LiuGong CLG835H - Service Manual

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201701001

CLG835H

WHEEL LOADER

SERVICE MANUAL

Applicable type and model: CLG835H PERKINS Engine 1204F-E44AT/ LIUGONG Wet Axle/ ZF

4WG158 Gearbox

Main Page

Table of Contents3
General Information5
How to Use the Manual7
Engine Identification10
Cable Code Identification12
Coating Materials14
Weight Table16
Unit Conversion Table17
Standard Torque Table18
Oils Use Specifications21
Technical Specification of the Complete Machine25
Power System39
Basic Information41
Safety41
Overview-Components and Position43
System Technical Parameters47
Universal Tool, Tooling List48
Structure Function Principle49
Engine System49
Overview49
Diesel Engine50
Intake and Exhaust System62
Intake and Exhaust Assembly62
Air Filter65
Diesel Particle Filter System67
DEF Pipeline Assembly68
DEF Tank70
DEF Pump73
Cooling System75
Overview75
Radiator Group80
Fan82
Refilling and Replacement of Coolant82
Fuel System83
Fuel Tank Assembly83
Fuel Lines84
Power Train System155
Basic Information157
Safety157
System Composition and Position158
System Technical Parameters158
System Schematic Diagram and Working Principle Description159
Overview of Transmission Fluid161
Maintenance and Replacement of Gearbox and Drive Axle Oil162
Universal Tool, Tooling List163
Special Tool, Tooling List163
Structure Function Principle164
Torque Converter - Gearbox System164
Drive Axle System170
Drive Shaft System172
Tire&Rim System173
Testing and Adjustment177
Torque Converter - Gearbox System178
Drive Axle System178
Removal and Installation179
Removal and Installation of Torque Converter-Gearbox System179
Disassembly and Assembly of Torque Converter-Gearbox Assembly191
Removal and Installation of Drive Shaft System192
Removal and Installation of Front Axle Assembly197
Removal and Installation of Rear Axle Assembly200
Disassembly and Assembly of the Drive Axle210
Fault Diagnosis and Troubleshooting Methods211
Power Train System214
Basic Information215
Safety215
System Composition and Position216
System Technical Parameters216
System Schematic Diagram and Working Principle Description217
Overview of Transmission Fluid219
Maintenance and Replacement of Gearbox and Drive Axle Oil220
Universal Tool, Tooling List221
Special Tool, Tooling List221
Structure Function Principle222
Torque Converter - Gearbox System222
Drive Axle System228
Drive Shaft System230
Tire&Rim System231
Testing and Adjustment235
Torque Converter - Gearbox System235
Drive Axle System235
Removal and Installation236
Removal and Installation of Torque Converter-Gearbox System236
Disassembly and Assembly of Torque Converter-Gearbox Assembly248
Removal and Installation of Drive Shaft System249
Removal and Installation of Front Axle Assembly254
Removal and Installation of Rear Axle Assembly257
Disassembly and Assembly of the Drive Axle267
Fault Diagnosis and Troubleshooting Methods268
Testing and Adjustment270
Power Train Test270
Hydraulic System273
Basic Information277
Safety Precautions for Hydraulic System277
Overviews of Hydraulic System280
Technical Parameters of Hydraulic System283
Hydraulic System Principle Schematic283
Universal Tools and Tooling for Hydraulic Maintenance284
Special Tools and Tooling for Hydraulic Maintenance285
Structure Function Principle290
Work Hydraulic System290
Hydraulic Oil Tank291
Plunger Pump292
Boom Cylinder294
Bucket Cylinder294
Control Valve295
Pilot Valve307
Steering Hydraulic System309
Steering Pump312
Metering Pump312
Priority Valve314
Steering Cylinder317
Brake System318
Brake Pump322
Brake Valve326
Charge Valve329
Accumulator Assembly331
Brake Cylinder334
Hydraulic Cooling System336
Cooling Pump340
Cooling Motor340
Solenoid Directional Valve341
Emergency Steering System343
Pilot System of Electronic Control Third Linkage345
Testing and Adjustment347
Pressure Release of Hydraulic System347
Pressure Test of Work Hydraulic System350
Positions of Every Gauging Points of Working Hydraulic System350
Description of Every Gauging Points of Working Hydraulic System351
Inspection and Adjustment for Pressure of Working Hydraulic Pressure System352
Pressure Inspection and Adjustment of Overload Valve of Bucket Tilting Large Chamber356
Pressure Inspection and Adjustment of Overload Valve of Bucket Tilting Small Chamber358
Pressure Inspection and Adjustment of Main Safety Valve of Control Valve360
Inspection and Adjustment for Cut-Off Pressure of Working Pump362
Adjustment for LS Relief Pressure of Control Valve364
Pressure Inspection and Adjustment of the Pilot Oil Supply Valve366
Boom Cylinder Test368
Bucket Cylinder Test369
Steering Hydraulic System Test370
Measuring Point Position of Steering Hydraulic System370
Description of Measuring Points of Steering Hydraulic System371
Pressure Testing and Adjustment of Steering Hydraulic System371
Steering Cylinder Test373
Brake System Test374
Layout of Pressure Measuring Points of Brake System374
Test Method of Rear Axle Brake Pressure375
Test Method of Front Axle Brake Pressure377
Removal and Installation378
Work Hydraulic System378
Removal and Installation of Hydraulic Oil Tank Assembly378
Removal and Installation of the Plunger Pump382
Removal and Installation of Boom Cylinder387
Disassembly and Assembly of Boom Cylinder392
Removal and Installation of Bucket Cylinder405
Disassembly and Assembly of Bucket Cylinder409
Removal and Installation of Control Valve422
Removal and Installation of Pilot Valve Assembly431
Removal and Installation of Metering Pump435
Air Conditioning System507
Basic Information509
Safety509
Universal Tool, Tooling List509
Special Tool, Tooling List510
Structure Function Principle510
Components and Position510
System Technical Parameters511
Description of Principle Diagram and Working Principle512
Testing and Adjustment515
Air Conditioning System Test515
Removal and Installation517
Introduction of Air Conditioner System Main Parts517
Removal and Installation of A/C Components518
Removal of Compressor518
Removal and Installation of Evaporator Mounting Assembly525
Replacement of A/C Control Panel531
Inspection and Replacement of A/C Fuse531
Removal and Replacement of Reservoir532
Removal and Installation of Condenser533
Removal and Installation of Pressure Switch534
Fault Diagnosis and Judgment535
Classification of Common Faults535
Overhauling Method535
Maintenance Method When Backlight of A/C Panel Is Not on and Button Does Not Work535
Maintenance Method When no Air Comes out of Air Conditioner or Air Outlet Volume Is Obviously Smaller than the Normal Volume536
Maintenance Method When Natural Air Comes out When Heating Is Switched on542
System Maintenance543
A/C System Regular Maintenance543
Cleaning of Recirculating Air Strainer543
Cleaning of Fresh Air Strainer544
Driver's Cab System551
Structure Function Principle553
Engine Hood553
Engine Hood Assembly553
Opening and Closing of Engine Hood555
Lifting Mechanism of Engine Hood Torsion Bar557
Removal and Installation560
Installation Requirements for Shock Cushion of Cab560
Removal and Installation of Cab560
Removal of Air Conditioning Components in Cab560
Disassembly of Hydraulic Components in Cab560
Disassembly of Power Components in Cab566
Replacement and Installation for Lifting Rings of Head Cover570
Removal of Shock Cushion570
Lift571
Removal of the Seat571
Exploded View of Driver Seat571
Removal of the Seat573
Removal of Console576
Removal of Decoration580
Removal of the Rear Right Positioning Lock Trim Cover in the Cab580
Removal of Left Decoration of Cab581
Removal of Right Decoration of Cab584
Removal of Decoration of Rear Plate585
Removal of Decoration and Platform and Attachment587
Top Decorations of Cab588
Assemble the Glass of Cab589
Installation of the Left Door Lock in Cab591
Removal and Installation of Engine Hood596
Removal and Installation of the Engine Hood Torque Mechanism602
Structure607
Structure Function Principle609
Frame System609
Articulated Hitch610
Counterweight Assembly611
Work Implement612
The Parameters of Work Implement612
Overview and Configuration Scheme of Work Implement System612
Work Implement Limit System614
Removal and Installation615
Removal and Installation of Hinge Assembly615
Removal and Installation of Counterweight Assembly626
Removal and Installation of Work Implement System628
Removal and Installation of Linkage628
Removal and Installation of Bucket Lever631
Removal and Installation of the Boom634
Replacement of Work Implement Bushing638
Removal and Installation of Accessory System640
Removal and Installation of Quick Coupler Bucket and Quick Coupler Frame647
Replacement of Bucket Movable Blade, Movable Tooth and Tip655
Option Work Implement and Accessory System656
Option of Work Implement System656
Option of Accessory System656
Electrical System659
Basic Information663
Instructions of Service Manual663
Notes for Welding663
The Introduction of Signs on the Electrical Schematic665
Structure Function Principle667
Power System667
Electric Lock669
Fuse670
Disconnect Switch673
Battery674
Power Supply Relay676
Starting Module679
Start Contactor682
Relay682
Starting Motor683
Alternator684
Monitoring System686
Circuit for Engine Water Temperature Indication686
Circuit for Torque Converter Oil Temperature Indication686
Circuit for Oil Pressure Alarm688
Circuit for Transmission Oil Pressure Alarm688
Circuit for Fuel Level Indication689
Circuit for DEF Level Indication691
Circuit for Vehicle Speed Indication691
Service Brake Indication Circuit691
Wiring Schematic Diagram of Braking692
Circuit for Parking Brake Power Cut-Off694
Circuit for Service Brake Clutch On/Off697
Circuit for Air Filter Blockage Alarm698
Circuit for Alternator Charging Indication698
Circuit for Voltage Indication700
Circuit of Preheat Indicator701
Circuit for Seatbelt Indicator702
Circuit for Lube System Failure Indicator702
Circuit for Lube System Activated Indicator703
Circuit for Steering System Failure Indicator703
Circuit for Secondary Steering Indicator704
Circuit of Ride Control Indicator706
Circuit for Radiator Fan Reverse Indicator709
Circuit for Engine Indicator710
Circuit for Engine Diesel Particle Filter Indicator710
Circuit for Latency Shut-Down Indicator710
Instrument711
Sound and Light Alarm System/Audible and Visual Alarm System/Acousto-Optic Alarm System715
Circuit for Electric Horn715
Circuit for Backup Alarm717
Wiper and Washer System718
Circuit Diagram for Wiper and Cleaning System718
Wiper Motor719
Washer Reservoir720
Positioner and Kickout System721
Principle for Auto Reset System721
Lighting System723
Circuit for Front Frame Illumination723
Circuit for Cab Lighting726
Circuit for Rear Frame Illumination729
Shift Control System731
Principle for Shift Control732
Electronic Control Unit735
Shift Selector735
Audio System737
Audio System Principle737
Radio738
Speaker738
Antenna738
Engine Electric Control Module739
DEF Heater Pipe739
Principle for Exhaust Disposal740
Electronic Throttle Line740
DEF Pump Supply Module Line741
Radiator Fan Control Module741
Control Strategy741
Electrical Schematic Diagram741
Electric Proportional Controller Module of the Third Linkage742
Seat Heater744
Backup Monitoring System745
Display Screen746
Power Cable746
Distribution Diagram of Front Frame Harness Connector747
Distribution Diagram of Work Light Harness Connector749
The Distribution Diagram of Cab Harness Connector751
Distribution Diagram of Rear Frame Harness Connector753
Appendix755
Schematic Diagram of Hydraulic System757
Schematic Diagram of Brake System758
A/C System Schematic Diagram759
Electrical Schematic Diagram760

LiuGong CLG835H - Service Manual

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