LiuGong CLG835H User manual

201701001
CLG835H
WHEEL LOADER
SERVICE MANUAL
Applicable type and model: CLG835H PERKINS Engine 1204F-E44AT/ LIUGONG Wet Axle/ ZF
4WG158 Gearbox

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

Contents January 24, 2017
CLG835H

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

1-2
General Information January 24, 2017
CLG835H

1-3
January 24, 2017 How to Use the Manual
CLG835H
How to Use the Manual
This manual is written for an experienced techni-
cian. Essential tools required in performing cer-
tain service work are identified in this manual
and are recommended for use.
This is the safety-alert symbol. When
you see this symbol on the machine
or in this manual , be alert to the
potential for person injury.
Technical manuals are divided in several parts :
repair and test . Repair sections tell how to repair
the components. Tests sections help you identify
the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of
all applicable essential tools, service equipment
and tools, other materials needed to do the job,
service part kit , specifications ,wear tolerances,
and torque values.
Technical Manuals are concise guides for spe-
cific machines. They are on-the-job containing
only the vital information needed for diagnosis,
analysis, testing, and repair .
Fundamental service information is available
from other sources covering basic theory of oper-
ation, fundamentals of troubleshooting, general
maintenance, and basic type of failures and their
causes.
Other reference manuals
●Parts manual
●Use and maintenance manual
●Cummins engine parts manual
●Cummins engine overhaul manual
●ZF axle case overhaul manual
User's Guidance
●Because the influences to the machine from
area or processing are different, it shall con-
firm which machine is applicable, and what
work implements it has.
●Some accessories and optional parts in the
Manual may not be transported to relevant
areas, and consult your local LiuGong dealer
if required.
●The materials and technical specifications in
the Manual are changed with variation of
products, and all information, diagrams and
specifications in the Manual are the latest
product information obtained at the time of
publication. The company reserves the right
to make modification without any notice. If it
needs to obtain the latest technical informa-
tion, please consult the dealer of LiuGong in
local area or Service Department of LiuGong
Wheel Loader Marketing Co., Ltd.

1-4
Important Safety Information January 24, 2017
CLG835H
Important Safety Information
Most accidents involving product operation,
maintenance and repair are caused by failure to
observe safety rules or precautions. An accident
can often be avoided by recognizing potentially
hazardous situations before an accident occurs.
A person must be alert to potential hazards. This
person should also have the necessary training,
skills and tools to perform these functions prop-
erly.
Improper operation, lubrication, maintenance or
repair on this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, main-
tenance or repair on this product, until you have
read and understood the operation, lubrication,
maintain and repair information.
Safety precautions and warnings are provided in
this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death
could occur to you or other persons.
The hazards are identified by the "Safety Alert
Symbol" and followed by a "Signal Word" such
as "WARNING" as shown following.
The meaning of this safety alert symbol is as fol-
lows:
Attention. Be alert. Your safety is involved.
The message that appears under the warning,
explaining the hazard, can be either written or
pictorially presented.
Operations that may cause product damage are
identified by NOTICE labels on the product and
in this publication.
LiuGong cannot anticipate every possible cir-
cumstance that might involve a potential hazard.
The warnings in this publication and on the prod-
uct are therefore not all inclusive. If a tool, proce-
dure, work method or operating technique not
specifically recommended by LiuGong is used,
you must satisfy yourself that it is safe for you
and others. You should also ensure that the
product will not be damaged or made unsafe by
the operation, lubrication, maintenance or
require procedures you choose.
The information, specification, and illustrations in
this publication are on the basis of information
available at the time when it was written. The
specification, torques, pressures, measure-
ments, adjustments, illustrations, and other items
can change at any time. These changes can
affect the service given to the product. Obtain the
complete and most current information before
starting any job. LiuGong has the most current
information available.
CALIFORNIA PROPOSITION 65
Diesel engine exhaust and some of its constitu-
ents are known to the state of California to cause
cancer, birth defects and other reproductive
harm.
Battery post, terminal and related accessories
contain lead and lead compounds, Always wash
hands after handling.

1-5
January 24, 2017 Manual Identification
CLG835H
Manual Identification
IMPORTANT: Use only supporting manuals
designed for your specific machine. If incorrect
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 sup-
porting manuals exist for different machine con-
figurations.
When necessary, product serial numbers and
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 left side of machine front frame under
the pin of boom . Each machine has a 17- char-
acter PIN or shown on this plate and under this
plate, The last 6 characters of the PIN represent
the machine's product serial number.
Figure 1 PIN Plate Location
P11000001

1-6
Engine Identification January 24, 2017
CLG835H
Engine Identification
The engine serial number plate is located on the right side of engine model 1204F. Each engine has two
engine numbers (LIST NO. and SERIAL NO.) shown on this plate.
Engine Emission Level Identification
EMISSION CONTROL INFORMATION: In the U.S., this engine is solely for export and is therefore
exempt under 40 CFR 1068.230 from emission standards and related requirements. Outside the U.S.,
the engine may be subject to other emission regulations.
Figure 2 Pin Plate (17-character with CE mark)
P11000002

1-7
January 24, 2017 Engine Identification
CLG835H
Figure 3 Engine Serial Number Plate Location
Figure 4 Engine Serial Number Plate
P11000003
P11000004

1-8
Cable Code Identification January 24, 2017
CLG835H
Cable Code Identification
The wire in circuit diagram is marked in combination with wire No., wire categories, color abbreviation
codes and wire gauge for maintenance. For example:
Wire No.
Wire No. is digital code for marking wire with three Arabic numbers in accordance with certain rules.
Wire categories
The wire categories selected for engineering machinery are AEX, AV, AVS, AVSS, and QVR in general.
For applicable range of ambient temperature of various wires, see following table.
Color abbreviation codes
S/N Wire type Wire name Description Heat resis-
tance
1 QVR Low-voltage wire for road vehicles 70 °C (158°F) heat-resisting, cop-
per core PVC-insulated ≤70°C(158°F)
2 AVSS Thin-wall insulated low-voltage wire
for vehicles
The thickness of insulation layer
is 0.30~0.40mm ≤80°C(176°F)
3AVS
Thin-wall insulated low-voltage wire
for vehicles
The thickness of insulation layer
is 0.50~0.70mm ≤80°C(176°F)
4 AV Insulated low voltage wire for vehicles The thickness of insulation layer
is 0.60~2.0mm ≤80°C(176°F)
5 AEX Heat-resisting low voltage wire for
vehicles
Heat resistance and cross-linking
polyethylene ≤110°C(230°F)
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
P28E00002

1-9
January 24, 2017 Cable Code Identification
CLG835H
Remarks: The code composed of 2 colors indicates double-color wire
For example: "RD/GN" shows red-green wire.
Wire specifications
Allowable current and voltage drop of AV wire, and approximate performances of AVS, AVSS, and QVR
shall be executed uniformly according to the following table.
Circuit type and color abbreviation code
For general corresponding rules between circuit type and wire color, see the following table.
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
Ambient temperature 30°C(86°F) 40°C(104°F) 50°C(122°F) 60°C(140°F) 70°C(158°F)
Allowable current/
voltage drop AmV/mAmV/mAmV/mAmV/mAmV/m
Nominal
sectional
area(mm2)
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
15 103 176 92 157 30 137 65 111 46 79
20 135 148 121 133 105 116 85 94 60 66
30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 60 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37
Circuit type Color abbreviation codes
Power line OR, RD
Signal line WH
Earthing BK, GY
Communication line RD/GN, YU/BU
Color English Abbreviation Color English Abbreviation

1-10
Coating Materials January 24, 2017
CLG835H
Coating Materials
Paint standard:
There are two main kinds of colors that applied to 835H:
Yellow: matte (50%) RAL1006 yellow
Grey: matte (40%) RAL7021 grey
The standard of paint quality is as follows (for more information, see QJ/LG 08.44-2013):
Name Specification Main features and purposes
1277 Thread locker seal-
ants 1277 ●Features: anaerobic and fast air drying ●Purposes: used for parts not frequently removed
1243 Thread locking seal-
ant 1243 Used for removable parts (speed sensor in general)
Long-term anti-rust agent LONG#2 light yellow
●Features: rust protection for a long time
●Purposes: used for mounting face of pump, sensor,
hydraulic fitting, etc
Efficient cleaning agent
1755 1755 ●Features: strong ability of cleaning ●Purposes: used for pump and motor
Anaerobic pipe thread
sealant 1567
●Feature: it has features of high-temperature resistance, self-
lubrication and medium resistance and is used for medium
(sealing oil, air, vapor, water) pipeline cone/taper thread
●Purposes: used for water temperature sensor and oil
pressure sensor
Cleaning agent for electro-
mechanical equipment HD-10 Used for cleaning oil pipe connectors, etc.
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
S/N Items Indicator Testing method Remarks
1
Paint film
appear-
ance
Paint film shall be uniform
color, and no blistering, crack,
wrinkle, under screen, rust,
damage, dirt and so on
Visual check
Refer to the require-
ments at all levels of
surface for details of
allowable defects
2Paint film
gloss
Meet the minimum require-
ments of paint film gloss at all
levels of surface
Visual/gloss meter
For details, see the
requirements at all lev-
els of surface. For
matte paint, refer to
the special require-
ments
3Paint film
thickness
Meet the minimum require-
ments of paint film thickness at
all levels of surface
Thickness gauge of paint film
For details, please see
the requirements at all
levels of surface

1-11
January 24, 2017 Coating Materials
CLG835H
4
Adhesion
of paint
film
Good adhesion and no peeling
in detection of paint film
Use single cutting edge or scriber to
perform the cross cut on the paint film
with five horizontal and vertical lines.
The distance between the scribing lines
is 1 mm~1.5 mm and the depth can
reach the steel plate substrate. Then
stick the transparent adhesive tape and
compact, then tear off the tape
Approval standard: No
the whole piece of grid
film drops. (Little film
drop around the scrib-
ing lines can be allow-
able.)
5Color dif-
ference
Meet color difference require-
ments at all levels of surface Visual check/Color difference meter
For details, please see
the requirements at all
levels of surface
6Shield
There is no paint contamina-
tion, mechanical impurity, rust
and dirts
Visual check
7 Decal
The decal should be correct,
complete, decorous, firm,
smooth and no popping
Visual check
S/N Items Indicator Testing method Remarks

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

1-13
January 24, 2017 Unit Conversion Table
CLG835H
Unit Conversion Table
The Manual uses ISO International System of Units, and ISO international units are converted into Brit-
ish units as shown in following figure:
Parameters Metric unit British unit Multiple
Length mm In 0.03937
mm ft 0.003281
Capacity
L US gal 0.2642
L US qt 1.057
m³ Yd3 1.308
Weight kg lb 2.205
Intensity N kgf 0.10197
N lbf 0.2248
Torque Nm kgf·m 0.10197
Nm lbf·ft 0.7375
Pressure MPa kgf/cm310.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C ×1.8+32
Speed
km/h mph 0.6214
min-1 rpm 1.0
Flow L/min US gpm 0.2642
mL/rev cc/rev 1.0

1-14
Standard Torque Table January 24, 2017
CLG835H
Standard Torque Table
TORQUE SPECIFICATIONS – METRIC HARDWARE
Use the following torques when specifications are not given.
These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or
when lubricated with engine oil, These values do not apply if graphite or Moly disulfide grease or oil is
used.
Grade 8.8 Bolts , Nuts , and Studs
Size N.m \ lbf·ft
M6 7.7±1.1 N.m \ 5.67±0.81 lbf·ft
M8 19±2.9 N.m \ 14.01±2.13 lbf·ft
M10 72±6 N.m \ 53±4 lbf·ft
M12 120±10 N.m \ 89±7 lbf·ft
M14 195±15 N.m \ 144±11 lbf·ft
M16 305±25 N.m \ 225±18 lbf·ft
M18 415±35 N.m \ 306±26 lbf·ft
M20 600±50 N.m \ 443±37 lbf·ft
M22 800±70 N.m \ 590±52 lbf·ft
M24 1020±100 N.m \ 752±74 lbf·ft
M27 1500±100 N.m \ 1106±77 lbf·ft
M30 1850±150 N.m \ 1364±111 lbf·ft
M33 2900±400 N.m \ 2139±295 lbf·ft
M36 3100±250 N.m \ 2286±184 lbf·ft
Grade 10.9 /12.9 Bolts , Nuts , and Studs
Size N.m
M10 72±6 N.m\ 53±4 lbf·ft
M12 120±10 N.m\ 89±7 lbf·ft
M14 195±15 N.m\ 144±11 lbf·ft
M16 305±25 N.m\ 225±18 lbf·ft
M18 415±35 N.m\ 306±26 lbf·ft
M20 600±50 N.m\ 443±37 lbf·ft
M22 800±70 N.m\ 590±52 lbf·ft
M24 1020±100 N.m\ 752±74 lbf·ft
M27 1500±100 N.m\ 1106±77 lbf·ft
M30 1850±150 N.m\ 1364±111 lbf·ft
M33 2900±400 N.m\ 2139±295 lbf·ft
M36 3100±250 N.m\ 2286±184 lbf·ft

1-15
January 24, 2017 Standard Torque Table
CLG835H
Tightening torque of 24° cone O-ring sealed hose connector
Tightening torque of flange-type sealed hose connector bolt
Series Thread size Hose inner diame-
ter mm
Tightening torque
N.m kgf.m
Light-type
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
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
Heavy type
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
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
Series Bolt Bolt performance
level
Tightening torque
N.m kgf.m
Light-type
M8
8.8
25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
M12 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
M8
10.9
33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
M12 136±6 12.8±0.6
M16 310±15 31.6±1.5

1-16
Standard Torque Table January 24, 2017
CLG835H
Tightening torque of thread angle type sealed hose connector
Heavy type
M8
8.8
25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
M12 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
M20 420±20 42.8±2.0
M8
10.9
33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
M12 136±6 12.8±0.6
M16 310±15 31.6±1.5
M20 577±27 58.9±2.8
Material of fasten-
ings Carbon steel, alloy steel Aluminum product
Thread size
Tightening torque Tightening torque
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 / /
Series Bolt Bolt performance
level
Tightening torque
N.m kgf.m