the torsion bar turnover mechanism anism used in this model is used on the engine
forms four-bar mechanism. hood of machine,the base acts as frame and the
turning parts act as hood; the base, lever arm,
1
link and turning parts forms four-bar mechanism;
the distance between point A and C increases
2 gradually to improve the torque in the later stage
3 during the turning process for opening the hood;
4 while the distance between point A and C
decreases gradually to reduce the torque of the
torsion bar against the turning part, i.e reducing
the tensile force necessary for closing the engine
hood to make easy closing of hood during the
turning process for closing the hood.
5
6
7
8
9 P18C00008
6-8
Structure Function Principle November 17, 2017
Engine Hood CLG835H

Figure 1 is the structure diagram that the torsion Figure 3 The structure diagram of link with
bar-assist type turnover mechanism is used on adjustable length
the hood of machine

P18C00012

P18C00010
1. Rear cover 2. Torsion bar

Figure 2 The structure diagram of the torsion

bar-assist type turnover mechanism

P18C00011

2. Torsion bar 5. Link

3. Base 7. Turnover mechanism
4. Lever arm
 6-9
November 17, 2017 Structure Function Principle
CLG835H Engine Hood

Figure 4 The relation diagram of rear cover opening angle vs required torque
rear cover and output torque of lifting mechanism
Difference between gravity moment of

Rear cover opening angle

P18C00013

As shown in the figure 2, the torsion bar-assist type turnover mechanism includes base 3, the turning
part 7 hinged on the base 3, which is provided with torsion bar2, which is mutual parallel to the center of
rotation of turning part 7, one end of torsion bar 2 is permanently connected to base 3, and the device for
adjusting the initial torque of torsion bar can be installed at this end, while the other end rotates relative
to base and is provided with spline by which permanently connected to lever arm 4; the link 5 is
connected between the free end of lever arm 4 and turning part 7, one end of link 5 is hinged with lever
arm 5 and the other end is hinged with turning part 7.
As shown in figure 2, the connection point of torsion bar 2 and lever arm 4 is point A, the articulated joint
of lever arm 4 and link 5 is point B, articulated joint of link 5 and turning part 7 is point C, articulated joint
of turning part 7 and base 3 is point D, and this four points form convex quadrangle. The included angle
formed by link 5 and lever arm 4 is acute angle. When the lever arm 4 rotates counterclockwise around
the point A, i.e the hood is being opened, the distance between point A and C increases gradually, and
included angle formed between CB and DC is reduced gradually to right angle from obtuse angle and
thus to improve the torque in the later stage during the turning process for opening the hood; when the
lever arm rotates clockwise around point A, i.e the hood is being closed, the distance between point A
and C decreases gradually, and included angle formed between CB and DC is increased gradually from
obtuse angle to reduce the torque of the torsion bar against the turning part, i.e reducing the tensile force
necessary for closing the engine hood to make easy closing of hood. When the rear cover is opened and
closed, the torsion bar-assist type turnover mechanism can provide the turning part of stable torque,
whose curve has the good consistency of matching with gravity moment of turning part.
In this example, under the condition that the specification of torsion bar is not changed, several opening
and closing force requirements of rear cover can be met through changing the effective length of lever
arm, and in case of used for opening the different weight of rear cover, the change of effective length of
lever arm can be achieved through the two methods below.
First method: the size of lever arm can be changed through changing the length of link 5 and if the link 5
uses screw mouth, whose structure is as shown in figure 3, the distance L between left U screw rod (left-
handed thread) and right U screw rod (right-handed thread) of the thread can be adjusted by rotating the
screw bushing and thus to change the length of link 5.
6-10
Structure Function Principle November 17, 2017
Engine Hood CLG835H

Second method: the adjusting mechanism is provided with long round hole at end of lever arm and
locking mechanism, the length direction of long round hole is the same with that of lever arm, articulated
shaft of link and lever arm is located in the mentioned long round hole and can move along the length
direction of long round hole, and the mentioned locking mechanism is used for locking the position of
positioning articulated shaft in the long round hole.
The Figure 4 shows the difference between gravity moment of rear cover and output torque of lifting
mechanism, and the difference refers to the force applied by operator when opening or closing the rear
cover. 0°indicates the close state of rear cover, 55° indicates the open state of rear cover. As can be
seen from the figure, when the rear cover is closed from 55° to 0°, the difference between both is
decreased gradually to make easy closing of engine hood.
 6-11
November 17, 2017 Removal and Installation
CLG835H Installation Requirements for Shock Cushion of Cab

Removal and Installation Removal of Air Conditioning

Components in Cab
Installation Requirements for Disassembly of air conditioning connector
Shock Cushion of Cab

The cushion of cab is installed with M30 bolts

and #46 torque wrench, torque value: tightening
torque (dry state) = 1055 N·m.

Removal and Installation of Cab

Disassembly Order of Cab Lifting

1. Remove A/C components →remove hydrau- When removing

lic components → remove power compo- the driver cab,
nents → remove electrical components → these four A/C
poles shall be
replace lifting rings of head cover → remove removed
cushion → lift.
2. Step of installing cab onto machine: install it P18C00014
by the opposite steps of removal.
Fluoridation of air conditioning

For fluoridation of air conditioning, refer to the

section of air conditioning in this manual.

Disassembly of Hydraulic Components

in Cab

Remove brake pedal

1. Removal steps of brake valve from the

machine:

Before removing brake valve, make sure that

the machine is in parking brake state.
6-12
Removal and Installation November 17, 2017
Removal and Installation of Cab CLG835H

Figures Operation step Tools

1. Mark the two hoses connect-
ing brake valve as "P1" and
"P2" respectively. Pay atten-
tion to that the markings
shall be firm.
Tool: Open-end
2. Loosen the joints of two wrench 27#
hoses.

P18C00015

3. Unscrew the 4 bolts tighten-

ing the brake valve.

Tool: Wrench
16#

P18C00016

4. Take out the brake valve

from the bottom of cab.
5. Shield the port of brake
valve and store it in dry and
clean place.

P18C00017

2. Step of installing brake valve onto machine: install it by the opposite steps of removal.
 6-13
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Cab

Remove console hydraulic system

1. Steps to remove the pilot valve from the machine:

First, remove all the pilot lines.

Figures Operation step Tools

1. Pull out the housing

P18C00018

2. Remove the parking brake

solenoid switch

P18C00019
6-14
Removal and Installation November 17, 2017
Removal and Installation of Cab CLG835H

Figures Operation step Tools

3. Remove the operating han-
dle and take out the armrest
upward

P18C00020

4. Screw off 4 screws and 2

bolts, and then remove the
upper housing.
Tool: cross
screwdriver, M6
inner hexagon
spanner

P18C00021
5. Remove 4 M6 captive bolts
with #10 open-end wrench,
and remove the pilot valve
from the console housing.

Tool: Wrench
10#

P18C00022
 6-15
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Cab

Figures Operation step Tools

6. Screw out pilot shutoff valve
nuts as tightened in the left
lower figure, and remove
shut-off valve.

Tool: Wrench
21#

P18C00023

2. Step of installing pilot operating valve onto machine: install it by the opposite steps of
removal.

Removal of metering pump

Figures Operation step Tools

1. Screw out 4 M10 bolts tight-
ening metering pump,
remove the metering pump
and move it out of cab.

Tool: Wrench
16#

P18C00024
6-16
Removal and Installation November 17, 2017
Removal and Installation of Cab CLG835H

Maintenance of hydraulic parts

Seat needs to be removed for maintenance of hydraulic parts. The procedures are as follows:

Figures Operation step Tools

1. Screw out 4 M8 bolts tight-
ening seat and remove seat.

Tool: Wrench
13#

P18C00025

2. Screw out 4 M10 bolts tight-

ening shield and remove the
shield.

Tool: Wrench
16#

P18C00026

3. Screw out 8 M8 bolts tight-

ening shield and remove the
bottom plate.

Tool: Wrench
#13

P18C00027
 6-17
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Cab

Figures Operation step Tools

4. Repair the hydraulic compo-
nents

P18C00028

Disassembly of Power Components in Cab

Removal of accelerator control system

Figures Operation step Tools

1. Unplug the harness connec-
tor of electronic accelerator

P18C00029

2. Lift up floor mat, remove 4

captive bolts on accelerator
control system, and remove
the accelerator control sys-
tem.
Tool:
Open-end
wrench 16#

P18C00030
6-18
Removal and Installation November 17, 2017
Removal and Installation of Cab CLG835H

Installation of accelerator control system

Installation of accelerator control system: install it by the opposite steps of removal.

Adjustment of accelerator control system

Normally, after the accelerator pedal is installed, the accelerator pedal can be operated smoothly and the
normal operating condition of engine can be guaranteed. For the cases that the accelerator pedal is diffi-
cult to operate, the accelerator pedal cannot reach its maximum position or accelerator pedal does not
return, check the installation procedures above until it can be operated smoothly.

Removal of electric appliance components in cab

The power of vehicle must be turned off before disassembling the electric appliance compo-
nents. The power (-) of the whole machine is disconnected when the negative switch is turned to
"O" (OFF). The power (-) of the whole machine is connected when the negative switch is turned to
"I" (ON).

P18C00031
 6-19
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Cab

Figures Operation step Tools

1. Screw out the earthing cable
on the front cab mounting
bracket-rh.

P18C00032

2. Pull out the ZF transmission

speed sensor on the trans-
mission-lh.

P18C00033
3. Pull out the connecting water
pipe of the washer reservoir
at the left ladder case.

P18C00034
6-20
Removal and Installation November 17, 2017
Removal and Installation of Cab CLG835H

Figures Operation step Tools

4. Pull out the shift control sole-
noid connector on the trans-
mission-rh.

P18C00035
5. Unplug the 4 rear frame har-
ness connectors on the left
mounting bracket of cab and
loosen the fixing ring nut fix-
ing the harness.

Tool:
Open-end
wrench 16#

P18C00036

6. Unplug the 1 front frame har-

ness connectors on the right
mounting bracket of cab and
loosen the fixing ring nut fix-
ing the harness.

Tool:
Open-end
wrench 16#

P18C00037
 6-21
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Cab

Replacement and Installation for Lifting Rings of Head Cover

Figures Operation step Tools

Tool:
Loosen 4 M16 bolts and replace
and install M16 lifting rings. Open-end
wrench 24#

P18C00038

Removal of Shock Cushion

1. Steps to removing the shock cushion from the machine:

Before removing cushion, make sure that the machine is in parking brake state.

Figures Operation step Tools

The cushion of cab is installed

with M30 bolts which are Tool:
screwed out with #46 torque
wrench. Mounting torque value: Open-end
tightening torque (dry state) = wrench 46#
1055 N.m.

P18C00039

2. Step of installing shock cushion onto machine: install it by the opposite steps of removal.
6-22
Removal and Installation November 17, 2017
Removal of the Seat CLG835H

Lift

Install M16 lifting rings on the cover of cab and lift the cab.

Removal of the Seat

Exploded view of driver seat

䶖ཪ
35C0877
2

3 ᢬ᢁ
34C3671

4
ᓝ䶖ᙱᡆ
14A7067

5ࠅ䴽ᷬ
47C1358

᭥ᓝ 1 6᭥ᓝᓋᶵ
14A7069
14A706B
7 ┇䖞
2048536
8 ᆿ㻻ᓋᶵ
LZY-LGZ6804001-1

P18C00040

1. Bracket(14A7068) 4. Backrest as(14A7067) 7. Slide rail(2048536)

2. Headrest(35C0877) 5. Shock absorption frame(47C1358) 8. Install the floor mat(LZY-
3. Handrail(34C3671) 6. Bracket bottom plate(14A7069) LG6804001-1)
 6-23
November 17, 2017 Removal and Installation
CLG835H Removal of the Seat

P18C00041

The seat consists of headrest, handrail, base assembly, shock mount, bracket, bracket bottom plate,
slide rail and mounting bottom plate.
6-24
Removal and Installation November 17, 2017
Removal of the Seat CLG835H

Removal of the Seat

1. Removal steps of the seat:

Figures Operation step Tools

1. As the headrest is not limited
by any fasteners and bayo-
nets, so it can be removed
by pulling out by hands
directly.
2. Insert the rod of headrest
aligning with the hole during
assembly.

P18C00042

3. Screw out two M8 cap nuts

on the side of handrail, and
the handrail can be
removed.

Tool:
Wrench 13#

P18C00043
 6-25
November 17, 2017 Removal and Installation
CLG835H Removal of the Seat

Figures Operation step Tools

4. Remove the clamp from the
dust cover by hand.
5. Remove four M8 bolts from
shock mount with #13
wrench and the backrest
assembly can be removed.

P18C00044 Tool:
Wrench 13#

P18C00045

6. Slide the seat forward;

remove the two M8 inner
hexagon bolts from the
shock mount lower part.
7. Slide the seat rearward;
remove the two M8 inner Tool:
hexagon bolts from the M8 inner hexa-
shock mount lower part. The gon spanner
shock mount can be
removed then.

P18C00046
6-26
Removal and Installation November 17, 2017
Removal of the Seat CLG835H

Figures Operation step Tools

8. Unscrew the upper bolts of
slide rail. (Slide the slide rail
forward and remove the two
front bolts; slide backward
and remove the two rear
bolts.)

Tool:
Wrench 13#

P18C00047

9. Unscrew the lower bolts of

slide rail. (Bolt head is under
mounting base plate)

Tool:
Inner hexagon
spanner #5

P18C00048
 6-27
November 17, 2017 Removal and Installation
CLG835H Removal of Console

Figures Operation step Tools

10. Unscrew the upper M12
bolts of slide rail. (Slide the
slide rail forward and remove
the two front bolts; slide
backward and remove the
two rear bolts.)

Tool:
Socket wrench
18#

P18C00049

2. Step of installing seat onto machine: install it by the opposite steps of removal.

Removal of Console

1. Removal steps of armrest:

Figures Operation step Tools

1. Remove the M10 bolts on
seat support and the console
can be removed entirely.

Tool:
Wrench 13#

P18C00050
6-28
Removal and Installation November 17, 2017
Removal of Console CLG835H

Figures Operation step Tools

2. Pull out the housing,
3. Remove the parking brake
solenoid

P18C00051

P18C00052
 6-29
November 17, 2017 Removal and Installation
CLG835H Removal of Console

Figures Operation step Tools

4. Remove adjusting lever on
the side of console and then
the armrest cushion can be
removed by pulling upward.

P18C00053

5. Screw out two M6 bolts on

support angle block of hand-
rail.

Tool:
Wrench 10#

P18C00054

6. Remove the 4 screws and 2

bolts around housing, and
then the upper housing can
be removed.
Tool:
cross screw-
driver, M6 inner
hexagon span-
ner

P18C00055
6-30
Removal and Installation November 17, 2017
Removal of Console CLG835H

Figures Operation step Tools

7. Screw out the 4 screws on
the lower housing and the
lower housing can be
Tool:
removed.
M6 inner hexa-
gon spanner,
open-end
wrench 8#

P18C00056

8. Screw out 4 M6 bolts as

tightened in the left figure,
and then remove the pilot
lever.

Tool:
Open-end
wrench 10#

P18C00057

9. Screw out pilot shutoff valve

nuts as tightened in the left
lower figure.

Tool:
Open-end
wrench 21#

P18C00058

2. Step of installing console onto machine: install it by the opposite steps of removal.
 6-31
November 17, 2017 Removal and Installation
CLG835H Removal of Decoration

Removal of Decoration

Removal of the Rear Right Positioning Lock Trim Cover in the Cab

Figures Operation step Tools

1. Screw out three setscrews
on window-rh fixing lock
cover and remove the cover.
Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00059
2. Screw out two countersunk
bolts on window-rh position-
ing lock cover.

Tool:
Screwdriver for
countersunk bolt
2 100P QB/
T2564.5-2002

P18C00060
3. Screw out the set inflating
screws on cover and remove
the cover.

Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00061
6-32
Removal and Installation November 17, 2017
Removal of Decoration CLG835H

Removal of Left Decoration of Cab

Figures Operation step Tools

1. Loosen and remove the
mounting bolt of fire extin-
guisher.

Tool:
Wrench 10#

P18C00062
2. Remove the floor mat
directly from the cab.

P18C00063
 6-33
November 17, 2017 Removal and Installation
CLG835H Removal of Decoration

Figures Operation step Tools

3. Screw off the 2 cross
recessed screws from the
cup mounting support.

Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00064

4. Remove the left door plate.

Left door plate

Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00066

5. Remove the set inflating

screws and setscrews on
Shield-lh door shield-lh and remove
the shield-lh.

Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00067
6-34
Removal and Installation November 17, 2017
Removal of Decoration CLG835H

Removal of Right Decoration of Cab

Figures Operation step Tools

1. Remove the set inflating
screws on right front
decorations and remove the
right front decorations.

Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P28C00302
2. Remove the set inflating
screws and mounting bolts
on the right side decorations
and remove the right side
decorations.
Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002, 6# Open-
end wrench

P18C00069

3. Remove the set inflating

screws on the right front side
decorations and remove the
right side decorations.
Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00070
 6-35
November 17, 2017 Removal and Installation
CLG835H Removal of Decoration

Removal of Decoration of Rear Plate

Figures Operation step Tools

1. Remove two setscrews on
access door by hands and
remove the access door.

P18C00071
2. Remove the 8 inflating
screws on the rear wall
guard plate decoration and
remove the rear wall guard
plate decoration. Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00072

3. Remove the 3 set inflating

screws on the decorations of
rear plate-lh and remove the
decorations of rear plate-lh.
Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00073
6-36
Removal and Installation November 17, 2017
Removal of Decoration CLG835H

Figures Operation step Tools

4. Remove the 4 bolts and 3
inflating screws on the deco-
rations of rear plate-rh and
remove the decorations of Tool:
rear plate-rh. Cross-screw-
driver 2 100P
QB/T2564.5-
2002, 6# Open-
end wrench

P18C00074

5. Remove the 5 bolts and 3

inflating screws on the deco-
rations of rear plate-lh and
remove the decorations of
rear plate-lh.
Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002, 6# Open-
end wrench

P18C00075
 6-37
November 17, 2017 Removal and Installation
CLG835H Removal of Decoration

Removal of Decoration and Platform and Attachment

Figures Operation step Tools

1. Remove the 7 set inflating
screws on front decorations-
lh and remove the front dec-
orations-lh.

Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00076

2. Remove the 6 set inflating

screws on front decorations-
rh and remove the front dec-
orations-rh.
Tool:
Cross-screw-
driver 2 100P
QB/T2564.5-
2002

P18C00077

3. Remove the captive bolts on

the platform decoration and
remove the platform.

Tool:
Screwdriver for
countersunk bolt

P18C00078
6-38
Removal and Installation November 17, 2017
Removal of Decoration CLG835H

Top Decorations of Cab

Figures Operation step Tools

Tool:
Cross-screw-
driver 2 100P
Remove the 12 setscrews on
QB/T2564.5-
the top decorations and remove
2002
the top decorations.
Tool: Clean non-
woven, Sika
primer.

P18C00079
 6-39
November 17, 2017 Removal and Installation
CLG835H Assemble the Glass of Cab

Assemble the Glass of Cab

Installation steps for glass:

Before installing the glass, be sure that the machine is in parking brake state.

Figures Operation step

1. Cleaning: dip a few amount of special
activating agent with clean non-woven fabrics,
and wipe the bonding position of steel window
frame in one direction.
2. Prime coat: Shake the Sika primer sufficiently
until the rolling of small ball inside the bottle
can be heard, and continue shaking for another
one minute. Wear protective gloves and apply
a circle of primer evenly on the glass-bonded
surface of window frame with a clean brush
free of dead hairs.

Clean and apply the base coat on it. Tools: Clean non-woven, sika primer.
P18C00080

3. Apply adhesive: wear protective gloves, apply

Sika adhesive evenly to the glass bonding
position or the bonding position of steel window
frame with the surface treated along glass
border, and make continuous triangular
adhesive bead.

Tool: Sika glue

Gluing
P18C00081
6-40
Removal and Installation November 17, 2017
Assemble the Glass of Cab CLG835H

Figures Operation step

4. Put rubber blocks: insert rubber blocks at the
inside of adhesive applying layer along the bot-
tom at an interval of 30~35cm.

Tool: Rubber limit block

Limit gommures Assist to affix the glass with

sucker
P18C00082

5. Check the glass if it is in good condition.

6. Bond glass: assist in installing the side glass
with glass sucker and then installing the middle
glass. Bond the glass to the steel window
frame symmetrically, and apply pressure to
bond glass, rubber blocks and steel window
frame together closely. Pay attention that the
gap between middle glass and side glass shall
be about 8mm. Meanwhile fix all the glass with
adhesive tape until the viscose dries.

Tools: Glass sucker, seal

CAUTION: The glass rim and angle should

not contact with the metal plate of cab, there
should be a clearance of 3~5mm.

Fix with adhesive tape after stickup

P18C00083
 6-41
November 17, 2017 Removal and Installation
CLG835H Assemble the Glass of Cab

Figures Operation step

7. Glass joint filler: bond the color separation
paper on both sides of adjacent glass edge,
about 5mm away from the glass edge, and
keep the spacing formed by color separation
papers on both sides consistent from up to
down; Meanwhile, seal the inside of glass joint
with color separation paper to avoid rugged
adhesive on the back when filling adhesive.
After applying adhesive, flatten with self-made
rubber plate.

Tool: Seal

CAUTION: The speed of applying adhesive

shall be even and the triangular adhesive bead
shall be uniform without lumps or breakpoints.
Insertion depth is 2mm. The rubber limit blocks
shall not be placed within the scope of 10cm
from corner point. The block shall not separate
the adhesive bead. Flatten excessive glue of
Glass gap filling sealant: One P18C00084 sheet metal side not receiving filler treatment,
line each on left and right for and no excessive adhesive shall remain.
both front and rear glasses
6-42
Removal and Installation November 17, 2017
Installation of the Left Door Lock in Cab CLG835H

Installation of the Left Door Lock in Cab

Before installing the left door lock, be sure that the machine is in parking brake state.

Figures Operation step Tools

1. Check: check whether the
left door lock parts are com-
plete and in good condition
or not.
2. Installation of lock block:
Install lock block in the
appropriate location of the Tool:
door, and fix it with M6×16 Cross screw-
screw. driver

CAUTION: The setscrews

must be tightened without
looseness.
P18C00085

3. Installation of outside han-

dle, mounting plate and pad:
Install outside handle and
mounting plate, pad in the
appropriate location of the
door together, and then fix Tool:
them with M6×20 screw. The Cross screw-
setscrews must be tightened driver
without looseness.

P18C00086
 6-43
November 17, 2017 Removal and Installation
CLG835H Installation of the Left Door Lock in Cab

Figures Operation step Tools

4. Installation of adapter plate:
Fix it with M6×16 screw, and
setscrews must be tightened
without looseness.

Tool:
Cross screw-
driver

P18C00087

5. Installation of shim and lock

buckle: Fix it with M8×20
screw after adjusting the
lock buckle to the best lock-
ing position. Setscrews must
be tightened without loose-
ness. Tool:
Cross screw-
driver

P18C00088

6. Installation of inside handle

in the left door locating lock:
Fix it with screw, and set-
screws must be tightened
without looseness.
Tool:
Cross screw-
driver

P18C00089
6-44
Removal and Installation November 17, 2017
Installation of the Left Door Lock in Cab CLG835H

Figures Operation step Tools

7. Adjust the mounting plate:
Install the link in natural state
into the mounting plate.
CAUTION: Adjust the
screw cap to the best posi-
tion, and install it into the
mounting plate. The link
needs to be left the movement
clearance as 1-1.5mm.
After installing the link, test
the opening flexibility of out-
side handle by hand, and
locking and opening in natu-
P18C00090 ral state should be flexible
and spontaneous.
8. Adjustment of the inside
handle in the left door
locating lock: Connect the
inside handle cable with the
left door locating lock with
adapter plate.
CAUTION: The setscrews
must be tightened without
looseness.
After fixing the cable and
adapter plate, the adapter
P18C00091 plate should be left the natural
movement clearance as 1-
2mm.
9. After installation, thoroughly
check whether transmis-
sion, opening and locking of
each parts of door lock are
flexible or not.

P18C00092
 6-45
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Engine Hood

Removal and Installation of Engine Hood

Removal of engine hood:

Reference picture Operation step Tools required

1. Remove the mounting bolts
of the left/right shield (sym-
metrical on both sides, 6 in
total) with wrench, remove
the left/right shield and place
them on the level ground.

P18C00093
Tool:
Wrench 16#

P18C00094

2. Open the engine hood to the

maximum angle, remove the
harness connectors of
license plate light, rear view
camera.
Hold the rear lifting points of Tool:
rear cover with crane, lifting Sling (1t), lifting
rings, etc. ring (2×M16)

P18C00095
6-46
Removal and Installation November 17, 2017
Removal and Installation of Engine Hood CLG835H

Reference picture Operation step Tools required

3. Remove the bolt assembly
of torsion spring at left and
right sides of engine hood.

P18C00096 Tool:
Wrench 24#

P18C00097

4. Remove the link bolts at left

and right sides of engine
rear hood and 4 in total.
Remove the captive bolts (2
in total) of hinge pin at left
and right sides of engine
rear hood and knock out the
pin.

P18C00098
 6-47
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Engine Hood

Reference picture Operation step Tools required

5. Lift the engine rear hood out
slowly and place it on the
level ground.

Tool:
Traveling crane
Sling

P18C00099

6. Remove the 4 captive bolts

from exhaust pipe tail sec-
tion and remove the exhaust
pipe.

Tool:
Open-end
wrench 13#

P18C00100

7. Remove the anchor bolts (4

in total) at left front and right
front sides of engine upper
hood bracket.

Tool:
Open-end
wrench 19#

P18C00101
6-48
Removal and Installation November 17, 2017
Removal and Installation of Engine Hood CLG835H

Reference picture Operation step Tools required

8. Remove the captive bolts (4
in total) at left rear and right
rear sides of engine upper
hood bracket.

Tool:
Open-end
wrench 19#

P18C00102

9. Lift up the upper hood slowly

and place it on the level
ground

Tool:
Traveling crane
Sling

P18C00103
 6-49
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Engine Hood

Installation of engine hood

Step of installing engine hood onto machine: install it by the opposite steps of removal.

Reference picture Operation step Tools required

1. Lift and install the rear hood
and hinge support together
to the complete machine
with a sling, a overhead
crane, etc.

Sling (1t)

P18C00104

2. After adjusting the position

of hood, install the bolts of
hood hinge support to the
brackets on the left and right
sides of hood with 16#
wrench and tighten them.

Wrench 16#

P18C00105

3. Operate the overhead crane

to lift and open the rear hood
to an angle about 50°

Sling (1t)

P18C00106
6-50
Removal and Installation November 17, 2017
Removal and Installation of Engine Hood CLG835H

Reference picture Operation step Tools required

4. Pass the torsion spring
through the hinge support
from both sides respec-
tively,where the torsion
spring- left is at bottom while
the torsion spring - right is at
top.

P18C00107

5. Adjust the position of torsion

spring and slowly lock the
torsion spring with bolts and
nuts, during which try to
loosen the lifting point and
the overhead crane can be
removed when the opening
angle of hood is kept
between 50°-52° without Wrench
changing.

P18C00108
 6-51
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Engine Hood

Reference picture Operation step Tools required

6. Pull down the lock along with
the direction of arrow to
close the engine hood slowly
until the pull force is nearly
the same with that of hood
before removal and installa-
tion and the hood adjust-
ment is completed, and if the
pull force is too large, the nut
and bolt locking the torsion
spring can be properly loos-
ened under the condition of
ensuring about 50° opening
of engine hood and if the
hood is opened less than
50°, the nut and bolt locking
the torsion spring can be fur-
P18C00109 ther tightened Wrench

P18C00110
6-52
Removal and Installation November 17, 2017
Removal and Installation of the Engine Hood Torque Mechanism CLG835H

Reference picture Operation step Tools required

7. Install the pedals-lh and rh
and shields-lh and rh and
tighten the mounting bolts
with 13# wrench (symmetri-
cal on both sides, 4 in total).

Wrench 13#

P18C00111

Removal and Installation of the Engine Hood Torque Mechanism

Disassembly of lifting mechanism of torsion bar

Reference picture Operation step Tools required

1. Refer toRemoval of engine
hood:
2. Remove the left and right
torsion spring from both
sides respectively.

P18C00112
 6-53
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of the Engine Hood Torque Mechanism

Reference picture Operation step Tools required

3. Remove the push rod at left
and right sides

P18C00113

4. Remove the bolts from the

engine hood hinge support
with 16# wrench (symmetri-
cal on both sides, 10 in
total).

Wrench 16#

P18C00114

5. Lift and place the left and

right support on the level
ground with overhead crane.

Overhead crane
(1t), Manila rope

P18C00115
6-54
Removal and Installation November 17, 2017
Removal and Installation of the Engine Hood Torque Mechanism CLG835H

Installation of lifting mechanism of torsion bar

Reference picture Operation step Tools required

1. Lift and place the left and
right support on the
mounting position with
overhead crane.

Overhead crane
(1t), Manila rope

P18C00116

2. Tighten the bolts of the

engine hood hinge support
with 16# wrench
(symmetrical on both sides,
10 in total).

Wrench 16#

P18C00117

3. Place the left and right push

rods at the mounting
position.

P18C00118
 6-55
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of the Engine Hood Torque Mechanism

Reference picture Operation step Tools required

4. Pass the torsion spring
through the hinge support
from left and right sides
respectively,where the
torsion spring- left is at
bottom while the torsion
spring - right is at top.
Copper bar

P18C00119

5. Refer toInstallation of engine

Wrench 16#
hood
6-56
Removal and Installation November 17, 2017
Removal and Installation of the Engine Hood Torque Mechanism CLG835H
 7-1
November 17, 2017 Structure
CLG835H

Structure
Structure Function Principle ..........................................................................................7-3
Frame System........................................................................................................................................7-3
Hinge Assembly .....................................................................................................................................7-4
Counterweight Assembly .......................................................................................................................7-5
Work Device...........................................................................................................................................7-6
Work Implement Parameters .............................................................................................................7-6
Overview and Configuration Scheme of Work Implement System ....................................................7-6
Work Implement Limit System ...............................................................................................................7-8

Removal and Installation ................................................................................................7-9

Removal and Installation of Hinge Assembly.........................................................................................7-9
Removal of Hinge Assembly ..............................................................................................................7-9
Installation of Hinge Assembly .........................................................................................................7-13
Removal and Installation of Counterweight Assembly .........................................................................7-20
Removal of Left and Right Battery Boxes (take left battery box as an example) .............................7-21
Installation of Left and Right Battery Boxes (take left battery box as an example) ..........................7-24
Removal and Installation of Work Implement System..........................................................................7-25
Removal and Installation of Linkage ................................................................................................7-25
Removal and Installation of Rocker Arm..........................................................................................7-28
Removal and Installation of the Boom .............................................................................................7-31
Replacement of Work Implement Bushing.......................................................................................7-36
Removal and Installation of Accessory System ...................................................................................7-38
Removal and Installation of Bucket..................................................................................................7-38
Replacement of Bucket Movable Blade, Movable Tooth and Tip ....................................................7-41
Optional Work Implement and Accessory System ...............................................................................7-43
Option of Work Implement System ..................................................................................................7-43
Option of Accessory System ............................................................................................................7-43
7-2
Structure November 17, 2017
CLG835H
 7-3
November 17, 2017 Structure Function Principle
CLG835H Frame System

Structure Function Principle

Frame System

Frame Overview

The frame system includes front frame and rear frame. Front frame is of a welded frame structure, and
installed with front axle system, work implement system, etc. Rear frame is of a welded frame structure,
and mainly consists of engine system, transmission & torque converter system, rear axle assembly,
cooling system, engine hood assembly, counterweight, etc.

Frame Structure Diagram

1 2 P28S00224

1. Front frame 2. Rear frame

7-4
Structure Function Principle November 17, 2017
Hinge Assembly CLG835H

Hinge Assembly

Overview and configuration scheme of hinge assembly

The hinge assembly is the key part to connect front frame and rear frame and make front and rear
frames to function in relatively steering.

P18S00002
1. Bolt 8. Bolt 15.Tapered roller bearing 22.Spacer sleeve
2. Washer 9. Washer 16.Grease fitting 23.Tapered roller bearing
3. Plate 10.Bolt 17.Bearing cover 24.Spacer sleeve
4. Lower hinge pin 11.Bolt 18.Bolt 25.Seal ring
5. Hinge pin 12.Bearing cover 19.Bearing cover 26.Bearing cover
6. Shim 13.Shim 20.Shim
7. Pin-on-disk 14.Seal ring 21.Seal ring
 7-5
November 17, 2017 Structure Function Principle
CLG835H Counterweight Assembly

Counterweight Assembly

Overview and Structure Diagram of Counterweight Assembly

Counterweight assembly is mainly connected and installed on both sides of rear frame tail by bolts, and
mainly used for installing the battery, disconnect switch, rear floodlight, etc.

2
2

3
3

2 3

P28S00225

1. Counterweight assembly 2. Plug 3. Bolt

7-6
Structure Function Principle November 17, 2017
Work Device CLG835H

Note: If it is necessary to remove or install left and right battery boxes, first take out plug, and then install
three M24 lifting ring screws, which are used for lifting the left and right battery boxes. When lifting the
battery box, the lifting ring screw and the lifting eye need match up nicely.

Lifting eye

P28S00226

Work Device

Work Implement Parameters

Standard boom+1.8 Extension boom+1.8 cube Ultra-long jib +3.0 cubic

Item cube bucket bucket bucket
Metric system British system Metric system British system Metric system British system
Dumping
2920mm 114.96In 3200mm 125.98 In 3644mm 143.46 In
height
Dumping
1014mm 39.92In 1004mm 39.53 In 1394mm 54.88 In
reach
Breakout force
105000N 23604Ibf 100000N 22480 Ibf 71500N 16073 Ibf
of the bucket
Breakout force
71600N 16096 Ibf 65400N 14702 Ibf 49900N 11217 Ibf
of the boom

Overview and Configuration Scheme of Work Implement System

As a reverse six-link mechanism, work implement is the critical part for the whole loader to load,
transport and dump, etc. Bucket is installed on the front end of work implement, and the rear end is
connected to front frame by the pin.
 7-7
November 17, 2017 Structure Function Principle
CLG835H Work Device

Work implement system

11

10 9 6
5
7
8
11

11
6
9
10

4 11

7 8
2

7
8

4 11
3 P28S00112

1. Boom 7. Washer
2. Rocker arm 8. Bolt
3. Linkage 9. Cushion cover
4. Link pin 10.Bolt
5. The middle pin of rocker arm 11.Oil cup
6. Pin assembly

Note: At each hinge pin shaft of work implement, the adjustable shim with appropriate thickness shall be
selected according to assembly clearance to make sure that the unilateral clearance is less than 1mm.
7-8
Structure Function Principle November 17, 2017
Work Implement Limit System CLG835H

Work Implement Limit System

Work implement limit system is mainly used to limit cylinder stroke so as to protect the cylinder and
whole work implement.
Schematic diagram of standard boom limit system

P28S00113

1. Block group 2. Bolt 3. Block grou

Requirements for work implement limit system assembly (Note: take standard boom as an
example here):

1. When the pin is 465mm from the ground, turn up the bucket to form an angle of 48° with horizontal
plane, then select the block with appropriate thickness in block components (1) to install it on plane A
according to the clearance between planes A and B, and guarantee it clings with plane B.
2. When the pin is 3,730mmmm from the ground, and the discharge angle is 45°, select block with
appropriate thickness in block components (3) to install it on plane C according to the clearance
between planes C and D, and guarantee it clings with plane D.
 7-9
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Hinge Assembly

Removal and Installation

Removal and Installation of Hinge Assembly

Removal of Hinge Assembly

Removal description: Before removing the hinge assembly, please remove bucket assembly, work
implement assembly, front axle assembly, cab assembly, engine assembly, transmission assembly,
radiator assembly, cover assembly, counterweight assembly, hydraulic system and electrical system,
etc., and only reserve front frame, rear frame, rear axle assembly and tire.

Figures Operation instruction Tools

1. Pad the front and rear ends
of rear frame with special
firm tooling to make sure
rear frame is in level, safe
and steady state (the front
end of rear frame is 660mm/
25.98in from the ground, and
Ground
the rear end is 980mm/
P18S00006
38.58in from the ground).
2. Hook the front frame by a lift-
ing appliance and tighten the
hanger slightly.
CAUTION: The personnel
operating lifting equipment Hoisting equip-
shall have relevant ment (over 5ton)
qualifications, and only can
operate on the premise that
equipment and lifting sling
are normal and safety is
guaranteed!
3. Install steering fixed link to
prevent front and rear
frames rotating.
Nipping pliers

P11000188
7-10
Removal and Installation November 17, 2017
Removal and Installation of Hinge Assembly CLG835H

Figures Operation instruction Tools

4. Remove upper hinge pin.
1) Remove the upper hinge
captive bolt and take down
the cover plate.

18# Wrench

P18S00008

2) Knock out the upper hinge

pin with pin knocking tooling
and sledge hammer.

Pin knocking
tooling and
sledge hammer

P18S00009
5. Remove lower pin.
1) Remove the captive bolt of
the lower hinge lock plate
and take off the plate.

18#, 24#
Wrench

P18S00010
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November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Hinge Assembly

Figures Operation instruction Tools

2) Knock out the lower hinge
pin with pin knocking tooling
and sledge hammer.

Pin knocking
tooling and
sledge hammer

P18S00011
3) Remove the spacer sleeve.

Removal tooling
of spacer sleeve

P18S00012

6. Remove steering fixed link,

and lift the front frame out
with lifting equipment and
place on firm ground.
 CAUTION: The personnel
operating lifting equipment Hoisting equip-
shall have relevant ment (over 5ton)
qualifications, and only can
operate on the premise that
P11000188 equipment and lifting sling
are normal and safety is
guaranteed!
7-12
Removal and Installation November 17, 2017
Removal and Installation of Hinge Assembly CLG835H

Figures Operation instruction Tools

7. Remove 6 captive bolts from
upper hinge and remove the
upper and lower end cover.

18# Wrench

P18S00014
8. Remove eight captive bolts
from lower hinge, and
remove upper cover and
lower end cover.

18# Wrench

P18S00015
 7-13
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Hinge Assembly

Figures Operation instruction Tools

9. Knock out the bearings of
upper and lower hinge with
bearing knocking tooling and
sledge hammer.

Bearing knock-
ing tooling and
sledge hammer

P18S00016

Installation of Hinge Assembly

Figures Operation instruction Tools

1. Lift rear frame with lifting
equipment and put it on spe-
cial firm tooling to make sure
it is in level, safe and steady
state (the front end of rear
frame is about 660mm/
25.98in from the ground, and
the rear end is about
980mm/38.58in from the Hoisting equip-
ground). ment (over 5ton)
 CAUTION: The personnel
Ground operating lifting equipment
P18S00017 shall have relevant
qualifications, and only can
operate on the premise that
equipment and lifting sling
are normal and safety is
guaranteed!
2. Put two pairs of bearing
cone cups into liquid nitro-
Liquid nitrogen,
gen for freezing until there is
hook fixture
not a lot of smoke coming
out.
7-14
Removal and Installation November 17, 2017
Removal and Installation of Hinge Assembly CLG835H

Figures Operation instruction Tools

3. Install dust rings into upper
and lower covers respec-
tively, and apply grease to
the lip of dust ring and the
inner walls of upper and
lower hinge hole.
Copper bar

P18S00018

4. Fix the lower hinge lower

cover on the rear frame with
bolts.

18# Wrench

P18S00019
 7-15
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Hinge Assembly

Figures Operation instruction Tools

5. Install one frozen tapered
roller bearing cone cup into Copper bar and
lower hinge hole. bearing knock-
ing tooling

6. Install two tapered roller

bearing cones into lower
hinge holes, and pay atten-
Copper bar
tion that two tapered roller
bearing cones are in oppo-
P18S00020 site directions.
7. Install another frozen taper
roller bearing cone cup into
lower hinge hole.

Copper bar and

bearing knock-
ing tooling

P18S00021

8. Select the shim with

appropriate thickness, install
the shim and upper and
lower covers, tighten
mounting bolts, and
tightening torque is: 18# Wrench
120±10N.m/ 88.5±7.375
lbf·ft. Torque wrench

P18S00022
7-16
Removal and Installation November 17, 2017
Removal and Installation of Hinge Assembly CLG835H

Figures Operation instruction Tools

9. Install the tooling for Bearing torque
measuring bearing torque. tooling
10. Measure the torque needed
to rotate upper hinge
bearing, and normal torque
is: 2.3~13.6N.m/ 1.7~10.03
Torque wrench,
lbf·ft. If the torque is not
18# wrench
within the scope, it can
decrease or increase the
shims to reach normal
rotating torque.
P18S00023 11. Install the lower hinge
referring to Steps 4~10.
12. Install the lower hinge
spacer sleeve

Copper bar

P18S00024

13. Measure the torque needed

to rotate lower hinge bear-
ing, and normal torque is:
7.9~22.6N.m/ 5.83~16.67
lbf·ft. If the torque is not Torque wrench
within the scope, it can
decrease or increase the
shims to reach normal rotat-
ing torque.
 7-17
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Hinge Assembly

Figures Operation instruction Tools

14. Install the lower bushing.

Copper bar

P18S00025

15. Lift front frame to mounting

position with lifting equip-
ment, and align the hinge
hole of front frame with that
of rear frame.
 WARNNING: Fingers
cannot be put into the hole
when aligning with the hole,
otherwise it may cause Hoisting equip-
personal injury! ment (over 5ton)
 CAUTION: The personnel
operating lifting equipment
shall have relevant
qualifications, and only can
operate on the premise that
equipment and lifting sling
are normal and safety is
guaranteed!
7-18
Removal and Installation November 17, 2017
Removal and Installation of Hinge Assembly CLG835H

Figures Operation instruction Tools

16. Install lower hinge pin.

Copper bar

P18S00026
17. Install upper hinge pin.

Copper bar

P18S00027
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November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Hinge Assembly

Figures Operation instruction Tools

18. Select the shim with appro-
priate thickness, install the
shim and lock plate, tighten
mounting bolts and the
torque of bolts fixing the
hinge pin is 68±14Nm/ 18#, 24#
50.15±10.325lbf·ft. spanner, torque
spanner

P18S00028
19. Install the upper hinge cover,
tighten mounting bolt, and
tightening torque is:
90±12N.m/ 66.375±8.85
lbf·ft.
18#
Wrench,torque
wrench

P18S00029
20. Install the joint of lubrication
pipe.

P18S00030
7-20
Removal and Installation November 17, 2017
Removal and Installation of Counterweight Assembly CLG835H

Removal and Installation of Counterweight Assembly

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 13#, 16# 2

2 Sleeve 32# 1
3 Lifting ring M20 1
4 Cross screwdriver 1
5 Sling 1

Other information
Weight of left counterweight 180kg
Weight of right counterweight 400kg

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipings, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.
 7-21
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Counterweight Assembly

Removal of Left and Right Battery Boxes (take left battery box as an example)

Removal description: Before removing left and right battery box, please remove radiator system and fuel
tank assembly.

Figures Operation instructions

1. Park the Machine and lift up the hood to the top
end.
2. Remove the diesel tank by referring to the
relevant chapter.

P28S00129

3. Remove the left counterweight

3.1 Remove 4 mounting bolts from the upper cover
plate and remove the cover plate.

P28S00130
7-22
Removal and Installation November 17, 2017
Removal and Installation of Counterweight Assembly CLG835H

Figures Operation instructions

3.2 Remove the harness connector (1) from the
battery.

2 4 3.3 Remove the relay mounting screw (2) from the

press plate and remove the relay.
3.4 Remove the press plate captive bolt (3) and
3 remove the press plate.
A
1 3.5 Take out the plug (2) from the lifting hole and
install a lifting ring. The lifting ring needs match up
the lifting eye (A) to lift the counterweight.

P28S00227 3.6 Hang the left counterweight with crane and

remove the counterweight mounting bolt (5). Lift
out the counterweight slowly, and place it at a
clean and safe place.

P28S00132

4. Take out the plug from the lifting hole of right

counterweight and install the lifting ring.

P28S00133
 7-23
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Counterweight Assembly

Figures Operation instructions

4.1 Remove the harness of the tail lamp.

P28S00134

4.2 Hang the counterweight with lifting rope,

remove the right counterweight captive bolt, lift out
the counterweight slowly and move it to a clean
and safty place.

P28S00135
7-24
Removal and Installation November 17, 2017
Removal and Installation of Counterweight Assembly CLG835H

Installation of Left and Right Battery Boxes (take left battery box as an example)

Figures Operation instructions

1. First take out plug (4), and then install two M24
4 4
lifting screws

P18S00031

2. Hang lug screws with hoisting equipment, lift

up the counterweight to mounting position, and
align with bolt mounting hole
 CAUTION: Do not put your fingers into the
holes when aligning, otherwise it may cause
personal injury!
The hoisting device operator shall have
relevant qualifications, and only when the
equipment and the lifting device work normally
for the sake of safety can they operate!
3. Install 3 mounting bolts and shims. Tightening
torque is 410±50N.m.

P28S00136
 7-25
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Removal and Installation of Work Implement System

Removal and Installation of Linkage

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 15#, 18# 1

2 Copper bar 1
3 Sling 1

Other information
Linkage weight 35.5kg

Removal of Linkage

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.

Figures Operation instructions

1. Remove front pin of link
Remove the linkage front pin by referring to the
steps for removing linkage front pin in removal of
bucket.
2. Remove rear link pin
1) Remove captive bolt of rear pin of link.

P18S00035
7-26
Removal and Installation November 17, 2017
Removal and Installation of Work Implement System CLG835H

Figures Operation instructions

2) Hang the link by a hoisting equipment and
tighten the hanger slightly.
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
3) Knock out the rear pin of link with pin knocking
tool and sledge.

P18S00036
4) Lift the link off to the firm ground with the
hoisting equipment.
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
 7-27
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Installation of Linkage

Figures Operation instructions

1. Install rear link pin
1) Lift the linkage off to mounting position with
hoisting equipment, and align the front end
hole of rocker arm with the rear end hole of
linkage.
 WARNING: Do not put your fingers into the
holes when aligning, otherwise it may cause
personal injury!
CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
2) Install rear link pin, and simultaneously select
the shim with appropriate thickness according
to clearance of rocker arm and link to make
sure the clearance at one side is less than
1mm.

P18S00038

3) Install captive bolt

P18S00039

2. Install front link pin

By referring to the steps for installing front link pin
in installation of bucket (P7.4.2), install front link
pin.
7-28
Removal and Installation November 17, 2017
Removal and Installation of Work Implement System CLG835H

Removal and Installation of Rocker Arm

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 15# 1
2 Copper bar 1
3 Sling 1

Other information
Rocker arm weight 140kg

Removal of Rocker Arm

Figures Operation instructions

1. Remove the linkage.
Remove linkage by referring to the steps for
installing and removing linkage.
2. Remove bucket tilting cylinder.
By referring to the steps for removing bucket tilting
cylinder in hydraulic system, remove the bucket
tilting cylinder from the machine.
3. Remove the middle pin of rocker arm.
1) Remove middle pin captive bolt of rocker arm.

P18S00040

2) Hook the rocker arm by a hoisting equipment

and tighten the hanger slightly.
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
 7-29
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Figures Operation instructions

3) Knock out the middle pin of rocker arm with
pin knocking tool and sledge.

P18S00041
4) Lift the rocker arm off to the firm ground with
the hoisting equipment.
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
7-30
Removal and Installation November 17, 2017
Removal and Installation of Work Implement System CLG835H

Installation of Rocker Arm

Figures Operation instructions

1. Lift rocker arm off to mounting position with
hoisting equipment, and align the middle pin
hole of rocker arm with arm mounting hole on
the boom.
 WARNING: Do not put your fingers into the
holes when aligning, otherwise it may cause
personal injury!
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
2. Install the middle pin of rocker arm, and
simultaneously select the shim with appropriate
thickness according to clearance of rocker arm
and boom to make sure clearance at one side
is less than 1mm.

P18S00041
3. Install captive bolt.

P18S00040
 7-31
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Removal and Installation of the Boom

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 16# 1
2 Wrench 18# 1
3 Copper bar
4 Sling 1

Other information
Boom weight 700kg

Removal of Boom

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.
The appropriate container shall be used to collect the liquid before removing any hydraulic oil
lines or disassembling any components that contain liquid during the inspection, maintenance,
test and adjustment of the machine. Dispose all the fluid in accordance with local laws and
regulations.

Figures Contents
1. Remove the bucket
By referring to steps for removal of bucket,
remove the bucket.
2. Remove the linkage
By referring to the steps for removing the link in
removal and installation of link, remove the link
3. Remove the rocker arm
By referring to the steps for removing the
rocker arm in removal and installation of rocker
arm, remove the rocker arm
7-32
Removal and Installation November 17, 2017
Removal and Installation of Work Implement System CLG835H

Figures Contents
4. Remove bucket tilting cylinder
By referring to the steps for removing bucket
tilting cylinder in hydraulic system, remove
bucket tilting cylinder
5. Remove boom cylinder
By referring to the steps for removing boom cyl-
inder in hydraulic system, remove boom cylin-
der
6. Remove lubrication pipe.

P28S00136
7. Remove the boom pin.
1) Lift by boom beam with hoisting equipment,
and strain lifting sling for holding the boom.
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!

P18S00048
 7-33
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Figures Contents
2) Remove the captive bolts of boom pin at left
and right sides.

P18S00047
3) Knock out boom pins on right and left sides
with pin knocking tooling and sledge.

P18S00046
4) Lift out the boom with hoisting equipment
gently and place it on firm ground
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
7-34
Removal and Installation November 17, 2017
Removal and Installation of Work Implement System CLG835H

Installation of Boom

Please keep clean. All the components shall be cleaned thoroughly with cleaning solution prior
to assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all the components. If the
components are worn or damaged, please replace them with new ones.

Figures Contents
1. Lift the boom off to mounting position with
hoisting equipment, and align boom hole with
the boom mounting hole on front frame.
 WARNING: Do not put your fingers into the
holes when aligning, otherwise it may cause
personal injury!
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!

P18S00048

2. Install boom pin, and simultaneously select the

shim with appropriate thickness according to
clearance of boom and front frame to make
sure clearance at one side is less than 1mm.

P18S00046
 7-35
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Figures Contents
3. Install captive bolt.

P18S00047
7-36
Removal and Installation November 17, 2017
Removal and Installation of Work Implement System CLG835H

Replacement of Work Implement Bushing

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 16#, 18# 2

2 Straight screwdriver Piece 1
3 Copper bar Piece 1
4 Sling Set 1
5 Liquid nitrogen Tank 1

Replacement of Linkage Bushing

Figures Operation instructions

Replace the linkage bushing

3 1. Remove the seal ring (3) with a flat head

screwdriver.
1 2 2. Knock out the linkage bushing (2) with bushing
knocking tooling and sledge hammer.
3
3. Put new linkage bushing (2) into liquid nitrogen
for freezing until there is not a lot of smoke
coming out.
3 4. Install frozen linkage bushing (2) into linkage
(1) with bushing knocking tooling and sledge
hammer , and reserve mounting position for
2 seal rings on both sides.
3
P28S00137 5. Knock new seal ring (3) into linkage (1) gently
with copper bar.
 7-37
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Work Implement System

Replacement of Rocker Arm Bushing

Figures Operation instructions

Replace the rocker arm bushing

1. Remove the seal ring (3) with a flat head
screwdriver
11 2. Knock out rocker arm bushing (2) with bushing
knocking tool and sledge
3
3
22 3. Put new rocker arm bushing (2) into liquid
nitrogen for freezing until there is not a lot of
33
smoke coming out
4. Install frozen rocker arm bushing (2) into rocker
arm (1) with special striking tool and sledge,
and reserve mounting position for seal rings on
both sides
5. Knock seal ring (3) into rocker arm (1) gently
1. Rocker arm
with copper bar
2. Rocker arm bushing
3. Seal ring
P18S00052

Replacement of Boom Bushing

Figures Operation instructions

Replace the boom bushing
3 2 1. Remove seal rings (3, 6) with a flat head
3 screwdriver
3
1 2 2. Knock frame bushing (2), boom bushing (4)
3 and bushing (5) out in sequence with bushing
knocking tooling and sledge hammer
3
3 3. Put new frame bushing (2), boom bushing (4)
and bushing (5) into liquid nitrogen for freezing
4 until there is not a lot of smoke coming out
3
3 4. Install frozen frame bushing (2), boom bushing
6 (4) and bushing (5) into the boom (1) in
5 4 sequence with bushing knocking tooling and
6
6 sledge hammer, and reserve mounting position
5 for seal rings on both sides
6
P28S00212 5. Knock seal rings (3, 6) into the boom (1) gently
with copper bar.
7-38
Removal and Installation November 17, 2017
Removal and Installation of Accessory System CLG835H

Removal and Installation of Accessory System

Removal and Installation of Bucket

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 18# 1
2 Wrench 15# 1
3 Copper bar Piece 1
4 Sling Set 1

Other information
Weight of bucket 715kg

Bucket removal

Relevant preparation before starting:

See the section of Machine Placement for parking the machine.

Please keep clean. Thoroughly clean the outer surface of the components before removal. It will
prevent foreign matters from entering the mechanism.
Stick label identification stickers on all pipelines, hoses, circuits and steel tubes for easier
installation. Clog up all the pipelines, hoses and steel tubes. That will prevent fluid loss and
prevent dirts from entering the system.

Figures Operation instructions

1. Remove front pin of link
1) Start the machine, put the boom in the lowest
position; lay flat the bucket and then switch off.
2) Disassemble the captive bolt of front link pin.

P28S00138
 7-39
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Accessory System

Figures Operation instructions

3) Lift by front end of link with hoisting
equipment, strain lifting tool gently, and
remove front link pin with sledge and pin
knocking tooling.
 CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
4) Gently put front linkage end to ground with
hoisting equipment, and pad the ground
contact with rubber or paperboard to prevent
bumping against the ground.
CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!

P18S00055
7-40
Removal and Installation November 17, 2017
Removal and Installation of Accessory System CLG835H

Installation of Bucket

In order to guarantee the traceability of the machine and bucket, the bucket cannot be replaced
when installed!
Please keep clean. All the components shall be cleaned thoroughly with cleaning solution prior
to assembly. The components are allowed for natural drying. Never wipe them dry with cloth. The
fiber from the cloth will accumulate on the parts and cause fault. Check all the components. If the
components are worn or damaged, please replace them with new ones.

Figures Contents
1. Install the lower pin of the bucket
1) Install front O-ring of boom.

P18S00058

2) Lift the bucket off to mounting position with

hoisting equipment, and align the lower pin
hole of bucket with the front end hole of boom.
 WARNING: Do not put your fingers into the
holes when aligning, otherwise it may cause
personal injury!
CAUTION: The hoisting device operator
shall have relevant qualifications, and only
when the equipment and the lifting device
work normally for the sake of safety can they
operate!
 7-41
November 17, 2017 Removal and Installation
CLG835H Removal and Installation of Accessory System

Figures Contents
3) Install the lower bucket pin on left and right
sides, and simultaneously select the shim with
appropriate thickness according to the
clearance of bucket and boom to make sure
the clearance at one side is less than 1mm.

P18S00059

4) Install captive bolts at left and right sides.

P28S00139

Replacement of Bucket Movable Blade, Movable Tooth and Tip

Tools required
Tool(s) Part description Standard Quantity

1 Wrench 50# 1
2 Copper bar 1
3 Sling Set 1
7-42
Removal and Installation November 17, 2017
Removal and Installation of Accessory System CLG835H

Figures Operation instructions

1. Replace the tip:
1) Use the hammer and pin knocking tooling to
remove the pin (9) connecting the tip and tooth
body.
2) Take out the tip (8) and the retainer (10).
3) Install new retainer (10) and tip (8).
4) Align the tip with tip mounting hole, and install
1 2 3 4 5 2 6 7 new pin (9).
2. Replace the middle tooth of bucket:
1) Remove the nut (2) and lock bolt (1) of fixing
tooth.
2) Take out the tooth (13).
3) Install new tooth (13) on main cutting board
(12).
4) Install new lock bolt (1) and nut (2).
3. Replace the side tooth of bucket:
1) Remove the nut (2) and lock bolt (6) of fixing
13 12 11 10 9 8
side tooth.
1. Lock bolt 8. Gear sleeve 2) Take out the side tooth (7).
2. Nut 9. Pin
3) Install new side tooth (7) on main cutting
3. Nut 10.Retainer board (12).
4. Washer 11.Movable Blade
5. Bolt 12.Cutting edge 4) Install new lock bolt (6) and nut (2).
6. Lock bolt 13.Gear body 4. Replace the movable blade:
7. Side gear body P18S00080
P18S0008
1) Remove nut (3), washer (4) and bolt (5) from
fixing movable blade.
2) Take down movable blade (11).
3) Place new movable blade (11) on
corresponding position of main cutting board.
4) Align the mounting holes of movable blade
and main cutting board, and install new bolt
(5), washer (4) and nut (3).
 7-43
November 17, 2017 Removal and Installation
CLG835H Optional Work Implement and Accessory System

Optional Work Implement and Accessory System

Option of Work Implement System
Work implement system has standard boom, extension jib and ultra-long jib for selection, please refer to
"Work Implement Parameters", and select it according to practical use and working conditions.

Option of Accessory System

Procedure for bucket selection:
1. Identify the target condition.
2. According to working condition, select suitable bucket type according to Attached Table 1 - Bucket
Classification Table.
3. Look up the attached table 3 Bulk Density of Bulk Materials to obtain the corresponding density of
material under working conditions.
4. According to material density value, select corresponding bucket capacity by checking Attached
Table 2 - Recommendation List for Bucket Selection.

Attached table 1: The bucket classification

Type of Buckets Acceptable density range Main purposes

It is applicable to various working conditions, provided with
GP bucket 1.2~1.9t/m3 excellent insertion performance and material holding
performance
It is mainly used under conditions of loose light loading
Light loading hopper 0.8~1.25t/m3 material
Rock bucket 1.8~2.0t/m3 It is used under conditions of heavy load, such as rocks, etc.

Attached table 2:

Bucket full rate

Density P28S00140
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Removal and Installation November 17, 2017
Optional Work Implement and Accessory System CLG835H

Attached table 3:
Bulk density and repose angle of loose materials

Bulk Repose angle Bulk Repose angle

Material density Material density
/t·m-3 Motion Rest /t•m-3 Motion Rest

Anthracite (Dry and

0.7~1.0 27°~30° 27°~45° Zinc flue dust 0.7~1.5
small)
Bitumite 0.8 30° 35°~45° Pyrite cinder 1.7~1.8
Plumbum-zinc
Lignite 0.6~0.8 35° 35°~50° 1.3~1.8
briquette
Peat 0.29~0.5 40° 45° Pyrite pellet 1.2~1.4
Slag of the open
Peat (damp) 0.55~0.65 40° 45° hearth furnace 1.6~1.85 45°~50°
(coarse)
Coke 0.36~0.53 35° 50° Blast furnace slag 0.6~1.0 35° 50°
Lead and zinc
Charcoal 0.2~0.4 granulated slag 1.5~1.6 42°
(wet)
Anthracite culm 0.84~0.89 37°~45° Dry coal ash 0.64~0.72 35°~45°
Bitumite powder 0.4~0.7 37°~45° Coal ash 0.70 15°~20°
Graphite powder 0.45 40°~45° Grit (dry) 1.4~1.9 50°
Magnet ore 2.5~3.5 30°~35° 40°~45° Silver sand (dry) 1.4~1.65 30°
Hematite 2.0~2.8 30°~35° 40°~45° Silver sand (damp) 1.9~2.1 30°~35°
Limonite 1.2~2.1 30°~35° 40°~45° Modeling sand 0.8~1.3 30° 45°
Limestone (large
Manganese ore 1.7~1.9 35°~45° 1.6~2.0 30°~35° 40°~45°
block)
Magnesia Limestone (medium
2.2~2.5 40°~42° 1.2~1.5 30°~35° 40°~45°
(agglomerate) block)
Magnesia powder 2.1~2.2 45°~50° Quicklime 1.7~1.8 25° 45°~50°
Copper ore 1.7~2.1 35°~45° Gravel 1.32~2.0 35° 45°
Copper concentrate 1.3~1.8 40° Dolomite (block) 1.2~2.0 35°
Plumbum
1.9~2.4 40° Dolomite fragment 1.8~1.9 35°
concentrate
Zinc concentrate 1.3~1.7 40° Gravel 1.5~1.9 30° 30°~45°
Plumbum-zinc
1.3~2.4 40° Clay (small block) 0.7~1.5 40° 50°
concentrate
Sintered iron 1.7~2.0 45°~50° Clay (wet) 1.7 27°~45°
Sinter fragment 1.4~1.6 35° Concrete 0.9~1.7 35° 40°~45°
Slaked lime
Lead sinter 1.8~2.2 0.5
(powder)
Lead-zinc sinter
1.6~2.0 Slaked lime (block) 2.0
cake
 8-1
November 17, 2017 Electrical System
CLG835H

Electrical System
Basic Information ............................................................................................................8-3
Instructions of Service Manual ...............................................................................................................8-3
Cautions for Welding Operation .............................................................................................................8-4
The Introduction of Signs on the Electrical Schematic...........................................................................8-5

Structure Function Principle ..........................................................................................8-7

Power System ........................................................................................................................................8-7
Function Introduction..........................................................................................................................8-7
Engine Start Switch............................................................................................................................8-9
Fuse .................................................................................................................................................8-11
Battery Disconnect Switch ...............................................................................................................8-13
Battery..............................................................................................................................................8-14
Contactor and Relay ........................................................................................................................8-16
Starting Module ....................................................................................................................................8-19
Start Contactor .................................................................................................................................8-23
Starting Motor...................................................................................................................................8-24
Alternator..........................................................................................................................................8-25
Monitoring System ...............................................................................................................................8-27
Circuit for Engine Water Temperature Indication .............................................................................8-27
Circuit for Torque Converter Oil Temperature Indication .................................................................8-27
Circuit for Engine Oil Pressure Alarm ..............................................................................................8-29
Circuit for Transmission Oil Pressure Alarm ....................................................................................8-29
Circuit for Fuel Level Indication........................................................................................................8-31
Circuit for Vehicle Speed Indication .................................................................................................8-33
Service Brake Indication Circuit .......................................................................................................8-33
Circuit for Parking Brake ..................................................................................................................8-35
Circuit for Parking Brake Power Cut-off ..........................................................................................8-36
Circuit for Service Brake Clutch ON/OFF.........................................................................................8-38
Circuit for Air Filter Blockage Alarm .................................................................................................8-39
Circuit for Alternator Charging Indication .........................................................................................8-39
Circuit for Voltage Indication ............................................................................................................8-40
Circuit for Seatbelt Indicator.............................................................................................................8-41
Circuit for Lubrication System Failure Indicator ...............................................................................8-41
Circuit for Lubrication System Activated Indicator............................................................................8-42
8-2
Electrical System November 17, 2017
CLG835H

Circuit for Steering System Failure Indicator....................................................................................8-42

Circuit for Secondary Steering Indicator ..........................................................................................8-43
Circuit of Ride Control Indicator .......................................................................................................8-46
Circuit for Radiator Fan Reverse Indicator.......................................................................................8-48
Circuit for Engine Indicator...............................................................................................................8-49
Instrument ........................................................................................................................................8-50
Audible and Visual Alarm System ........................................................................................................8-54
Circuit for Electric Horn ....................................................................................................................8-54
Circuit for Backup Alarm ..................................................................................................................8-56
Wiper and Washer System ..................................................................................................................8-57
Circuit Diagram for Wiper and Cleaning System..............................................................................8-57
Wiper Motor......................................................................................................................................8-58
Washer Reservoir ............................................................................................................................8-59
Positioner and Kickout System ............................................................................................................8-60
Principle for Auto Reset System ......................................................................................................8-60
Lighting System ...................................................................................................................................8-62
Circuit for Front Frame Illumination..................................................................................................8-62
Circuit for Cab Lighting.....................................................................................................................8-65
Circuit for Rear Frame Illumination ..................................................................................................8-68
Shift Control System ............................................................................................................................8-70
Principle for Shift Control .................................................................................................................8-71
Electronic Control Unit .....................................................................................................................8-74
Shift Selector....................................................................................................................................8-74
Audio System .......................................................................................................................................8-76
Audio System Principle ....................................................................................................................8-76
Radio................................................................................................................................................8-77
Speaker............................................................................................................................................8-77
Antenna............................................................................................................................................8-77
Engine Electric Control Module............................................................................................................8-78
Electronic Throttle Line ....................................................................................................................8-78
Radiator Fan Control Module ...............................................................................................................8-78
Control Strategy ...............................................................................................................................8-78
Seat Heater ..........................................................................................................................................8-79
Appendix ..............................................................................................................................................8-80
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November 17, 2017 Basic Information
CLG835H Instructions of Service Manual

Basic Information The module failure diagnosis and test introduced

in the Manual does not cover all the faults, thus
please rack your brain and focus on the
Instructions of Service Manual accumulation of experience during the
troubleshooting.
The Manual is written by introducing the different In order to describe the electrical principles
modules divided by the main functions of intuitively, colored filling lines are applied to
electrical system, whereby, the maintenance present the current flow when introducing the
operations of maintenance technicians are electrical system principles in the Manual.
facilitated as they are enabled to promptly find Full consideration to the relationship between the
the chapters and sections corresponding to the general and the individual (system and
failure at any time. Besides, the professional component) when determining the failures will
descriptions are compiled to be accessible in the contribute to the rapid, accurate and facilitated
Manual, nonetheless, the maintenance troubleshooting.
personnel shall be provided with necessary
professional knowledge to understand the On condition that digital multimeter (hereinafter
Maintenance Manual. referred to as DMM) is applied to detect faults,
the inherent measuring errors might result in a
When dividing the modules, the Manual starts value slightly differing from that described in the
from introducing the functions of the module, Manual. For instance, when selecting the 200Ω
then presents the main components of the of Ω gear of DMM, the values described in the
functions, including the principles, functions an Manual are comparable through shorting out the
electrical diagrams of main components. red and black probes, measuring the lead
Whereafter, operation of module function and the resistance and subtracting such lead resistance
diagnosis and test of module failure are from the measured resistance of other circuits.
introduced.
The component symbols on the schematic
diagram indicate the representing methods of
components on the diagram. The majority of
component symbols signify the actual schematic
diagram of the components, whereas, the
exceptions are specified when introducing the
components. It will help to judge the failure
symptom of components.
The component failure detection methods are
also included in the component descriptions
herein. In particular, such methods are only for
the components, whereby, the failures are
detected through dismounting the components
from the complete machine. As it is unfeasible to
detect the failures in accordance with the above-
mentioned methods if the components are
mounted on the complete machine. Then
determine in line with the failure detection
methods described behind the system, or
disassemble the components if necessary, to
judge the condition of components based on the
component troubleshooting method.
8-4
Basic Information November 17, 2017
Instructions of Service Manual CLG835H

Cautions for Welding Operation

Be sure to comply with the correct welding

procedures, so as to safeguard the electrical
components and bearings against potential During welding, the earthing point of welder
damages. When welding on a loader or diesel on the frame shall be close to the welding
engine equipped with electrical components, point to the greatest extent, for which a
please follow the operating steps below: reliable large-area earthing shall be
guaranteed.
1. Park the machine on flat ground.
Do not use the earth point of any electric
2. Turn the engine start switch to "OFF" position component on the machine as the earth point
to shut down the diesel engine. of the welding machine!
3. Engage the parking brake. For welding near the earth point of the
4. Turn off the battery disconnect switch, and electric appliance, you must not perform
shut off the connection between battery and welding operation until you disconnect the
frame. earth point of the electric appliance and make
sure that the welding circuit of the welding
5. Clamp the parts to be welded with the machine does not pass through the electric
grounding cable of the welder tightly. The appliance. Otherwise, it will damage the
closer the grounding position with the components of the electric appliance, and
welding, the better. Check from earthing even lead to a fire!
cable to circuit of welding assembly, to verify
any of the below components has not been To prevent possible losses, for the machine
passed through: equipped with electronic control
components, such as the control unit EST-
● Bearings 117 of ZF, control box, instrument, and engine
● Hydraulic cylinders ECM etc., ensure that the welding circuit is
disconnected from that of the
● Internal circuits of the controller or other aforementioned electronic control
electrical units. components before weldment, while the
connectors closest to such control
Doing in this way is to keep the following parts
components shall be unplugged to cut the
away from the possible damage:
circuit off.
● Bearings
● Hydraulic parts
● Electronic components
● Other available components of the machine
6. Keep the inflammables away from the
welding site while protect the cables, to
safeguard them against the loss and damage
resulted from the fire caused by splashing
sparks and welding slag.
7. Perform the weldment according to the
normal welding safe performing procedure.
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November 17, 2017 Basic Information
CLG835H Instructions of Service Manual

The Introduction of Signs on the Electrical Schematic

Graphic symbol of double position manual

Graphic symbol of the control switch
control switch
S/N Name Graphic symbol Description S/N Name Graphic symbol Description

Normally Emergency stop

1 Pressure switch 1 Keeping
open switch

Normally Instantaneo
2 Pressure switch 2 Button switch
closed us acting

Temperature
3 3 Knob switch Keeping
switch

Instantaneo
4 Liquid level switch 4 Knob switch
us acting

Induction
5
proximity switch

Magnetic
6 induction
proximity switch

Graphic symbol of the relay Graphic symbol of the electromagnet

S/N Name Graphic symbol Description S/N Name Graphic symbol Description

One group of
Electromagnet
1 GP relay normally-open 1
of the switch
contacts
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Basic Information November 17, 2017
Instructions of Service Manual CLG835H

Graphic symbol of the relay Graphic symbol of the electromagnet

S/N Name Graphic symbol Description S/N Name Graphic symbol Description

A group of break-
before-make
With contact
changeover Proportional
2 relay normally 2
contacts, coil in electromagnet
closed
parallel to
restrain diode

Double-coil
3
electromagnet

Light and signal graphic symbol Graphic symbol of the sensor

S/N Name Graphic symbol Description S/N Name Graphic symbol Description

1 Lamp 1 Rheostat sensor

Rotating Temp sensor

2 2
beacon with alarm switch

Pressure sensor
3 Electric horn 3
with alarm switch

Inductive speed
4 Buzzer 4
sensor

5 Speaker

6 Flash relay
 8-7
November 17, 2017 Structure Function Principle
CLG835H Power System

Structure Function Principle

Power System

Function Introduction

The power system equipped in this machine supplies power to the electrical appliances of the complete
vehicle. The diesel engine is powered by battery separately before starting, which is then jointly powered
by battery and alternator during running.
Under normal operating circumstances, the normal power supply is available through switching on the
engine start switch or starting the diesel engine.
The electrical components, including dome lights, rotating beacons, hazard flashers, clearance light and
electric horn work properly once the negative switch is closed.
Other than the backup alarm and air conditioning function module, the electrical components are ready
for normal use once the engine start switch is turned to position ON.
Schematic diagram of Power System

P18E00001
8-8
Structure Function Principle November 17, 2017
Power System CLG835H

Analysis of the electrical schematic diagram

1. After closing the negative switch, the circuit is shown as below. The bus fuse, which does not pass
through the engine start switch, is powered. Red part represents the powered section, while the
arrows indicate the current directions, the same representing methods are applied to the sections
below.

P18E00002

2. The power relay contacts turn on once the engine start switch is turned to Position ON, and the bus
fuse, which passes through the engine start switch, is powered.

P18E00003
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November 17, 2017 Structure Function Principle
CLG835H Power System

Engine Start Switch

Circuit power-on diagram

Connector
code
Gears
Steering
column

P28E00154
P28E00151
Specification of the positions of the engine
start switch

"HEAT"-The first gear of the clockwise rotating

key after inserting the key to the engine start
switch. This gear is generally used for the air
intake preheating control of the complete
machine of non-electronic fuel injection engine
and incapable of self-hold, after releasing, the
engine start switch key returns automatically to
"OFF" position.
"OFF"-the position to insert and extract the
electrical lock key. At this gear, cut off the power
P28E00152 the electrical equipment on the vehicle. Except
for some electrical equipment (such as dome
light), which are controlled by the battery
disconnect switch instead of the engine start
switch.
"ON"-The first gear of the clockwise rotating key
after inserting the key to engine start switch.
"ON" connects the powers of electrical
equipment throughout the machine, which are
powered by battery.
"START"-the second gear of the clockwise
P28E00153 rotating key after inserting the key to the engine
start switch. This gear starts the diesel engine,
which is incapable of self-hold. The key to the
engine start switch returns automatically to "ON"
once it is loosened.

Precautions

After starting the oil engine, loosen the key of the

electrical lock immediately to make it return to its
position. Otherwise it will lead to serious
electrical fault.
8-10
Structure Function Principle November 17, 2017
Power System CLG835H

Switch off the engine start switch if it fails to start Procedures of failure detection for the engine
for the first time, then proceed on to second start switch
starts. First turn the electrical lock key to "OFF"
position. Second, turn it to the "ON" position; 1. Unplug the connectors connected with the
Finally to "START" position, which completes a engine start switch, thus to separate the
startup circle. engine start switch from the machine circuit.
If the diesel engine fails to start within 15S, 2. Turn the digital multimeter to 200 Ω of Ω
switch off the engine start switch. Continual position.
starting should be less than three times. Each 3. According to the engine start switch gear
start time shall be controlled within 15S, or else logical table, pins with " " in each gear should
power loss may be resulted in for the continuous be connected, and the display value of
high-power output of battery. multimeter should be "0" when measuring;
If the diesel engine fails to start in three pins with " " and without " " should be
consecutive trials, switch off the engine start disconnected, and the value of multimeter
switch, and implement the second starting round should be "1" when measuring. Otherwise, it
after 30 minutes. Inspect the battery and start can be judged as the engine start switch
circuit, if necessary, to see whether there are fault.
failures in the way of starting. Note: "0" indicates the resistance between the
A majority of the start difficulties happen two pins is measured as zero; "1" indicates the
outdoors in the cold winter, where the ambient resistance between the two pins is infinite.?
temperature may be even lower than 5°C. If
possible, try to start the diesel engine indoors Circuit power-on diagram
instead, or improve the start with auxiliary Connector
heating. code
Gears
For the disassembly of other components of the
machine induced by the engine start switch
removal or installation, please refer to the
corresponding tool lists which are excluded from
the section hereof.

P28E00154
 8-11
November 17, 2017 Structure Function Principle
CLG835H Power System

Fuse The colors of plug-in fuse vary in accordance

with the specifications, the specifications and
Fuse acts as protecting terminal equipment colors of plug-in fuses applied in the machine,
during short circuit or overcurrent. Different together with the corresponding LiuGong part
series of fuses are applied in the power system, numbers are listed in the table below for
such as plug-in fuse and bolt fuse. The reference only.
specifications of plug-in fuse diversified from 20A
LiuGong
to 15A, 10A, 7.5A and 5A, for the branch circuits. component number
Specification Color
The specifications of bolt fuse ranges from 30A,
50A, 60A, 80A, 150A, for the main circuit. 37B2023 5A Brown

Location diagram of complete bolt type fusing 37B2024 7.5A Brown

machine 37B2025 10A Red
37B2026 15A Blue
37B2027 Running time Yellow

P28E00568

Location diagram of complete inserting disk fus-

ing machine

P18E00008
8-12
Structure Function Principle November 17, 2017
Power System CLG835H

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

P18E00009

1. Aux control 4 13.Standby 12 25.Standby 1

2. DC-DC 14.Engine start switch 26.Standby 3
3. Aux control 2 15.Fuel lift pump 27.Standby 5
4. Headlight 16.Aux control 1 28.Standby 7
5. Standby 6 17.Flasher/small lamp 29.Electric horn / backup alarm
6. Seats 18.Emergency steering system 30.ECM power
7. Front work light 19.Radio and tape player/cigar Lighter 31.Standby 13
8. Standby 2 20.Aux control 3 32.Brake light
9. Standby 4 21.Instrument 33.Right brake light
10.ECM power 22.Rear work light 34.Left brake light
11.Left small lamp 23.Defroster
12.Right small lamp 24.Wiper system
 8-13
November 17, 2017 Structure Function Principle
CLG835H Power System

Precautions
Battery Disconnect Switch
The specifications of different fuses are available
from calculation during the circuit design,
accordingly, the blown fuse shall be replaced
with that of the same series and specifications.
Don’t replace the fuse with a fuse of different
specifications.
On condition that the replacement of blown fuse
break down again, proceed on replacing after
inspecting the circuit under the jurisdiction of the
fuse and troubleshooting.

The troubleshooting method of fuse P28E00568

Remove the plug-in fuse from the fuse holder, to Precautions

determine the condition of fuse visually. The
inspection methods of bolt fuses can also be 1. Be sure to turn off the negative switch at the
applied in the judgment. end of each operation or driving, or else
severe consequences (such as electric
Adjustment steps for blowout of bolting type fuse: leakage) might be resulted in;
1. Turn the digital multimeter to 200 Ω of Ω 2. Don’t close the negative electrode switch
position. during engine’s running. Such error has a
2. Connect both terminals of the fuse with the severe influence on the electrical systems of
DMM probes respectively. the complete machine.

3. The indicated value "1" of the DMM signifies 3. Turn off the engine start switch and then the
that the fuse is blown and replacement is negative switch to halt the machine.
needed, while the value "0" displayed on the 4. Turn on the negative switch and then the
DMM indicates the good service condition of engine start switch to start the machine.
fuse.
5. Be sure to turn off the negative switch before
Battery Disconnect Switch connecting battery cable, fastening the pile
tip of battery cable or disassembling battery
Battery disconnect switch regulates the cable.
connection between battery (-) and the machine 6. Be sure to turn off the negative switch before
frame. The power (-) of the whole machine is implementing welding operation on the whole
disconnected when the battery disconnect switch machine.
is turned to "O" (OFF). The complete vehicle
electrical equipment cannot work even turn on
the electrical lock. Turn the battery disconnect
switch to "I" (ON), the power (-) of the whole
machine is connected. Whereby, the engine start
switch controls the connections between the
electrical components and powers throughout
the machine, as well as starts the diesel engine.
8-14
Structure Function Principle November 17, 2017
Power System CLG835H

Battery gently after it is fully cooled. The battery shall be

scrapped, provided that the above-mentioned
The machine obtains +24 V power through the transparently light color remains.
series connection of 2 batteries. The rate 1. Turn the negative switch to state "0". Turn the
capacity is 55Ah, and cold-starting current is electrical lock to "OFF", and extract the key.
850CCA.
2. Disassemble the battery from the machine.
As reversible DC (direct current), the battery Turn off the battery cable (-) and battery
connects in parallel with the alternator to jointly cable (+) successively before disassembling
power the electrical equipments of the complete the battery.
machine. Battery supplies great current in a short
time, to start the motor and further drive the 3. Wipe the battery terminal and surface with a
diesel engine to start. Besides, the battery clean cloth, to remove the oxide scale on the
serves as an electrical appliance, which surface.
safeguards electrical equipment of the machine 4. Connect the charger positive (+) clip to the
through absorbing the overvoltage arising from battery positive (+) terminal, while charger
the circuit at any moment. negative (-) clip to the battery negative (-)
terminal at room temperature. Confirm that
the battery terminals are clean, and the
charging circuit is in good connection.
5. Charge the battery with the charger of 16.0V
(within 16.2V) constant voltage until the
battery hydrometer turns green. The green
hydrometer indicates that the battery is fully
charged.
6. On condition that constant voltage is
P18E00011 unavailable, use constant current instead.
Charge the battery with 12A charging current
until the battery hydrometer turns green. The
State detection of battery
green hydrometer indicates that the battery is
Observe the built-in hydrometer of the battery fully charged.
cover in well-lighted condition, to figure out the The relative relationship of auxiliary charging
charge state of battery or take appropriate time with voltage of battery:
measures in accordance with the color displayed
Battery 12.45~ 12.45~ 12.45~ 12.45~
in the hydrometer, in particular:
voltage 12.55V 12.35V 12.20V 12.05V
Indicator color Green Black Transparent Recharging
2 hours 3 hours 4 hours 5 hours
Need be Need be time
State or solution Good
charged replaced Battery 12.45~ 11.95~ 11.80~ 11.65~
voltage 11.95V 11.80V 11.65V 11.50V
Battery charging Recharging
6 hours 7 hours 8 hours 9 hours
time
For the batteries whose hydrometer is black,
Battery 11.50~ 11.30~ Below
recharging is required. voltage 11.30V 11.00V 11.00V
For the batteries whose hydrometer has Recharging
10 hours 12 hours 14 hours
transparently light color, there might be bubbles time
in the hydrometer. Whereupon, remove all the
battery connecting cables and shake the battery
 8-15
November 17, 2017 Structure Function Principle
CLG835H Power System

7. For the battery suffering severe power loss, it Steps of battery troubleshooting
may be non-chargeable at the beginning of
charging. As battery charging proceeds, the The machine is in braking state, while the shift
charging current of battery can return to control lever is in neutral position. The
normal gradually. It takes about 14 hours to densimeter mounted inside the battery cover is
complete the charging process. green. The test in this step need assist of
partner.
8. If the battery temperature gets too high
(approximately 45 °C) during the charging 1. Turn the negative switch to position "0".
process, stop charging the battery until the 2. Turn the digital multimeter to 50 V of voltage
battery is cooled to room temperature, then position.
recharge it through halving the charging
current. 3. Connect the red probe of DMM to the positive
terminal of one battery, while the black probe
9. Check the hydrometer state once every hour to the negative terminal of the other battery.
during battery charging. The green battery Be sure not to connect them to the cable
hydrometer indicates that the battery has terminals. The value displayed on the DMM
been fully charged, and stops charging at this shall be controlled within "24" to "32" V.
time.
4. Keep the two pointers of the digital
10. Coat the terminal with Vaseline after the multimeter still. Put disconnect switch in the
charging is completed, to prevent galvanic position of "I". Switch on the electrical lock
corrosion. and start the diesel engine.
Precautions for battery charging 5. The value displayed on the DMM is between
"20" to "24"V at the moment the cranking
1. Never charge two batteries in series. motor starts running. The value returns to
2. Maintain a ventilated environment during that described in step 3 once the diesel
charging, and charge at a normal engine starts smoothly.
temperature. Any battery that is capable of completing the
3. If acid is sprayed from the battery vent during above steps and successfully starting the diesel
charging, the charging shall be stopped engine, is in good service condition; otherwise,
immediately. test by following steps.

4. Charge the battery in well-ventilated area, 1. Disconnect all the battery connecting cables,
and pay attention to the electrical safety. thereby, two batteries are completely
disconnected.
5. Any battery that leaks or has a broken
housing, shall rather be scrapped than 2. Turn the digital multimeter to 50 V of voltage
recharged. position.

6. Any battery that has a broken terminal, shall 3. Connect the red probe of DMM to the positive
rather be scrapped than recharged. terminal of one battery, while the black probe
to the negative terminal, the value displayed
7. Any battery that is inflated or bulged for over- on the DMM is around "12" to "16" V.
discharge or overcharge, shall rather be
scrapped than recharged. 4. Inspect the other battery according to step3.
The displayed value is the same as the step
8. If the hydrometer remains black after being 3. Any battery that fails to implement the test
charged for a period of time, check whether procedures, shall be charged or replaced.
the charging cable is well connected, the joint
point is clean, or the charging voltage
reaches 16V.
8-16
Structure Function Principle November 17, 2017
Power System CLG835H

Contactor and Relay Precautions

The machine is equipped with a contactor for +A1 indicates the current input direction, and -A2
power control, besides, other than normally shows the current output direction. In the case of
closed contacts, a group of normally open connection error, the inoperative magnetic
contacts is also provided. Both the contactor blowout function of contactor will shorten its
parameters and internal schematics are labeled service life.
on the contactor housing. The rated current of Socket relay is concentrated on the control box,
normally open contacts on the contactor contact of which the location schematic and function
circuit is 100A. Apply +24V voltage to the diagram are as shown below. The location and
contactor coil, then the electromagnetic force function definitions of socket relay will not appear
generated by the energized attracts the armature hereinafter.
inside the contactor, whereby, the normally open
contracts switch on.
The contactor is assembled around the
centralized control box of electric appliance.

P18E00012

P18E00013
 8-17
November 17, 2017 Structure Function Principle
CLG835H Power System

P28E00569
8-18
Structure Function Principle November 17, 2017
Power System CLG835H

S/N Definition PDM number S/N Definition PDM number

K1 Electric horn 31B0173 K13 Front window washer 31B0173
K2 Brake light 31B0173 K14 Auto swing arm shock absorber 31B0173
K3 Fan reversing 31B0173 K15 Back-up Alarm 31B0173
K4 Defroster 31B0173 K16 G Relay 31B0173
K5 Secondary steering 31B0173 K17 D Relay 31B0173
K6 Standby 31B0173 K18 Starting protection 31B0173
K7 Standby 31B0173 K19 Neutral startup interlock 31B0173
K8 Ready to regenerate 31B0173 K20 Boom limit 31B0173
K9 Fuel lift pump 31B0173 K21 Bucket positioning 31B0173
K10 Standby 31B0173 K22 Standby 31B0173
K11 Wiper Position 2 31B0173 K23 DCU power 31B0095
K12 Wiper Position 1 31B0173 K24 Heating valve 31B0095
FL1 Flasher 31B0005

Troubleshooting procedures of power relay

1. Remove the relay from the relay socket.

2. Turn the digital multimeter to 200 Ω of Ω position.
3. Connect the red probe of DMM to the relay terminal "86", while the black probe to terminal "85", the
value displayed on DMM shall be around 250Ω thereby.
4. Turn the digital multimeter to 200 Ω of Ω position.
5. Connect the one probe of DMM to the relay terminal "30", while the other to terminal "87", the value
displayed on DMM shall be "1" thereby;
6. Apply +24V external power (+) to the terminal "86" of relay, while (-) to terminal "85"; on the other
hand, connect one probe of DMM to the terminal "30" of relay, the other probe to terminal "87",
thereby, the DMM displayed value shall be "0".
After completing the above steps, if the values displayed on DMM conform to that described in the steps,
the relay is in good service condition.
The above steps are inapplicable to the operating contacts where the abrasion is very severe.

Mini-relay Micro-relay
 8-19
November 17, 2017 Structure Function Principle
CLG835H Starting Module

Starting Module

Schematic diagram of starting module

P28E00570
8-20
Structure Function Principle November 17, 2017
Starting Module CLG835H

Analysis of the electrical schematic diagram

1. Turn on negative switch and turn the engine start switch to "ON", the analysis of the schematic
diagram hereof can be found in the power supply system;
2. Turn the shift control lever to neural position, No.584 wire of the ZF shift controller outputs a high
level signal of (+24V); No.800 wire of engine D+ outputs a low level;

P28E00571
 8-21
November 17, 2017 Structure Function Principle
CLG835H Starting Module

3. After the engine start switch is rotated to START;

P28E00572
8-22
Structure Function Principle November 17, 2017
Starting Module CLG835H

4. After the machine starts, No.800 wire of alternator D+ outputs high level signal, and starter protection
function is enabled, at the same time release the engine start switch from "START" to "ON".

P28E00573
 8-23
November 17, 2017 Structure Function Principle
CLG835H Starting Module

Start Contactor

A contactor of 100A is equipped in the machine to control the start. The rated load current of the
contactor contact circuit is 100A, only a group of operating contacts are provided as normally open
contacts. Apply +24V voltage to the contactor coil, and the generated electromagnetic force drives the
internal armature to switch on the operating contact-normally open contact against the spring force.
Whereby, the external circuit, of which the rated load current is 100A, is connected. Disconnect +24V
applied voltage to the contactor coil, the contactor recovers to reset condition.

P28E00575
Troubleshooting procedures of contactor

1. Turn the digital multimeter to 200 Ω of Ω

position.
2. Connect both probes of DMM to the
connector terminals of the contactor
respectively, the value displayed on DMM
shall be around "96Ω" thereby.
3. Connect both probes of DMM to the bolts
(the operating contact terminals) of the
contactor respectively, the value displayed on
DMM shall be around "1" thereby.
P18E00020
4. Apply +24 V power to the connector (coil
Precautions terminal) of contactor, while connect both
probes of DMM to the bolts of contactor
A1+ indicates the current input direction, and A2- respectively, the value displayed on DMM
shows the current output direction. In the case of shall be around "0" thereby.
connection error, the inoperative magnetic
After completing the above steps, if the values
blowout function of contactor will shorten its
displayed on DMM conform to that described in
service life.
the steps, the contactor is in good service
condition. The above steps are inapplicable to
the operating contacts (normally open) where the
abrasion is very severe.
8-24
Structure Function Principle November 17, 2017
Starting Module CLG835H

Starting Motor

The starter motor equipped in the machine is configured for 24V/4.8KW. The DC motor within the starter
motor translates the electrical energy of battery into mechanical energy, whereby the internal
transmission gear drives the motor flywheel to start the engine.

P18E00022 P18E00022

P28E00584
 8-25
November 17, 2017 Structure Function Principle
CLG835H Starting Module

Alternator

As the main power unit of the machine, the alternator translates the energy from diesel engine into
serviceable electric energy of electrical equipment. The electrical components are configured for 24V/
70A, with electronic voltage regulator equipped inside. The alternator is connected in parallel with the
battery to power the machine. The battery supplies power to the electrical components before the diesel
engine starts; then after it starts, alternator powers the electrical components while charging the battery.
Once the energy of alternator fails to meet the needs of the electrical components, the alternator and
battery jointly power the machine.
This machine uses three terminals of generator, i,e. 1. Battery Positive; 2. Ground; 3. D+.

D+ to #800
D+᧛#800

B+ to #177
B+᧛#177

Ground to #290
Ground᧛#290

P18E00176
P18E00176

Precautions

The alternator of the machine is strictly prohibited to power the electrical equipments on the machine
separately in the absence of battery.
Metal tools or other metal conductors shall be kept away from the "B +" (Battery Positive) terminal and
"Ground" terminal of generator during operating the diesel engine. In order to avoid short-circuit. Short
circuit on the engine will lead serious results.
8-26
Structure Function Principle November 17, 2017
Starting Module CLG835H

Troubleshooting procedures of alternator

Differing from the introduced fault detection methods for other components, the alternator fault detection
is implemented on the entire machine, which shall not be removed for individual inspection.
The following detection steps are inapplicable to the cases where the battery is fully charged and the
terminal voltage reaches 25V or above.
1. Turn the digital multimeter to 200V of voltage position.
2. Turn on disconnect switch of the machine, do not start the diesel engine, put red probe of a digital
multimeter over "B+" end of an alternator, put black probe over "Ground" terminal of the alternator,
and write down displayed value of the digital multimeter. The normal value is about 24-25 V.
3. Start diesel engine, step on accelerator, follow the measuring method described in step 2, and note
down the value on DMM again. Such value shall be higher than the measured value in step 2,
whereby, the alternator is in normal condition.
The above test procedures shall be implemented on unloaded machine (unload: the condition that the
engine start switch is switched on, yet all the electrical switches or components on the machine are
switched off).
If the value on DMM is unchanged through the tests in steps 2 and 3, switch off the engine start switch to
inspect the alternator as per the following steps.
1. Inspect the transmission belt of alternator in accordance with the methods introduced in the
specification. Readjust if it is too loose.
2. Check the security of alternator terminal, and fasten it with a wrench if necessary.
If the above-mentioned methods fail to solve the problem, please contact maintenance service sites of
LiuGong and CUMMINS.
 8-27
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Monitoring System

Circuit for Engine Water Temperature Indication

P28E00574

This machine uses electric injection engine whose ECM sends the water temperature (WT) signal to the
meter by CAN bus. The meter microcontroller processes information after reading WT data, and finally
to actuate the engine water-thermometer.

Circuit for Torque Converter Oil Temperature Indication

P18E00026

The temperature sensor used in the machine is resistance thermometer of contact type and negative
temperature coefficient. The resistance of its internal temperature sensitive elements changes along with
the temperature variation of measured medium, and the higher temperature of measured medium, the
lower resistance of temperature sensitive elements. Once the circuit is connected, the characteristics of
resistance changing with temperature are converted to that of voltage varying with temperature. The
changing voltage signal enters into the microcontroller of combination instrument, which outputs signal
through the operation processing of microcontroller, to drive the stepping motor-type instrument for
temperature indication.
8-28
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Torque converter oil temp sensor

P28E00575

Precautions

Switch off the engine start switch, and replace the temperature sensor until the machine is completely
cooled if necessary. Therein, measured liquid overflows once the temperature sensor is loosened, which
shall be supplemented timely after the replacement.

The detection of torque converter oil temp sensor

1. Unplug the connector, through which the rear frame harness connects to the temperature sensor;
2. Disassemble the temperature sensor from the complete machine;
3. Place the temperature probe of temperature sensor into the liquid (water/ torque converter oil), and
heat the liquid, to evaluate the temperature sensor performance based on the parameters below.
Temperature(°C) Resistance (Ω) Error± % Min value Max value
0 33650 8.8 30700 36600
25 10000 7 9304 10700
90 865.5 2.1 847.3 883.7
 8-29
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Engine Oil Pressure Alarm

This machine uses electric injection engine whose oil pressure signal is acquired and processed by
ECM. If ECM decides the oil pressure falls below a specified value after processing, it will send alarm
signal to the meter by CAN bus. The microcontroller actuates the appropriate alarm indicator light to ON
after reading this signal.

P28E00576

Circuit for Transmission Oil Pressure Alarm

For monitoring the pressure of shift control valve, the shifting oil pressure alarm indicator is lit once the
pressure of shift control valve is lower than 1.45Mpa.

P28E00238
8-30
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Transmission oil pressure switch

P28E00575

Precautions

Be sure to switch off the engine start switch and wait until the machine is fully cooled, to replace the
pressure switch if necessary.
Therein, measured liquid overflows once the pressure switch is loosened, which shall be supplemented
timely after the replacement.

Test on pressure switch failures

1. Unplug the connector, through which the rear frame harness connects to the engine oil pressure
switch;
2. Remove the pressure switch from the complete machine;
3. Assess the operating value of pressure switch with pressure test bed, and the operating value of its
normally closed contact is 1.45Mpa.
 8-31
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Fuel Level Indication

It is used to monitor the oil quantity of diesel tank.

P18E00031

Fuel level sensor

Floaters are applied in the sensor, which shift up and down along with the oil level of the fuel tank. The
floater influences the resistance value passing through the sensor. Once the circuit is connected, the
characteristics of resistance changing with oil level are converted to that of voltage varying with oil level.
The changing voltage signal enters into the microcontroller of combination instrument, which outputs
signal through the operation processing of microcontroller, to drive the stepping motor-type instrument
for oil level indication.

P28E00575

Precautions

Switch off the engine start switch, and replace the fuel level sensor until the machine is completely
cooled if necessary. When replacing, prevent foreign matters from getting into the diesel tank.
8-32
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Test steps of fuel level sensor faults

Technical Parameters
1. Disconnect the wiring harness of fuel level (After floater drops to the bottom, then rises to test)
sensor and the wiring harness of the
complete vehicle. Fuel level surface
Gear Resistance (Ω)
position (H)
2. Remove the fuel level sensor from the fuel
35 Full level 68
tank.
85 9/10 136
3. Turn the digital multimeter to 1000Ω of Ω 112.5 8/10 187
position. 140 7/10 255
4. Connect the red probe to the terminal at #1 167.5 6/10 306
hole site of the sensor connector, while black 195 5/10 374
probe to #2 hole site. 222.5 4/10 442
250.5 3/10 493
5. Measure the varied resistance values of fuel
279 2/10 561
level sensor corresponding to the different
positions of the floater. 310 1/10 612
>310 0 level 680

Washer

Fuel level surface

P28E00577

Earthing cable (black)

Sensor signal terminal (green)

P18E00034
 8-33
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Vehicle Speed Indication

For monitoring the machine speed condition. The output speed sensor, installed on the gearbox housing,
is used to detect the speed of gearbox output gear. The speed sensor consists of coil, permanent
magnet and pole. The coil is wound outside the pole, and the pole is connected with the permanent
magnet. The magnetic field is formed around the permanent magnet, magnetic lines of force pass
through air gap and act on the teeth of gear, forming a closed magnetic circuit. When the gear is rotating,
the magnetic field acts on the tooth gap and tooth repeatedly, so the change in air gap is sometimes big
and sometimes small; the flux changes with the air gap, and the changing flux induces sinusoidal signal
in the coil, which is in proportion to speed. Connect to ZF harness, followed by being processed in the
electrical control unit, the processed signal therefrom is sent to the instrument.

P18E00036

Service Brake Indication Circuit

When sercive brake pressure is less than 9MPa, the pressure switch turns on and brake low pressure
indicator turns on.

P28E00578
8-34
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Low pressure alarm pressure switch of

service brake

P28E00579

Test on pressure switch failures

1. Unplug the connector connected to pressure

switch in the rear frame harness;
2. Remove the pressure switch from the
complete machine;
3. Assess the action value of pressure switch
with pressure test bed, and its contact type is
normally closed with action value up to 9Mpa.
 8-35
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Parking Brake

When parking brake switch is pressed down, connect pin 3 and 4. When brake pressure is less than
11MPa, the low pressure alarm switch of parking brake turns on and indicator turns on.
When brake pressure is less than 7MPa, control pressure switch of parking brake turns off, parking
brake valve is outage and the output shaft of transmission is locked by action of brake.

P28E00580

Parking brake low pressure alarm switch Parking brake control pressure switch

P28E00579 P28E00579

Test on pressure switch failures Test on pressure switch failures

1. Unplug the connector connected to pressure 1. Unplug the connector connected to pressure
switch in the rear frame harness; switch in the rear frame harness;
2. Remove the pressure switch from the 2. Remove the pressure switch from the
complete machine; complete machine;
3. Assess the action value of pressure switch 3. Assess the action value of pressure switch
with pressure test bed, and its contact type is with pressure test bed, and its contact type is
normally closed with action value up to normally open with action value up to 7Mpa.
11Mpa.
8-36
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Circuit for Parking Brake Power Cut-off

P28E00581

When the parking brake switch is pulled up, pin 1 and 2 is connected, the input signal of gearbox power
cut-off is high, and the complete machine lie in the status of power cut-off, at the same time power cut-off
indicator turns on.

P28E00582

When the brake pressure is less than 6MPa, parking brake clutch on/off switch turns on, the input signal
of gearbox power cut-off is high, and the complete machine lie in the status of power cut-off, at the same
time power cut-off indicator turns on.
 8-37
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

P28E00583

Parking brake power cut-off Switch Parking brake button

This switch includes a button and two contact
modules (one is normally open, the other is
normally closed). Press up the button, the
normally-closed contact (1,2) is active, the
normally-open contact (3,4) is inactive. When
pressing down the button, the normally-closed
contact is in active and normally-open contact
active.

P28E00579

Test on pressure switch failures

1. Unplug the connector connected to pressure

P18E00046
switch in the rear frame harness;
2. Remove the pressure switch from the
complete machine;
3. Assess the action value of pressure switch
with pressure test bed, and its contact type is
normally closed with action value up to 6Mpa.

P18E00047
P18E00047
8-38
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Circuit for Service Brake Clutch ON/OFF

Turn the clutch on/off switch to "on/off", the service clutch shutoff pressure switch is turned on once the
brake pedal is pressed during the service, and the indicator of clutch shutoff switch on instrument is lit.
This function is active only when the position selector is at I or II position.

P18E00048

Pressure switch for service power cutoff Clutch on/off switch

POS3 indicates to select the service clutch

shutoff function, while on the other hand, POS1
signifies not to select such function.

P28E00585 P18E00050

Precautions
Be sure to switch off the engine start switch and
wait until the machine is fully cooled, to replace
the pressure switch if necessary.
Test on pressure switch failures
1. Unplug the connector connected to pressure
switch in the cab harness;
2. Remove the pressure switch from the P18E00051
complete machine;
3. Assess the action value of pressure switch
with pressure test bed, and its contact type is
normally open with action value up to
1.5Mpa.
 8-39
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Air Filter Blockage Alarm

The intake air filter alert indicator is lit if the intake resistance exceeds 6.3KPa. The type of air filter
blockage alarm switch is normally open.

P28E00586

Circuit for Alternator Charging Indication

It is used for monitoring whether the alternator supplies power to the external circuit after the machine
starts. The indicator goes out, which means the engine is in the state of supplying power outward.

P28E00587

Analysis of the schematic diagram

1. When the complete vehicle is energized but not started, D+ terminal of alternator is under low level,
at which the relay acts due to the voltage difference at the end 85 and 86, pin 30 and 87 of relay is
connected to make No.802 wire suspend and indicator turns on.

P28E00588
8-40
Structure Function Principle November 17, 2017
Monitoring System CLG835H

2. After entire vehicle starts, if engine is normal, D+ terminal should output high level, at which the relay
stays at normally-closed contact due to "Zero" voltage difference at the end 85 and 86, pin 30 and
87a is connected to make No.802 wire energize and indicator turns off.

P28E00589

Circuit for Voltage Indication

For monitoring the machine system voltage, lights when the machine power voltage is lower than 24.8V,
extinguishes when within 24.8-29.5 V, lights when within 29.5-31.5 V, and blinks when greater than
31.5V.
The machine uses electric injection engine whose ECM sends the voltage parameter of complete
machine to the meter by CAN bus after monitoring and reading. The meter judge the range of voltage by
analysis of CAN agreement, eventually to control the ON/OFF of voltage indicator.

P28E00590
 8-41
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Seatbelt Indicator

When the seatbelt is not buckled up, this indicator is active.

When the seatbelt is buckled up, this indicator turns off. At the same time, the rear seatbelt indicator of
cab roof turns on.

P18E00059

Circuit for Lubrication System Failure Indicator

When the failure occurs in the lube system, the appropriate indicator light is active.

P18E00060
8-42
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Circuit for Lubrication System Activated Indicator

When the centralized lube function is activated, this indicator light is ON.

P18E00061

Circuit for Steering System Failure Indicator

When the pressure of steering system is less than 0.6Mpa, the pressure switch contact is closed. If the
instrument indicator is active. it indicates the steering system failure.

P28E00591

Failure detection for steering system low-voltage alarm switch

1. Unplug the connector connected to pressure

switch in the rear frame harness;
2. Remove the pressure switch from the
complete machine;
3. Assess the action value of pressure switch
with pressure test bed, and its contact type is
normally closed with action value up to
0.6Mpa.

P28E00619
 8-43
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Secondary Steering Indicator

When the secondary steering function is active, this indicator light is ON. The secondary steering
function has two kinds of enabled methods: manual and automatic.

P18E00064

Manual method is controlled by secondary steering switch, schematic analysis:

P18E00065
8-44
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Automatic method controls signal by instrument output, schematic analysis:

P18E00066

Timing diagram of secondary steering control signal output by instrument:

Power on or hang

Earthing Ground (failure)

Steering system failure signal
Vehicle speed >5km/h

Vehicle speed =0km/h

Speed signal
Power voltage

Secondary steering output signal

P18E00067

Troubleshooting for secondary steering pressure switch

1. Unplug the connector connected to pressure switch in the rear frame harness;
2. Remove the pressure switch from the complete machine;
 8-45
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

3. Assess the action value of pressure switch with pressure test bed, and its contact type is normally
open with action value up to 0.6Mpa.

P18E00068
8-46
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Circuit of Ride Control Indicator

You can select manual and automatic methods according to actual situations. In auto mode, it is active
when the speed is greater than 7 km/h.

P28E00595

Manual method, move the ride control switch to manual gear, schematic analysis:

P28E00596
 8-47
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Automatic method, move the ride control switch to automatic gear and instrument output control signal
according to vehicle speed, schematic analysis:

P28E00597

Ride control switch

POS1 is in manual mode, while POS3 is in auto

mode.

P18E00073

P18E00072
8-48
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Circuit for Radiator Fan Reverse Indicator

When the radiator fan reverse indicator switch is pressed down, this indicator is ON. If the reverse signal
is not received within 1 s, this indicator is out.

P18E00074

Fan reversing switch, manual

This switch is active instantly. When in POS1

mode, the fan reverse function is active.

P18E00076

P18E00075
 8-49
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Circuit for Engine Indicator

The electric injection engine equipped in this machine, whose ECM transports to failure indicator, stop
indicator, preheating indicator, and alarm indicator of low fuel pressure to the meter by CAN bus, and the
meter drive indicator to be active.

P28E00598
8-50
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Instrument

Two instruments equipped in this machine are main instrument and accessory instrument (indicator
module), which both are electronic combination instrument.

Main instrument

Main instrument is divided into three indicator zones: pointer type instrument zone, indicator alarm zone
and LCD display zone.
Pointer type instrument zone

1 2 3

P28E00599

1. Fuel level gauge 2. Engine water temperature gauge 3. Torque converter oil temperature guage

Indicating area
Items
The first region The second area (green) The third area (red)
Engine water temp gauge 40-70°C(Yellow) 70-101°C 101-120°C
Torque converter oil
40-60°C(Yellow) 60-116°C 116-140°C
temperature gauge
Fuel level gauge 0-0.2(red) 0.2-1
 8-51
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Indicator alarm zone

Color of Whether The input sig- The input sig-
S/N Name the warn- it flashes nal level under nal level under Icon
ing light or not normal state alarm state

Flashing and
1 Left turn indicator Green Yes Hang intermittent
signal

Flashing and
2 Right turn indicator Green Yes Hang intermittent
signal

Front floodlight high beam

3 Blue No Hang +24V
indicator

4 Power-off indicator Yellow No Hang +24V

5 Parking brake indicator Red No Hang +24V

Engine oil pressure alarm

6 Red No CAN bus actuated
lights

Brake low pressure warning

7 Red No Hang +24V
lights

Transmission oil pressure

8 Red No Hang Earthing
warning lights

Engine air filter blockage

9 Red No Hang Earthing
indicator

Set the D+ or L terminals of the

10 Alternator charging indicator Red No alternator as charging indicating
control

11 Preheating indicator lamp Amber No CAN bus actuated

12 Heater activated indicator Yellow No Hang +24V

8-52
Structure Function Principle November 17, 2017
Monitoring System CLG835H

Indicator alarm zone

Color of Whether The input sig- The input sig-
S/N Name the warn- it flashes nal level under nal level under Icon
ing light or not normal state alarm state

13 State indicator Red Yes

14 Transmission alert indicator Red No Hang +24V

15 FNR state indicator Yellow No Hang +24V

16 Voltage indicator Yellow Yes CAN bus actuated

17 Stop indicator Red No CAN bus actuated

18 Warning indicator Amber No CAN bus actuated

19 Water in fuel indicator Amber No CAN bus actuated

Sub instrument

P18E00082
 8-53
November 17, 2017 Structure Function Principle
CLG835H Monitoring System

Whether The input signal The input signal

Color of the
S/N Name it flashes level under level under Icon
warning light
or not normal state alarm state

Lube system activated

1 Green No Hang +24V
indicator

2 Lube system fault indicator Red No Hang Earthing

DPF regeneration disabled

3 Amber No CAN bus actuated
indicator

4 DPF regenerating indicator Amber Yes CAN bus actuated

DPF regeneration activated

5 Amber No CAN bus actuated
indicator

6 DEF low indicator Red No CAN bus actuated

7 Seatbelt warning light Red No +24V Hang

Steering system failure

8 Red No Hang Earthing
indicator

9 Secondary steering indicator Yellow No Hang +24V

Ride control activated

10 Green No Hang +24V
indicator

11 Radiator fan reverse indicator Yellow No CAN bus actuated

12 Hydraulic oil temp alarm light Red No Hang Earthing

8-54
Structure Function Principle November 17, 2017
Audible and Visual Alarm System CLG835H

Whether The input signal The input signal

Color of the
S/N Name it flashes level under level under Icon
warning light
or not normal state alarm state

Emission system failure

13 Red No CAN bus actuated
indicator

If any one of the parking brake, brake low pressure, engine oil pressure, engine air filter
blockage, lube system failure, gearbox oil pressure and gearbox failure alert indicators is active, the
state indicator flickers; when and one of the parking brake, brake low pressure and engine oil pressure
alarm indicators is active, and the signal that the engine is activated is detected, the buzzer sounds.

Audible and Visual Alarm System

Circuit for Electric Horn

Three horn buttons are connected in parallel in the machine, locating on the steering column,
combination lever and pilot-operated lever.

P18E00083
 8-55
November 17, 2017 Structure Function Principle
CLG835H Audible and Visual Alarm System

Electric horn Detection procedure of combination lever

1. Disconnect the wiring harness of the
Electrical parameters: 1. rated voltage 24V; 2.
combination lever and the cab;
maximum working current 3A; 3. basic frequency
400±20Hz; 4. sound level 105dB-118dB(A) 2. Separate the combination lever from the
steering column;
3. Turn the digital multimeter to 200Ω of Ω
position.
4. Measure whether the pins are energized
corresponding to the different function
positions of the lever based on the function
wiring diagram;

Wipers reset Red

P18E00084
OV Output Yellow

Steps of electric horn troubleshooting Wipers at

position2 Green
1. Connect the 24V DC power (+) to the Wipers at Black
position1 yellow
terminal at #1 hole bit of the horn, thereby,
while DC power (-) to the terminal at #2 hole
bit; Horn Brown/yellow
2. Turn on the DC power; Water spray Blue

3. The horn alarms at a sound level within

105dB-118dB(A). Left turning White black
Right turning :KLWH
Combination lever

It integrates the functions of horn, front wiper, Blue white

front washer, turn signal light and dimmer switch. Floodlight
power Yellow green

Low beam Blue yellow

High beam Purple yellow
Flashing power supply Black
P18E00086

Input terminal of the handle

Blue Green
Yellow Black yellow

White black Purple yellow

Black Yellow green

White Blue yellow

P18E00085
Brown yellow Red
P18E00087
8-56
Structure Function Principle November 17, 2017
Audible and Visual Alarm System CLG835H

Circuit for Backup Alarm

P18E00088

Backup alarm The electrical parameters of backup alarm

An intermittent buzzer is applied as the backup 1. Rated voltage 24V;

alarm, which works together with the backup light 2. Working current 0.3A;
during the operator's backup operation.
3. Sound level 107dB±4dB(A).

The detection procedures of backup alarm

1. Connect the 24V DC power (+) to the

terminal at #1 hole site of the backup alarm,
while the (-) to the terminal at #2 hole site;
2. Turn on the DC power;
P18E00089 3. Back up alarm makes alarm sound and the
sound level is in the range of 107dB±4dB(A).

P28E00239
 8-57
November 17, 2017 Structure Function Principle
CLG835H Wiper and Washer System

Wiper and Washer System

Circuit Diagram for Wiper and Cleaning System

The functions of front wiper and front washer are implemented through the combination lever.

P18E00091

Rear wiper, rear window washer are all enabled by rocker switch.
REAR WIPER SW

REAR WIPER
MOTOR

REAR WINDOW
WASHER MOTO
REAR WINDOW WASHER SW

AUX. FUNCTION

WIPER SYSTEM
P28E00200
8-58
Structure Function Principle November 17, 2017
Wiper and Washer System CLG835H

Wiper Motor
Rear wiper motor
Front wiper motor

P18E00095
P18E00093

Surface of the connector

Surface of the connector Low speed (green)

Low speed (green) High speed (blue wire)
High speed (blue wire)
Cathode (black wire)
Cathode (black wire)
Anode (red wire)
Anode (red wire)
Reset (white wire)
Reset (white wire) P18E00096
P18E00094
 8-59
November 17, 2017 Structure Function Principle
CLG835H Wiper and Washer System

Washer Reservoir

P18E00097

Surface of the connector

Negative cable Positive cable

(Black) (Redε
P18E00098
8-60
Structure Function Principle November 17, 2017
Positioner and Kickout System CLG835H

Positioner and Kickout System

No matter the operator lower or lift the boom through pushing the control lever forward or backward, the
control lever remains automatically in a forward or backward position, which returns to the neutral
position automatically if the boom is lifted to the limit; on the other hand, when the boom is lowered to the
limit, it requires the operator to move the control lever back to the neutral position instead of its automatic
return. If the operator withdraws the bucket by pushing the control handle to the left, the control handle
will remain in the position towards the left, which returns to the neutral position automatically once the
bucket is leveled.

Principle for Auto Reset System

P28E00600
 8-61
November 17, 2017 Structure Function Principle
CLG835H Positioner and Kickout System

Test on bucket and boom proximity switches

Approach switch
1. Connect the 24V DC power (+) to the
Boom limit terminal at #1 hole of the proximity switch,
approach switch while the (-) to the terminal at #2 hole;
Bucket limit
approach switch 2. Turn on the DC power;
3. Draw the metal induction board to the
inductive surface of proximity switch, the
proximity distance shall be less than or equal
to 12mm, while the induction area shall be
equal or greater than 2/3;
4. At this moment, the LED at the end of the
switch is lighted up;
5. Turn the digital multimeter to 200V of voltage
position.
P18E00100 6. Connect the black probe to the DC power (-),
while the red probe to the terminal at #3 hole
site of the parking brake switch, thereby, the
value displayed on the DMM shall be 24V.

P18E00101

Shaded area is the

effective induction part

P18E00102
8-62
Structure Function Principle November 17, 2017
Lighting System CLG835H

Lighting System

The reverse light is used to illuminate the area behind the vehicle when reversing. The machine is
equipped with backup alarm, which works together with the backup light during backup operation. The
brake light is used to alarm vehicles behind that this vehicle is braking.
The turn signal light indicates the direction to that the vehicle is turning, and the potential danger signals
(when used as parking light).
The position lights are used for driving or operating at night, which indicate the relative location of the
machine. The front headlamp and the rear headlamp are used to illuminate for the whole vehicle driving
and working. The working light is mainly applied to lighting of complete machine. Dome light is used for
illuminating and reading in the cab at night.

Circuit for Front Frame Illumination

P28E00601
 8-63
November 17, 2017 Structure Function Principle
CLG835H Lighting System

Position light & floodlight sw

1. Turn the switch to POS3, the lighting function
of combination light is shut down;
2. Turn the switch to POS2, the switch beacon,
instrument backlight, and the front and rear
position lights are lit.
3. Turn the switch to POS1, in addition to the
functions in the above-mentioned step 2, the
front floodlight is lit. At this moment, select
P18E00104 high/low beam through operating the
combination lever.

P18E00105

P28E00602
8-64
Structure Function Principle November 17, 2017
Lighting System CLG835H

Hazard flasher switch

P18E00107

P18E00108

POS3 indicates the closed parking function, while POS1 signifies the enabled parking function.

P28E00603
 8-65
November 17, 2017 Structure Function Principle
CLG835H Lighting System

Front combination light

Function of integrated steering, high/low beam

and clearance light.

Right front
combination light Left front
combination light

Turn
High beam lightφ Position lightφ signal lightφ
24V/75W 24V/5W 24V/21W
P18E00110 Low beam lightφ24V/70W P18E00111

Circuit for Cab Lighting

P18E00112
8-66
Structure Function Principle November 17, 2017
Lighting System CLG835H

Work light switch Rear working light switch: POS3 means the
working light is turned OFF; POS1 means the
Front working light switch: POS3 means the working light is turned ON.
working light is turned Off; POS1 means the
working light is turned ON.

P18E00115

P18E00113

P18E00116

P18E00114

P18E00117
 8-67
November 17, 2017 Structure Function Principle
CLG835H Lighting System

Work light

This machine is equipped with four work lights, front: two lights, rear: two lights.

Electrical equipment parameters:

1. Rated working voltage is 24 V;

2. Rated power 70W.

2
P28E00218

1. Front work light 2. Front work light 3. Rear work light 4. Rear work light

P28E00219
P28E00604
8-68
Structure Function Principle November 17, 2017
Lighting System CLG835H

Dome light

Electrical equipment parameters:

1. Rated working voltage is 24 V; 2. Rated power 10W.

P18E00119

Circuit for Rear Frame Illumination

P28E00605
 8-69
November 17, 2017 Structure Function Principle
CLG835H Lighting System

Brake light switch

P28E00585

After pressing the brake pedal, 1. The brake light switch acts, 2. Brake light is lit, 3. Brake light is lit.

P18E00122

Precautions

Be sure to switch off the engine start switch and wait until the machine is fully cooled, to replace the
pressure switch if necessary. Therein, measured liquid overflows once the pressure switch is loosened,
which shall be supplemented timely after the replacement.

Test on pressure switch failures

1. Unplug the connector, through which the rear frame harness connects to the engine oil pressure
switch;
2. Remove the pressure switch from the complete machine;
3. Assess the action value of pressure switch with pressure test bed, and its contact type is normally
open with action value up to 0.5Mpa.
8-70
Structure Function Principle November 17, 2017
Shift Control System CLG835H

Rear combination light Shift Control System

Integrate functions of steering, driving/braking
and backup light. The electronic control unit of the shift control
system receives the external signals from gear
Rear right selector, speed sensor and KD button, process
combination light such signals and send them to CPU for
Rear left computing. Eventually, CPU drives the shift
combination light
control valve combination located on the
transmission by virtue of the output circuit, to get
the operator selected gear.
The transmission assembled in the machine is 4-
speed transmission, with 4 gears for forward and
3 for reverse. DW-3 gear selector shifts reverse 4
P18E00123 gears, the electronic control unit actually outputs
the control signal of reverse 3 gears.
Stop and
Reversing light (P21W) position
Turn signal indicator 21W light The electronic control unit of the shift control
(P21/5W)
190
system receives the external signals from gear
selector, speed sensor and KD button, process
such signals and send them to CPU for
computing, where the driving state of vehicle is
determined by comparison signal between the
two speed sensors and other signals. Eventually,
CPU drives the shift control valve combination
located on the transmission by virtue of the
output circuit, to get the operator selected gear.
Certainly, as required by driving speed, this gear
Reflex reflector P18E00124
is possibly lower than that selected by the
operator, but not higher than it.

P18E00125
 8-71
November 17, 2017 Structure Function Principle
CLG835H Shift Control System

Principle for Shift Control

Shift control system is provided with the functions of neutral start interlock, clutch shutoff, backup alarm,
KD, FNR (optional) & speed displays and manual/ automatic shift (full-auto gearbox).

Neutral start interlock function

If the DW-3 gear selector is shifted to gear N, the electronic control unit will output a high level (24V) of
#584, and the neutral interlock relay enabled. The exploded electrical schematic as follows:

P18E00126

KD functions

Apart from the KD button on DW-3 gear selector, another KD button is assembled on the pilot-operated
lever of the machine. The exploded electrical schematic as follows:

P28E00618
8-72
Structure Function Principle November 17, 2017
Shift Control System CLG835H

Function of backup alarm

If the DW-3 gear selector is shifted to gear R, #588 outputs a high level, and the backup alarm relay
enabled. The exploded electrical schematic as follows:

P18E00128

Power cut-off function

The power shutoff consists of parking clutch shutoff and service clutch shutoff, both of which shut off the
powers at gear I and II of the transmission. The parking power cutoff system is started once the stop
brake switch is pulled up, as shown below:

P18E00129
 8-73
November 17, 2017 Structure Function Principle
CLG835H Shift Control System

If the clutch on/off switch is turned on, the service clutch shutoff will start through press the brake pedal
during the service, schematics as follows:

P18E00130

Function of indicating the speed

For the circuit of this part, please refer to Vehicle Speed Indicating Line Schematic Diagram.

Manual/ automatic shift function

When the rocker switch is pressed down, turning on switch indicates automatic shift mode, and turning
off switch indicates manual shift mode.

AUTO/ MANUAL SHIFT MODE SW

P28E00606

Manual/ automatic shift rocker switch

P28E00607
8-74
Structure Function Principle November 17, 2017
Shift Control System CLG835H

Electronic Control Unit Shift Selector

As the core of the shift control system, the The internal part of a gear selector consists of
electronic control unit processes and operates many mini switches. When the operator selects
the signals of operator-selected gear, speed gears and directions, the internal micro switch
sensor, KD and engine shutoff. Whereby, the works, and the changed gear and direction
electronic control unit drives the solenoid valve signals ultimately enter into the electronic control
group combination through outputting control unit through the connecting of harness.
signals, to implement the gear selection and shift
of transmission. Besides, the electronic control
unit also outputs neutral signals, to drive the
gear/neutral interlock relay to act when the DW-3
gear selector is in neutral position. Output the
reversing alarm signal and drive the reversing
alarm relay to work.

P18E00135
P18E00133

Gear positions

P18E00136

Fault detection procedures of DW-3 shift

selector

1. Turn the digital multimeter to 200 Ω of Ω

position.
2. Move DW-3 gear selector to N1 position;
3. Test if only [B1, B3], [B1, AS], [B3, AS] are
pairwise energized;
4. Shift the gear selector to other appropriate
gears, and check the parallelism in
P18E00134
P18E00134 accordance with the gear logic diagram;
 8-75
November 17, 2017 Structure Function Principle
CLG835H Shift Control System

5. The gear selector is in normal condition, provided that all the gears conform to the gear logic
diagram.

AUSGABE OUTPUT SIGNAL

YOWAERTS FORWARD RUECKWAERTS REVERS NEUTRAL
GANG GEAR
1 2 3 4 1 2 3 4 1 2 3 4 KD
AD1 B1 ● ● ● ● ● ●
AD2 B2 ● ● ● ● ● ●
AD3 B3 ● ● ● ● ● ● ● ● ● ● ● ●
AD4 V ● ● ● ●
AD5 R ● ● ● ●
AD6 AS ● ● ● ●
AD7 KD ●

AD3 (B3)

AD2 (B2)

AD1 (B1)

AD7 (KD)

ED1 (+/VP)

AD6 (N)

AD4 (V,F)
(VORWAERTS, FORWARD)

AD5 (R)
(RUECKWAERTS,REVERSE)
P18E00137
8-76
Structure Function Principle November 17, 2017
Audio System CLG835H

Audio System

Audio System Principle

P18E00138
 8-77
November 17, 2017 Structure Function Principle
CLG835H Audio System

Radio

P18E00141

Antenna

P18E00139

Speaker

P18E00142

P18E00140
8-78
Structure Function Principle November 17, 2017
Engine Electric Control Module CLG835H

Engine Electric Control Module

Electronic Throttle Line

P28E00608

Radiator Fan Control Module

Control Strategy

Water temperature: 90°C~100°C, target temperature: 95°C, PID regulation, i.e. fan begins to
accelerate when the temperature is more than 95°C, or vice versa
Torque oil temperature: 105°C~110°C, linear adjustment, i.e. fan operates at the minimum speed when
the temperature is not more than 105°C and other temperatures are not in the adjustable range; fan
operates at the maximum speed when the temperature is more than 110°C; when the temperature is
between 105°C~110°C, an corresponding speed can be achieved through linear scale calculation.
Air-air intercooler: temperature control node: 40, Fmin; 55, F80%; 70, 80%; 75, Fmax;
Electrical schematic diagram

P28E00609
 8-79
November 17, 2017 Structure Function Principle
CLG835H Seat Heater

Seat Heater

Supply power to the sear after the complete machine is energized, and seat heater is controlled the ON/
OFF by the switch on the seat.

P18E00152

Seat
heater switch

P18E00153
8-80
Structure Function Principle November 17, 2017
Appendix CLG835H

Appendix

Distribution diagram of front frame harness connector

P28E00610
 8-81
November 17, 2017 Structure Function Principle
CLG835H Appendix

6 7
1 5

4 9

8
2

P28E00611

1. XQ1 4. XQ4 7. XQ6

2. XR2b 5. XR4b 8. XQ7b
3. XQ3 6. XQ5 9. XQ8
8-82
Structure Function Principle November 17, 2017
Appendix CLG835H

Distribution diagram of work light harness connector

3
6
5

8
2

P28E00612 P28E00613

1. XK1b 4. XK5b 7. XJ5

2. XJ1, XJ3 5. XJ6, XJ0, XH3b 8. XK4b
3. XJ2, XJ4 6. XJ8b
 8-83
November 17, 2017 Structure Function Principle
CLG835H Appendix

Distribution diagram of cab harness connector

P28E00614
8-84
Structure Function Principle November 17, 2017
Appendix CLG835H

24 25 26

22 23

20 21
29
27
19 36
16 18 28
15 17
30
35

33
34
41
39 40
1
38
2 32 31 37

4
14
5

11

7 10
9
13
8 12
P28E00615

1. XV4, XU6, XU5, 9. XE6 18. XZ2, XZ3 27. XS7 35. XL8a, XL8b
XU3, XU4, XU7 10. XR2a 19. XV8, XV9 28. XM4 36. XS8a
2. XL4 11. XT4, XT6, X2b, X3b 20. XV6 29. XL7 37. X2, X3, X4, X7, X5a,
3. XS2 12. XX7a, XX8a, XC6b, XX9a 21. YV5 30. X9a X12a, X13a
4. XL6 13. XK1a 22. YS5, XU9 31. XL2, XM3 38. XM9
5. XN1 14. XF1b, XF1a 23. XM5 32. XM2a, XH5 39. XN6b
6. XM6, XM7 15. XL5 24. XK6, XK7 33. XT9a 40. XS3a, XS4a, XS5a
7. X6a, X7a 16. XM1a 25. XZ5, XB10 34. XT8, XT9 41. XN7, XN8
8. XE8 17. XV2, XV3 26. YS6
 8-85
November 17, 2017 Structure Function Principle
CLG835H Appendix

Distribution diagram of rear frame harness connector

P28E00616
8-86
Structure Function Principle November 17, 2017
Appendix CLG835H

21 19
20
16

15

17
27
14 28 26
18

11 12
24

23
13
25

22

10
1 9

2 6
7 5

4
8

3
P28E00617

1. XX7b, XX8b, XX9b 9. XE3 17. XA1 25. XE5

2. XY3 10. XE4 18. XA2 26. XB1
3. XB8, XB9 11. XW3 19. XD5 27. XB7
4. XE6 12. XD8 20. XD6 28. XB2
5. XE7 13. XB6 21. XB4
6. XF1 14. XA3 22. XG1
7. XE9 15. XA8, XA9 23. XA5, XA7
8. XE8 16. XC1 24. XA6
 9-1
November 17, 2017 Appendix
CLG835H

Appendix
Schematic Diagram of Hydraulic System......................................................................9-3
A/C System Schematic Diagram ....................................................................................9-4
Schematic Diagram of Electrical System ......................................................................9-5
9-2
Appendix November 17, 2017
CLG835H
 9-3
November 17, 2017 Schematic Diagram of Hydraulic System
CLG835H

Schematic Diagram of Hydraulic System

50Y1275
 9-4
November 17, 2017 A/C System Schematic Diagram
CLG835H

A/C System Schematic Diagram

Control panel

Red Red
Blue/white Compressor relay Control panel relay
Air speed switch gear 3
Yellow
White White White Blower unit
Rheostat
Yellow Yellow Black

Blue/
white Blue/white

Black Black

Red/blue

Red/blue
White (gray)

White (gray)
gray

Black

gray
Black
Mode switch
Cooling Red/blue Red/blue

Venting
Heating lamp Earthing
Heating
Blue/yellow Blue/yellow Ignition signal

Blue/black Blue/black
Cooling adjust button

Cooling lamp

Outer circulation switch

Blue/yellow
Blue/black

Red/blue
White

Green
Black
White
White
Outer circulation lamp Green
Green Green

Black

Black

White
black
Blue/
yellow
Blue/

Red

Black

Blue
Compressor

Air vent fan Air vent fan Temperature

sensor Thermostat

Pressure switch Aluminum housing grounded

P28A00115
 9-5
November 17, 2017 Schematic Diagram of Electrical System
CLG835H

Schematic Diagram of Electrical System

电喇叭
HORN

左前组合灯 FRONT COMBINATION LIGHT-LH

前左转向灯
FRONT LEFT TURN SIGNAL LIGHT
左前小灯
FRONT POSITION LIGHTLH
左远光灯
FRONT FLOODLIGHT HIGH BEAMLH

左近光灯
FRONT FLOODLIGHT LOW BEAMLH

右前组合灯 FRONT COMBINATION LIGHT-RH

前右转向灯
FRONT RIGHT TURN SIGNAL LIGHT
右前小灯
FRONT POSITION LIGHTRH
右远光灯
FRONT FLOODLIGHT HIGH BEAMRH

右近光灯
FRONT FLOODLIGHT LOW BEAMRH

右铲斗示廓灯(选装)
POSITION LIGHTRH(OPTIONAL)
接至驾驶室线束
TO CAB HARNESS
至第2页
TO PAGE 2
左铲斗示廓灯(选装)
POSITION LIGHTLH(OPTIONAL)

动臂限位开关
BOOM LIFT KICKOUT SW

铲斗限位开关
BUCKET POSITIONING SW

PK
S2
BU
DK
BR/GN
S1
集中润滑系统(选装) RD/BK
B+
CENTRALIZED LUBRICATION BR
GND
SYSTEM(OPTIONAL)

动臂减震电磁阀
RIDE CONTROL SOLENIOD

50Y1268-1
 9-6
November 17, 2017 Schematic Diagram of Electrical System
CLG835H

GPS模块 GPS MODEL 散热控制器 仪表总成 INSTRUMENT AS

COOLING FAN CONTROLLER 应急转向开关 SECONDARY STEERING SW 怠速调节开关 IDLE INC/DEC SW
J1
J2 钥匙开关电源 +24V KEY-ON +24V
变矩器油温信号(I)
壁灯 DOME LIGHT 蓄电池电源 +24V BATTERY SUPPLY +24V
前雨刮电机 J3 空空中冷(备用)
地 GND
FRONT WIPER MOTOR J4 GND5
SAE J1939 SHIELD
CAN_L 液压油温信号(I)
SAE J1939(-)
CAN_H 换向输出(O)
收放机 RADIO 音响系统 RADIO SYSTEM SAE J1939(+)
电源(蓄电池) 自动反转信号(I)
集中润滑开关(选装) CENTR LUBRICATION SW(OPTIONAL) 预热控制输出 PERHEATING CONTROL OUTPUT
GND 手动反转信号(I)
仪表背光灯电源 +24V INSTRUMENT SUPPLY +24V
GND6 IGNITION 电源1
计时信号 TIMER
电源 水温(备用) BATTERY 电源2
车速信号 VEHICHE SPEED
比例输出(O) GROUND 地
后雨刮电机(选装) 转速信号 ENGINE SPEED
REAR WIPER MOTOR(OPTIONAL) (灰) RS232/RXD
发电机D+
KEY-ON 发动机水温传感器 ENGINE COOLANT TEMP
SPEAKER-RH 右扬声器(+)
GND1 风扇手动反转开关 FAN M-MODE SW 故障诊断开关 DIAG SW 变矩器油温传感器 TORQUE CONVERTER OIL TEMP
SPEAKER-RH 右扬声器(-)
BATTERY 气压传感器 BRAKE AIR PRESSURE
SPEAKER-LH 左扬声器(+)
120Ω1W CAN_L 燃油油位传感器 FUEL LEVEL SENSOR
总线网络端电阻 SPEAKER-LH 左扬声器(-)
CAN_H 环境温度 AMBIENT TEMP
CANBUS TERMINATION RESISTOR
GND2 液晶屏切换开关 MONITOR SHIFT SW
GND3 发动机空滤堵塞指示 INTAKE AIR FILTER IND
左扬声器
TXD 变速箱故障报警灯 TRANS. FAILURE IND
喇叭开关(方向机柱) HORN SW(ON STEERING COLUMN) SPEAKER-LH
RXD 变速油压压力开关 TRANS OIL PRESSURE SW
串口GND 预热输入 PERHEATING INPUT
地
右扬声器 加热器运行指示 HEATER RUNNING IND
30A电源
SF_MODE SPEAKER-RH 制动低压报警灯 BRAKE OIL PRESSURE IND
发动机运行信号
(黑) 停车制动指示 PARKING BRAKE IND
压缩机离合器
空调控制单元 等待起动指示灯 WAIT TO START IND
组合开关手柄 COMBINATION SW LEVER
A/C CONTROLLER 停机指示灯 STOP IND
指示灯模块 INDIC AS 警告指示灯 WARNNING IND
电磁水阀
电磁水阀 发动机机油压力开关 ENGINE OIL PRESSURE SW
钥匙开关电源 +24V KEY-ON +24V 速率选择开关 HSG DROOP SW 发电机充电指示 ALTERNATOR CHARGE IND
地 GND 动力切断指示 TRANS CLUTCH CUT-OFF IND
地 GND 前大灯远光指示 HIGH BEAM IND
制动灯开关 SAE J1939 SHIELD 右转向指示 RIGHT TURN IND
BRAKE LIGHT PSW LG通讯口 SAE J1939(+) 左转向指示 LEFT TURN IND
LG COMMUNICATION SAE J1939(-)
动臂减震输出 PAYLOAD OUTPUT
后窗喷水开关(选装) REAR WASHER SW(OPTIONAL)
120Ω1W 总线网络端电阻
行车制动动力切断开关 CAN-BUS TERMINATION RES.
SERVICE BRAKE CLUTCH
CUT-OFF PSW
电锁 START SW
应急转向输出控制 SECONDARY STEERING CONTROL
转向系统故障开关 STEERING FAILURE SW
液压油污开关 HYDRAULIC OIL FILTER SW 后雨刮开关(选装) REAR WIPER SW(OPTIONAL)

停车制动开关 安全带指示 SAFE BELT IND

PARKING BRAKE SW 1.5KΩ 1/8W
润滑系统运行指示 LUBRICATION RUNNING IND
润滑系统故障指示 LUBRICATION FAILURE IND
接至后车架线束
液压油温开关 HYDRAULIC OIL TEMP SW TO REAR FRAME HARNESS
尿素液位低指示灯 DEF LOW IND 至第3页
点烟器 LIGHTER TO PAGE 3

动臂减震指示 RIDE CONTROL IND

应急转向运行开关 SECONDARY STEERING SW
动臂浮动电磁阀 座椅电源(选装) 前工作灯开关 FRONT WORK LIGHT SW
BOOM FLOAT SOLENOID SEAT(OPTIONAL)
动臂限位电磁阀
BUCKET POSITIONER 安全带开关
SAFETY BELT SW
铲斗限位电磁阀
LIFT KICKOUT SOLENOID
后退监视/称重系统(选装)
动臂减震开关(选装) RIDE CONTROL SW(OPTIONAL)
REARVIEW/WEIGHING SYSTEM(OPTIONAL) 后工作灯开关 REAR WORK LIGHT SW
先导手柄控制开关
电子油门踏板 SW ON PILOT VALVE LEVER
ACCELERATOR PEDAL
KD键 SD1
KD SW AS 自动/手动模式选择开关 AUTO/ MANUAL SHIFT MODE SW
RF
喇叭开关 KD
HORN SW ED9
小灯及大灯开关 POSITION LIGHT AND FLOODLIGHT SW 接应急转向系统
AD9
TO SECONDARY STEERING
SYSTEM

(+)1
(+)2
AD7
AD8
4WG 158全自动电控系统 后视镜除霜开关(选装) R-MIRROR DEFROSTER SW(OPTIONAL)
4WG 158 TRANS.ECU ()1
()2
九针数据诊断口
DIAGNOSTIC CONNETOR
液晶屏切换开关 DISPLAY SHIFT SW
ED3
B3 FS
S5 驻车灯开关 HAZARD FLASHER SW
ED4

接驾驶室地
TO GROUND
接驾驶室地 SD1 旋转信号灯开关(选装) ROTATING BEACON SW(OPTIONAL)
TO GROUND

动力切断选择开关 CLUTCH ON/OFF SW 接驾驶室地

TO GROUND

FNR手柄 FNR HAND LEVER 接至前车架线束

FNR控制器
FNR CONTROLLER TO FRONT FRAME HARNESS
至第1页
HORN ZF-KD
TO PAGE 1
COM3 FNR-KD ZF-F
FNR-R ZF-N
F +24V ZF-R
N GND CAN_H
R SF_MODE R
COM2 CAN_L N
串口GND F
KD TXD KD
COM1 RXD ZF-B3
FNR-N ZF-B2
FNR-F ZF-B1
ZF手柄 ZF LEVER （黑） （灰）

VP(+)
F
R
N
TO ZF HARNESS
接至ZF线束
B3 接至顶灯线束
B2 TO DOME LIGHT HARNESS
B1
至第5页
KD
TO PAGE 5

接至电器集中控制盒线束 TO VEC HARNESS

FNR控制系统(选配) 至第4页 TO PAGE 4
FNR CONTROL SYSTEM (OPTIONAL)

TO ZF HARNESS
TO ZF LEVER
接至ZF线束
接至ZF手柄

50Y1268-2
 9-7
November 17, 2017 Schematic Diagram of Electrical System
CLG835H

左后组合灯 REAR COMBINATION LIGHT-LH

左后小灯
REAR POSITION LIGHT-LH
左制动灯
BRAKE LIGHT-LH
风扇比例电磁阀
COOLING FAN PROPORTION SOLENIOD 左倒车信号灯
BACKUP LIGHT-LH

后左转向灯
风扇换向电磁阀 REAR LEFT TURN SIGNAL LIGHT
COOLING FAN REVERSE SOLENIOD 右后组合灯 REAR COMBINATION LIGHT-RH

右后小灯
REAR POSITION LIGHT-RH
右制动灯
变矩器油温传感器(散热控制用) BRAKE LIGHT-RH
TORQUE CONVERTER OIL TEMPERATURE
右倒车信号灯
SENSOR(FOR COOLING FAN CONTROLLER) BACKUP LIGHT-RH

后右转向灯
REAR RIGHT TURN SIGNAL LIGHT
空调压缩机离合器
A/C COMPRESSOR CLUTCH
倒车报警器
BACKUP ALARM

电磁水阀
SOLEOID WATER VALVE
牌照灯(选装)
LICENCE LIGHT(OPTIONAL)
变矩器油温传感器(仪表用)
TORQUE CONVERTER OIL TEMPERATURE
SENSOR(FOR INSTRUMENT)

120Ω 1W 总线网络A端电阻
变速油压报警开关
TRANSMISSION OIL PRESSURE ALERT PSW

电喷柴油机ECM

怠速关 OFF IDLE SW

燃油油位传感器 诊断开关 DIAGNOSTIC SW.
FUEL LEVEL SENSOR 油门踏板信号 PEDAL SIGNAL
怠速开 ON IDLE SW
速率选择开关 HSG DROOP SW

停车制动动力切断开关 油门踏板电源PEDAL SUPPLY

PARKING BRAKE CLUTCH CUTOFF PSW 油门踏板地 PEDAL RETURN
增怠速开关 INC. SW
减怠速开关 DEC. SW

停车制动低压报警开关 冷却水位 COOLANT LEVEL

接至驾驶室线束 扭矩选择 ALTERNATE_TORQUE
PARKING BRAKE LOW PRESSURE ALERT PSW
TO CAB HARNESS
传感器地 SENSOR RETURN
TO CAB HARNESS 回流 STARTER LOCKOUT RETURN
至第2页 开关回流 SW RETURN
TO PAGE 2 SAE J1939（SHIELD）
行车制动低压报警开关
SERVICE BRAKE LOW PRESSURE ALERT PSW SAE J1939（+）
SAE J1939（-）
电锁信号 KEY_SWITCH
进气加热控制 INTAKE AIR HEATER OUTPUT
转速表 TACHOMETER
停车制动控制开关
回流 INTAKE AIR HEATER RETURN
PARKING BRAKE CONTROL PSW
停机指示 STOP IND
警告指示 WARNNING IND
启动保护 STARTER LOCKOUT
停车制动电磁阀
等待起动指示 WAIT TO START IND
PARKING BRAKE SOLENOID

BATT（-）
二极管DIODE
BATT（-）
BATT（+）
接后车架地
BATT（+）
TO GROUND

起动接触器 发动机冷却液位开关
START RELAY ENGINE COOLANT LEVEL SW

接负极地
TO GROUND S
F/I
L
P

发电机 ALTERNATOR
起动电机
START MOTOR E
+12V DC +12V DC

B+

蓄电池组 BATTERY GP
空滤堵塞报警开关
INTAKE AIR FILTER ALERT SW
负极开关 DISCONNECT SW

接至驾驶室线束
TO CAB HARNESS 前窗水洗马达
FRONT WINDOW WASHER MOTOR

格栅加热器保险125A
GRID HEATER FUSE 125A
后窗水洗马达 (选装)
发电机80A REAR WINDOW WASHER MOTOR(OPTIONAL)
ALTERNATOR 80A

主电源60A
MAIN SUPPLY 60A

电器集中控制盒保险50A
CONTROLLER FUSE 50A

应急转向运行指示开关
空调系统30A
SECONDARY STEERING RUNNING
A/C SYSTEM 30A
INDICATOR PSW

转向系统低压报警开关
ECM保险30A
STEERING SYSTEM LOW
ECM FUSE 30A
PRESSURE ALERT PSW

格栅加热接触器
GRID HEATER RELAY

应急转向电机
SECONDARY STEERING MOTOR 格栅加热器 GRID HEATER

二极管DIODE

应急转向系统(选装) SECONDARY STEERING SYSTEM(OPTIONAL)

辅助起动装置(选装)
AUXILIARY START EQUIPMENT(OPTIONAL)

50Y1268-3
 9-8
November 17, 2017 Schematic Diagram of Electrical System
CLG835H

非过电锁电源总线 UNSWITCHED BUS

电锁 KEY START SW 7.5A

ECM电源 ECM UNSWITCHED PWR 7.5A

二极管 D3
DIODE D3
闪光器/小灯 FLASHER/POSITION LAMP 7.5A
闪光继电器
FLASHER

B 二极管 D2
辅助功能1 AUX. FUNC.1 10A DIODE D2
L

E
二极管 D1
制动灯 STOP LAMP 7.5A 电喇叭继电器
DIODE D1
HORN RELAY

电喇叭/倒车报警 HORN/BACK-UP ALARM 10A D继电器

86
D RELAY
87A
87
30 86
85 87A

制动灯继电器 87
BRAKE LIGHT RELAY 30
85 接至驾驶室线束
TO CAB HARNESS
86 至第2页
87A TO PAGE 2
87
过电锁电源 SWITCHED BUS
30 前雨刮2档继电器
85 2ND POSITION FRONT WIPER RELAY
收放机/点烟器 RADIO/LIGHTER 10A
风扇换向阀继电器
COOLING FAN REVERSE SOLENIOD RELAY 86
辅助功能4 AUX. FUNC.2 7.5A 87A
87 起动保护继电器
86
30 START PROTECTION RELAY
87A
85
87
应急转向系统 SECONDARY STEERING SYSTEM 10A
30 前雨刮1档继电器 86
85 IST POSITION FRONT WIPER RELAY 87A
87
ECM电源 ECM SWITCHED PWR 10A
86 30

87A 85

87 空档起动联锁继电器
仪表 INSTRUMENT 7.5A 30 NEUTRAL START INTERLOCK RELAY
85

辅助功能2 AUX. FUNC.2 10A 前窗喷水继电器 86

FRONT WASHER RELAY 87A
87
应急转向继电器
辅助功能3 AUX. FUNC.3 7.5A SECONDARY STEERING RELAY 86 30

87A 85

87
86
大灯 FRONT FLOODLAMP 10A 30
87A
85
87
后工作灯 REAR WORK LAMP 10A 30 自动动臂减震继电器
85 AUTOMATIC RIDE CONTROL RELAY

86
87A
87
座椅 SEAT 15A 30
85
雨刮系统 WIPER SYSTEM 20A
倒车报警继电器
BACK UP ALARM RELAY
前工作灯 FRONT WORK LAMP 15A

86
87A
87
30
左制动灯 BRAKE LAMP LH 5A 85
动臂限位继电器
G继电器 BOOM LIFT KICKOUT RELAY
右制动灯 BRAKE LAMP RH 5A G RELAY

86
86 87A
左小灯 POSITION LAMP LH 5A 87A 87
87 30
右小灯 POSITION LAMP RH 5A 30 85
85

铲斗限位继电器
BUCKET POSITIONER RELAY

86
电源接触器
87A
POWER RELAY
87
30
85

50Y1268-4
 9-9
November 17, 2017 Schematic Diagram of Electrical System
CLG835H

左前工作灯一
FRONT WORK LIGHTLH

右前工作灯一
FRONT WORK LIGHTRH

左前工作灯二 (选装)
FRONT WORK LIGHTLH(OPTIONAL)

右前工作灯二 (选装)
FRONT WORK LIGHTRH(OPTIONAL)

左后工作灯一
REAR WORK LIGHTLH

右后工作灯一 接至驾驶室线束
REAR WORK LIGHTRH TO CAB HARNESS
至第2页
TO PAGE 2

左后视镜除霜装置(选装)
REARVIEW MIRROR
DEFROSTERLH(OPTIONAL)

右后视镜除霜装置(选装)
REARVIEW MIRROR
DEFROSTERRH(OPTIONAL)

旋转信号灯(选装)
ROTATING BEACON(OPTIONAL)

安全带信号灯(选装)
SAFE BELT BEACON(OPTIONAL) 50Y1268-5
 9-10
November 17, 2017 Schematic Diagram of Electrical System
CLG835H