CLG4215 Motor Grader: Applicable Type and Model: CLG4215 (DCEC Engine + Meritor Axle + ZF Gearbox)

201904001
CLG4215
MOTOR GRADER
SERVICE MANUAL
Applicable type and model: CLG4215 (DCEC Engine + Meritor axle + ZF Gearbox)
April 17, 2019 Contents
CLG4215
Contents
General Information ........................................................................................................1-1
Power System ..................................................................................................................2-1
Power Train System ........................................................................................................3-1
Hydraulic System ............................................................................................................4-1
Electrical System.............................................................................................................5-1
Air Conditioning System.................................................................................................6-1
Frame System ..................................................................................................................7-1
Work Implement..............................................................................................................8-1
Cab System ......................................................................................................................9-1
Contents April 17, 2019
CLG4215
1-1
April 17, 2019 General Information
CLG4215
General Information
How to Use the Manual ...................................................................................................1-1
Important Safety Information .........................................................................................1-2
Safety Symbol ........................................................................................................................................1-2
Safety Signs ...........................................................................................................................................1-2
General Hazard Information ...........................................................................................1-4

Crushing and Cutting Prevention ..................................................................................1-8
Burn Prevention...............................................................................................................1-8
Fire & Explosion Prevention...........................................................................................1-9
Fire Extinguishers and First-aid Kit.............................................................................1-10
Electrical Storm Injury Prevention...............................................................................1-11
Tire Explosion Prevention ............................................................................................1-11
Attachment Cautions ....................................................................................................1-12
Cautions about Machine Operation .............................................................................1-12
Standard Recommended Torque .................................................................................1-18
Standard Thread Torque in Metric System ..........................................................................................1-18
Standard Thread Torque in British System ..........................................................................................1-19
Standard Torque of Nut for Hose Connector .......................................................................................1-19
Metric thread ..................................................................................................................................1-19
Pipe Thread in British system ........................................................................................................1-20
JIC Thread in American System ....................................................................................................1-20
ORFS Thread in American System................................................................................................1-21
Unit Conversion Table ..................................................................................................1-22

Purpose and Main Technical Parameters of Complete Vehicle ................................1-23
Purpose and Working Environment Requirements ..............................................................................1-23
Main Technical Parameters .................................................................................................................1-24
Overall dimensions drawing ...........................................................................................................1-24
Completed vehicle parameters ......................................................................................................1-28
Tire Inflation Pressure...................................................................................................1-31

Pressure Release...........................................................................................................1-32
2
General Information April 17, 2019
CLG4215
Technical Specifications for Lubricant .......................................................................1-33

Time interval of oil change and approximate filling volume ...........................................................1-33
Technical specification for oil .........................................................................................................1-34
Transportation of Vehicle .............................................................................................1-35

Hoisting of Vehicle .......................................................................................................1-36
Removal Process for Grader Overhaul .......................................................................1-38
Removal Process for Grader Overhaul ................................................................................................1-38
Specific Removal Process and Instruction...........................................................................................1-39
New Vehicle Running-in................................................................................................1-43

Regular Maintenance ....................................................................................................1-45
Important Maintenance Programs ...............................................................................1-48
Patrol inspection ..................................................................................................................................1-48
Complete Machine Inspection Table ...........................................................................1-49

1-1
April 17, 2019 How to Use the Manual
CLG4215
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
the Manual are changed with variation of
Technical manuals are divided in several parts: products, and all information, diagrams and
repair and test. Repair sections tell how to repair specifications in the Manual are the latest
the components. Tests sections help you identify product information obtained at the time of
the majority of routine failures quickly. 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, ● For the replacement of environment-friendly
and torque values. key parts and components when maintaining
Technical Manuals are concise guides for an engine, please use the OEM parts and
specific machines. They are on-the-job components of the same type and the same
containing only the vital information needed for specifications. Otherwise, LiuGong accepts
diagnosis, analysis, testing, and repair. no legal liability for any consequence
resulting from the use of unapproved parts.
Fundamental service information is available
from other sources covering basic theory of Applicable type and model of this manual:
operation, fundamentals of troubleshooting,
general maintenance, and basic type of failures CLG4215 (DCEC Engine + MERITOR Axle+ ZF
and their causes. Gearbox)
Other reference manuals
● Parts Manual of Grager

● Operation & Maintenance Manual of Grager
● DCEC Engine Parts Manual
● DCEC Engine Overhaul Manual
● ZF Gearbox Overhaul Manual
● MERITOR Axle Overhaul Manual
1-2
Important Safety Information April 17, 2019
Safety Symbol CLG4215
Important Safety Information Safety Signs
Most accidents involving product operation, Definitions of the safety signs with the words
maintenance and repair are caused by failure to "Danger", "Warning" and "Caution" which appear
observe safety rules or precautions. An accident in this manual and on the machine are as
can often be avoided by recognizing potentially follows:
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
properly. DANGER: this word denotes an impending
danger, failure to observe instructions could
Improper operation, lubrication, maintenance or result in death or serious injuries.
repair on this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication,
maintenance or repair on this product, until you
WARNING: this word denotes potential danger,
have read and understood the operation,
failure to observe instructions could result in
lubrication, maintain and repair information.
death or serious injuries.
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.
CAUTION: this word denotes potential danger,
The hazards are identified by the "Safety Alert failure to observe instructions could result in
Symbol" and followed by a "Signal Word" such minor to medium degree of injury.
as "WARNING".
"Caution" is also used to indicate safety
information relating to unsafe operations which
Safety Symbol may cause personal injuries. "Danger"
represents the most dangerous conditions. The
The symbol for safety alerting appears safety signs "Danger" or "Warning" are placed
on machines, safety signs, manuals or near particular dangerous places. General notice
for important safety information at information is placed on the safety sign
other places. When you see this "Caution."
symbol, you should follow the instructions in the The message that appears under the warning,
safety information, guarding against any explaining the hazard, can be either written or
possibility of personal injuries or death. pictorially presented.
Operations that may cause product damage are
identified by NOTICE labels on the product and
in this publication.
1-3
April 17, 2019 Important Safety Information
CLG4215 Safety Signs
LiuGong cannot anticipate every possible

circumstance that might involve a potential
hazard. The warnings in this publication and on
the product are therefore not all inclusive. If a
tool, procedure, 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,
measurements, 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

constituents 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.
1-4
General Hazard Information April 17, 2019
Safety Signs CLG4215
General Hazard Information
Be familiar with all safety cautions, failure to

observe could result in property damage, serious
injury or even death.
Only trained and qualified personnel should be
allowed to operate or maintain the machine.
Wear relevant personal protective equipment

(PPE) such as a hard hat, ear protection, safety
glasses, safety shoes and gloves when
operating or servicing the machine.
Do not operate the machine if you feel sick,

sleepy or after taking some medication. Check
with your doctor if unsure. Never operate
machinery while under the influence of drugs or
alcohol.
Attach a DO NOT OPERATE or similar warning
tag to start switch or control levers before
servicing or repairing the machine.
Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high
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pressure liquids, when maintaining storage

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batteries, by flying scraps when the engine is in

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operation or you are using tools. When you

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remove springs or resilient parts, add acid/

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electrolyte to batteries, you should wear a full

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face protective mask. When carrying out welding

Do not wear loose fitting clothing, dangling operations or gas cutting operations with a
jewelry or long hair that can catch on controls or welding torch, wear specific safety goggles
in other moving parts of the machine. suitable for the task being performed. Consult
your welding equipment dealer for more
information.
1-5
April 17, 2019 General Hazard Information
Pay attention when opening fluid compartments

to prevent foreign materials from entering the
system. Always remove loose materials from
near caps and plugs.
When working under high noise conditions, wear

appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high Know the appropriate worksite hand signals and
noise on your hearing. who gives them. Accept signals from one person
only.
No smoking and keep open flames away when
maintaining air conditioner or if there is
refrigerant gas, the flames contact the refrigerant
and the cigarette smoke will cause personal
injury or death.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
Make sure all protective guards and covers are
other materials.
secured in place on the machine. Always replace
protective guards and covers removed for Use all cleaning solutions with care. Do not use
servicing or maintenance. Repair damaged any flammable material to wash components, for
guards and covers before operation. example, diesel oil or gasoline. They may easily
catch fire.
Keep the machine, especially the panels,
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.
Report all required repairs in time.

1-6
General Hazard Information April 17, 2019
Do not allow unauthorized personnel on or Wear safety glasses and leather gloves. Never
around the machine. check for high-pressure leaks with your
unprotected hand. Use a board or cardboard
Guangxi Liugong bears no responsibility for
when checking for leaks.
failures caused by modifications to machine
structure without Liugong’s permission.
Compressed Air
Compressed air can cause personal injury. When

using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. Never
aim compressed air at yourself or others.
Compressed air could penetrate your skin and
cause serious injury or death. The maximum air Even a pin-hole size leak can cause serious
pressure used should not exceed 25psi injury, If you are hit by spraying high-pressure oil,
(0.2Mpa). see a doctor for treatment at once.
High-pressure Fluid
Avoid injury from high-pressure oil. When

repairing hydraulic lines, ensure that
system pressure is completely released
before beginning the repair. Hydraulic oil
under pressure contacting the skin could
Disposal of Waste Fluids
cause serious injury or damage.
Improper handling of the waste fluid will cause
Use caution before disconnecting hydraulic lines pollution of the environment. Obey all local
or connectors. High pressure oil that is released regulations for disposal of waste fluids.
can cause a hose to whip.
Collect all waste fluids when performing
Always support attachments and release inspections, maintenance, testing, adjusting and
residual pressure before attempting to repairs to the machine.
disconnect hydraulic lines. Pressure applied by
loads on attachments could cause hydraulic oil to Prepare to collect fluids with suitable containers
spray when lines are removed. before opening any compartment or
disassembling any component that contains
fluids.
1-7
April 17, 2019 General Hazard Information
Use suitable containers to collect waste fluids. Always release pressure in the accumulator
Do not use food containers or beverage bottles before disposing of it.
as they could mislead people to drink the
contents. Asbestos Danger
Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
● Never use compressed air to clean up
asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.
Cautions about Accumulators ● A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
High-pressure nitrogen is contained in the can also be used.
accumulators making them dangerous articles.
Read the following requirements and pay ● Do not grind materials that contain asbestos.
attention to the proper use of accumulators. ● Operate the machine on the windward side of
Check accumulators before charging with the asbestos as far as possible.
nitrogen. Safe use cannot be guaranteed if there ● Obey environmental regulations for the
is not a nameplate attached to the accumulator. disposal of asbestos.
Never charge accumulators that have an
incomplete nameplate or that are of an ● Shower after contact with asbestos.
unidentified type. ● Wear an approved respirator if there is no
Accumulators are charged with nitrogen. The other way to control the dust.
use of oxygen, compressed air or other
flammable air in the accumulator could cause an
explosion and possible injury, death and damage
to the machine.
When charging accumulators with nitrogen, care
should be taken not to damage the diaphragm.
The accumulator's valve should be installed
facing vertically upward. Do not attempt to fix
accumulators by welding them.
Do not drill any hole in the accumulator or close
a hole by welding.
Do not weld a boss on the accumulator.
Accumulators are high-pressure vessels and
should be repaired only by trained specialized
personnel.
1-8
Crushing and Cutting Prevention April 17, 2019
Crushing and Cutting If the machine must be repaired with engine

running, make sure that a qualified operator is
Prevention available in the cab to shut down the engine if
required.
Don't put hands, arms, or any other parts of the Do not use a kinked or frayed wire cable. Wear
body in the way of removable parts. gloves when handling wire cables.
Support equipment and attachments properly Retainer pins, when struck with force, can fly out
when working beneath them. Do not depend on and injure nearby persons. Make sure the area is
hydraulic cylinders to hold up the implement/ clear of people when driving retainer pins. Wear
attachment. The implement/attachment can fall if protective glasses when striking a retainer pin to
a control lever is accidentally moved, or if a avoid injury to your eyes.
hydraulic line breaks.
Chips or other debris can fly off objects when
struck. Make sure no one can be injured by flying
debris before striking any object.
Burn Prevention
Some parts of the machine become hot during

normal operation. Use caution when maintaining
the engine and hydraulics. Allow the machine to
For those parts fitted with shields, if it is cool after it has been operating for a long period
necessary to remove shields in order to perform of time.
maintenance, always install the shields after the
maintenance is performed. Coolant
Rotating or moving parts have cutting or crush At operating temperature, the engine coolant is
hazard. Keep clear or stop engine before hot and under pressure. The radiator and all
servicing. lines to heaters and the engine contain hot water
or steam. Any contact can cause severe burns.
Keep hands and objects away from moving fan

blades. They can throw or cut any object that
contacts the moving blades.
Check the coolant level only after the engine has
Never attempt adjustments while the machine is been stopped and the coolant filler cap is cool
moving or the engine is running unless otherwise enough to remove with your bare hand.
specified.
Remove the cooling system filler cap slowly to
relieve pressure.
1-9
April 17, 2019 Fire & Explosion Prevention
Coolant contains alkali that can cause personal Always wear protective glasses and gloves when
injury. Avoid contact with the skin, eyes and checking batteries.
mouth.
Oil
Hot oil and components can cause personal

injury. Do not allow hot oil or components to
contact the skin.
Fire & Explosion Prevention
All fuels, most lubrication and some coolant

At operating temperature the hydraulic oil tank is
mixtures are flammable.
hot and can be under pressure.
Fuel leaked or spilt onto hot surfaces or electrical
Remove the hydraulic oil tank cap only after the
components can cause a fire.
engine has been stopped and the cap is cool
enough to remove with your bare hand. Do not smoke while refueling or in a refueling
area, or where flammable materials are stored.
Remove the hydraulic oil tank oil filling cap
slowly to relieve pressure.
Relieve all residual pressure in air, oil, fuel or
cooling systems before any lines, connectors or
related items are disconnected or removed.
Batteries
Batteries give off flammable fumes which can Clean and tighten all electrical connections.
explode. Check daily for loose or frayed electrical wires.
Batteries and battery terminals may contain lead; Have all loose or frayed electrical wires
do not touch batteries with your bare hands. tightened, repaired or replaced before operating
Always wash your hands right after maintaining a the machine.
battery. Check the electric circuit periodically to avoid fire
Do not smoke when observing the battery caused by overload or short circuit.
electrolyte levels. Keep all fuels and lubrications stored in properly
Electrolyte is an acid and causes personal injury marked containers and away from all
if it contacts skin or eyes. If contact occurs flush unauthorized persons.
with water and seek medical attention right away. Store all oily rags or other flammable materials in
a protective container away from naked flames
or other sources of ignition.
Do not weld or flame cut pipes that contain
flammable fluids. Clean the flammable fluids
before welding or flame cutting on them.
1-10
Fire Extinguishers and First-aid Kit April 17, 2019
Remove all flammable materials such as fuel, Make sure that all clamps, guards and heat
lubrication and other debris before they shields are properly installed. During operation
accumulate on the machine. this will prevent vibration, abrasion, friction with
other parts and guard from excessive heat.
Do not operate the machine near an open flame.
Before removing or servicing any lines of the air
Keep all open flames or sparks away from the
conditioning system, always ensure there is not
battery. Do not smoke in battery charging areas.
an open fire nearby; any escaping gas coming
Do not charge a frozen battery. This may cause into contact with fire could result in poisonous
an explosion. fumes. Never smoke when servicing or repairing
the air conditioning system, any escaping gas
Ether that burns and inhaled can cause bodily harm or
death.
Starting the machine by use of ether could result
in serious damage to the engine or personal
injury or death. Fire Extinguishers and First-
aid Kit
A fire extinguisher that meets with all local fire

extinguisher laws and regulations should be
available on the machine.
Maintain the fire extinguisher in accordance with
all local laws and regulations. Contact your local
fire department for further information.
Cautions Concerning Lines, Tubes and Know how to use the fire extinguisher and first-
Hoses aid kit.
Do not bend or strike high-pressure lines. Do not A first-aid kit should be available at the work site.
install bent or damaged tubes or hoses. Periodically check the contents of the kit and
replace used medical supplies as necessary.
Tighten any loose fuel or oil pipes, hydraulic
system tubes or hoses. Repair any damaged fuel Keep telephone numbers of doctors, first-aid
or oil lines, tubes or hoses. Leaks can cause centers or fire stations etc with you so you can
fires. Contact Liugong or your Liugong Dealer for contact them in case of an emergency. Post the
factory authorized replacement parts. contact telephone numbers in regulated places.
Ensure that all persons know where the
If you see evidence of any of the following telephone numbers are located and know the
situations, replace the part before using: correct contact method.
● Connectors damaged or leaking.
● Outer covering frayed or cut and reinforcing
wire exposed.
● Outer covering ballooning.
● Evidence of kinking or crushing.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
1-11
April 17, 2019 Electrical Storm Injury Prevention
Inspect and service the fire extinguisher Explosions of tires have resulted from gas heat-
regularly. Obey the recommendations on the induced and combustion inside the tires.
instruction plate and all local laws and Explosions can be caused by heat that is
regulations relating to fire extinguishers. generated by welding, by heating rim
components, by external fire, or by excessive
use of brakes.
Electrical Storm Injury
A tire explosion is much more violent than a
Prevention blowout. The explosion can propel the tire, the
rim components, and the drive train components
When lightning is striking in the vicinity of the as far as 500 m (1500 ft) or more from the
machine, the operator should never attempt to machine. Both the force of the explosion and the
mount and dismount the machine. flying debris can cause property damage,
personal injury, or death.
If you are in the cab during an electrical storm,
stay in the cab. If you are on the ground during Do not approach a warm tire. Maintain a
an electrical storm, stay away from the machine. minimum distance, as shown. Stay outside the
shadow area.
AT LEAST 15m(50ft) AT LEAST 500m(1500ft)
Tire Explosion Prevention
Maintenance, removal, repair and installation of

Dry nitrogen is recommended for inflation of
the tires and wheel rims must be performed with
tires. If the tires were originally inflated with air,
special equipment and a trained repairer.
nitrogen is still preferred for adjusting the
Therefore, it is better to repair and maintain the
pressure. Nitrogen mixes properly with air.
tires in a tire service shop.
Nitrogen inflated tires reduce the potential of a
tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation
of the rubber, deterioration of rubber, and
corrosion of rim components.
Avoid over inflation. Use proper inflation
equipment, and training for using the equipment
is necessary. Improper equipment or using will
result in tire break or rim damage.
Inproper tire and rim maintenance may cause tire
explosion, and such explosion can lead to
serious personal injury or death. Only trained
personnel with proper tools and correct
procedure can maintain the tires and wheel rims.
1-12
Attachment Cautions April 17, 2019
Attachment Cautions Face the machine when getting on or off, grab

the handrails with both hands and step onto the
steps or ladders. Touch three points
Attachments should only be installed by simultaneously (two feet and one hand or two
authorized people who have been trained to hands and one foot) to ensure stability of the
operate and maintain the attachment according body.
to the operator’s manual.
Refer to the instructions in the operation manual
and any other related information when installing
and using attachments.
Incorrect installation of attachments or optional
parts not only will result in safety problems, but
also will negatively influence the operation and
service life of the machine and the attatchments.
It is forbidden to modify the machine or any Never jump off the machine.
attachments without permission from your
LiuGong dealer. Never get on or off a moving machine.
LiuGong bears no responsibility for injuries, Be careful not to touch any control levers when
accidents or machine damage resulting from the getting on or off the machine.
use of unauthorized attachments. Do not try to climb on or off the machine when
carrying tools or supplies. Use a rope to pull
Cautions about Machine equipment up onto the platform or have an
assistant pass them to you.
Operation
Understand Your Machine
Mounting and Dismounting Be able to operate all the equipment on your
machine.
Before mounting or dismounting the machine,
check the condition of handrails, ladders and Understand the purpose of all control systems,
steps. Clean them of grease, lubricants and dirt instruments and indicators.
before use. Repair any damaged parts and Understand the rated load, speed range, the
tighten loose bolts. characteristics of braking and steering, turning
Mount and dismount the machine only where radius and the space clearance for operation.
there are handrails, steps or ladders. Remember that rain, snow, ice, gravel and soft
earth may change the performance of the
machine.
Understand the safety signs on the machine
(Danger, Warning, Caution) and any other signs.
1-13
April 17, 2019 Cautions about Machine Operation
Understand Your Working Area Replace all damaged or lost parts and carry out
lubrication according to the maintenance interval
Before starting, inspect the area where you will schedule.
be working. You should check: adequate
ventilation the position of any slopes, visible Remove all loose objects from the cab. Loose
ditches, falling or hanging objects, conditions of objects may affect the operation and cause
soils (soft or hard), accumulated water and accidents.
swamp areas, rocks or stumps, hidden Make sure that all the windows if fitted are clean
groundwork, posts or the outer limits of walls, the and the screenwiper works normally.
outer limits of the areas where garbage is buried
or that are filled in with earth, holes or openings, Adjust the operators seat to a position that is
obstacles, mud or ice, traffic, heavy dust, heavy most comfortable and provides for easiest
smoke, heavy fog, the exact locations of cables operation of the machine. Check the seat belt
or pipes for power supply, gas supply, phone and the condition of mounting hardware. Repair
service, water supply, sewage disposal and other or replace any items that are damaged. Replace
utilities that are hidden or hung. If necessary the seat belt after three years of use or any time
before starting work you should ask the utility the belt shows signs of wear or damage.
companies to mark out, close or move out these Check all the illumination equipment before
utilities. operation in low light, and ensure that the
illumination system is in good condition.
Before Starting the Engine
Check to make sure the steering frame lock is in
Inspect the machine carefully before starting the the RELEASED position.
engine, ensure all systems are in good
operational condition. Make sure nobody is on or Engine Starting
around the machine before starting the engine.
Do not start the engine if there is a DO NOT
Keep the steps and handrail clean. Clear any dirt OPERATE or similar tag attached to the start
and sands from your shoes before mounting the switch or control levers.
machine.
Check all structural members, covers and
fenders for deformation or damaged.
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Check the condition of safety guards such as

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doors, guards and covers. Repair any damage

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as necessary.
Check the hydraulic system for oil leakage.
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Check the condition of hoses and pipes.

Check all fasteners for security. Do not start the engine until seated in operators
seat and the seat belt is firmly fastened.
Check the condtion of electrical wiring harness
and fuses, replace or repair as neccessary. Also
check the connectors for good connection.
Check the fuel level and fuel system for normal
condition, drain any water or sediment in the
water/fuel separator. Dispose of fluids in
accordance with local regulations.
1-14
Cautions about Machine Operation April 17, 2019
Ensure the hydraulic control levers are all in the Never run the engine in a closed or poorly
NEUTRAL position and the shift control lever is ventilated environment. If working inside a
in the NEUTRAL position before starting the building, open the doors and windows to ensure
engine. enough ventilation and try to prevent exhaust
gas poisoning. Use a power exhaust system
Sound the horn to alert personnel before starting
when working in an enclosed area.
the engine.
Beep
Before Operating the Machine

Only start the engine from the operators seat in Make sure the machine is free of personnel and
the cab. Never start the engine by short-circuiting fasten the seat belt before operation.
the starter motor terminals. Starting the engine
by short-circuiting could result in damage of the Keep all the windows, lightshades and rearview
electrical system, personal injury or death. mirrors clean. Secure doors and windows in
either the open or shut position.
After the engine is started, you should observe,
instruments and warning lights, and make sure Adjust the rearview mirrors for best vision,
that they work and every reading is within especially close to the machine.
working range. Clear all obstacles from where the machine will
Observe machine movements and listen be working. Be aware of hazards such as high
carefully for unusual noises. If there is any fault voltage wires, ditches, etc.
or abnormality, you should stop the engine Make sure the horn, backup alarm (if equipped)
immediately. Locate the source of the problem and all other alert devices are working properly.
and fix before further operation.
Machine Operation
Before operating the machine on roads, check

whether the machine meets the requirements of
the local laws and regulations for road operation.
Make sure that you get the road operating
permission from relevant road administration
offices. Observe the local traffic regulations when
driving the machine on roads.
1-15
Know the maximum dimensions of your Always raise all implements as much as possible
machine. while driving. Keep the mold board blade inside
the width of the machine, to ensure the wheels
don't touch the mold board blade when turning.
Only operate the machine while seated. The seat

belt must be fastened while you operate the
machine. Only operate the control levers while
the engine is running.
Before driving the machine, you should carefully
observe the surroundings to make sure that Do not go close to the edge of a cliff, a dyke, or a
nobody will be endangered. hillock to avoid collapse.
Do not allow another person to sit on the
machine unless an additional seat, seat belt and
Rollover Protective Structure (ROPS) are
provided.
Before operating the machine, you should

operate the machine slowly in an open area,
check for proper operation of all control levers
and all protective devices.
If driving or operating the machine with a bad
view or in a crowded area, you should work with
a signalman, keep the signalman within the field
of your vision, and coordinate your hand signals.
Note any needed repairs during machine
operation such as an abnormal noise, vibration,
smell, wrong reading of gauges, gas or oil
leakage, etc.. Stop what you are doing and report
any needed repairs in time.
During continuous operation after rain, always

remember the ambient condition has been
changed, be extra careful.
1-16
Cautions about Machine Operation April 17, 2019
Be extra careful during operation in snow or Be careful when working beside high voltage
cleaning snow, because a small slope can cause wire. If it is possible to contact the electrical wire
sideslip. When snow is pushed to one side of the while working, consult the Electricity Company
machine, pay extra attention to the obstacles before working.
buried under snow.
When transporting, make sure that the hooks
and the towing devices are adequate. Connect
trailing equipment to a drawbar or hook only.
Never straddle a wire rope cable or similar
device, nor allow others to do so.
Avoid any conditions that can lead to the

machine tipping. The machine can tip when you
work on hills, on banks and on slopes. Also, the
machine can tip when the machine goes across
ditches, hillocks or other unexpected
obstructions.
No personal should be between the machine and
Avoid operating the machine across a slope. If it trailing equipment when maneuvering to connect
is necessary, operate the machine directly to up them. Block the tongue or hook of trailing
and down a slope, do not turn on the slope. equipment to align it with the drawbar or hook.
Parking the Machine
When possible, choose flat level ground to park

the machine, apply the parking brake (if
equipped), always lower any attachment to the
ground and ensure the machine will not move,
possibly causing damage or injury.
Consider any overhead hazards such as the
posibility of falling rocks, any powerlines or any
other overhead hazards that may exist.
If the machine begins to slip sideway when
working on a slope, immediately stop working Consider the ground conditions. Do not park the
and drive the machine downhill. machine near the edge of a cliff, close to an open
excavation or pit.
Do not perform neutral coast when going
downhill, always keep control of the machine, do Consider environmental conditions such as the
not control with the brake. posibility of flooding, heavy snow fall, electrical
storms and exposure to wind and cold. Any of
The machine can only be used within its these conditions may cause damage to the
capability. Any operation beyond its capability will machine.
bring damage to the machine. Refer to
Specification section for the capabilities. Do not cause an obstruction, consider the site
access and other emergency conditions the
Always keep the Rollover Protective Structure machine may obstruct.
(ROPS) installed during machine operation.
1-17
If it is necessary to park the machine on a slope When leaving the machine lock all equipment
or incline, lower the implement to the ground, covers and doors with the key. Remove the key
engage the parking brake and shut off the and keep it with you.
engine. Place chocks under the wheels at the
downhill side on both sides to prevent the
machine from moving.
Lowering the Attachment/ Implement with

Engine Stopped
Understand and obey all regulations relating to

public roads, if the machine is parked on a public For a machine controlled by electro-
road. Additional signage or lighting may be hydraulically control lever, in order to lower
required. the implement, the engine start switch must
Always lower attachments or other equipment be on ON position .Turn the engine start
before leaving the machine, apply the parking switch to OFF position after lowering the
brake. implement.
Put the hydraulic control levers to NEUTRAL In order to lower the implement to the ground or
position and the shift control lever to NEUTRAL trailer, move all control levers to DOWN position.
position. When release them, they will return to HOLD
Engage the parking brake (if equiped). position.
Keep the engine running at idle speed for five Store Accessories Safely
minutes to let the engine cool down gradually.
Store accessories and tools safely so as to
Stop the engine, and take out the key from the prevent them from falling and causing serious
switch. injury or death. Keep playful children and
Turn the battery disconnect switch to OFF bystanders away from the storage area or any
position to avoid battery discharge. area accessories are being stored whilst in use.
1-18
Standard Recommended Torque April 17, 2019
Standard Thread Torque in Metric System CLG4215
Standard Recommended Torque
Bolts involved in this machine shall be fastened in accordance with the torque requirements specified in
the following table, unless special declaration.
Standard Thread Torque in Metric System
Standard torque (N•m)

Thread size
Grade 8.8 strength Grade 10.9 strength
M6 10.5±1.5
M8 26±4
M10 52±7 72±6
M12 90±12 120±10
M14 145±20 195±15
M16 225±35 305±25
M18 310±45 415±35
M20 410±50 600±50
M22 600±80 800±70
M24 760±100 1020±100
M27 1100±150 1500±100
M30 1500±200 1850±150
M33 2050±300 900±400
M36 2650±350 3100±250
In general, the required torque for grade 10.9 shall meet the tightening requirements of grade 12.9.
1-19
April 17, 2019 Standard Recommended Torque
CLG4215 Standard
Standard Thread Torque in British System
Thread size Standard torque (N•m)

1/4 12±4
5/16 25±7
3/8 45±7
7/16 70±15
1/2 100±15
9/16 150±20
5/8 200±25
3/4 360±50
7/8 570±80
1 875±100
Standard Torque of Nut for Hose Connector
Metric thread
Thread Torque of spiral nut (N.M)

M12X1.5 10-20
M14X1.5 20-35
M16X1.5 25-40
M18X1.5 30-45
M20X1.5 35-50
M22X1.5 40-70
M24X1.5 40-70
M26X1.5 60-100
M30X2.0 80-120
M36X2.0 100-150
M42X2.0 150-220
M45X2.0 180-250
M52X2.0 200-300
1-20
Standard Recommended Torque April 17, 2019
Standard Torque of Nut for Hose Connector CLG4215
Pipe Thread in British system

G1/8"X28 11-12
G1/4"X19 25-28
G3/8"X19 41-48
G1/2"X4 72-82
G5/8"X14 96-110
G3/4"X14 124-137
G1"X11 151-165
G1.1/4"X11 192-206
G1.1/2"X11 261-275
G2"X11 343-357
JIC Thread in American System

7/16"X20 15-16
1/2"X20 19-21
9/16"X18 24-28
3/4"X16 49-53
7/8"X14 77-85
1.1/16"X12 107-119
1.3/16"X12 127-140
1.5/16"X12 147-154
1.5/8"X12 172-181
1.7/8"X12 215-226
2.1/2"X12 332-350
1-21
April 17, 2019 Standard Recommended Torque
CLG4215 Standard
ORFS Thread in American System

9/16"X18 14-16
11/16"X16 27-27
13/16"X16 43-47
1"X14 60-68
1.3/16"X12 90-95
1.7/16"X12 125-135
1.11/16"X12 170-190
2"X12 200-225
1-22
Unit Conversion Table April 17, 2019
Standard Torque of Nut for Hose Connector CLG4215
Unit Conversion Table
Name Unit Conversion unit Conversion ratio

Inch (in) Millimeter (mm) 25.4
Millimeter (mm) Inch (in) 0.03937
Length
Foot (ft) Meter (m) 0.3048
Meter (m) Foot (ft) 3.28084
Square Inch (in2) Square centimeter (cm2) 6.4516

Area
Square centimeter (cm2) Square Inch (in2) 0.1550
UK gallons (gal) Liter (L) 4.54609
Liter (L) UK gallons (gal) 0.219969
Volume US gallons (gal) Liter (L) 3.78541
Liter (L) US gallons (gal) 0.264172
Liter (L) Cubic decimeter 1
Pound (lb) Kilogram (kg) 0.453592
Mass
Kilogram (kg) Pound (lb) 2.204622
Pound force.inch (lbf.in) N.m 0.112985
Torque
N.m Pound force.inch (lbf.in) 8.85075
Pound force per square inch (psi) Bar 0.06895
Pound force per square inch
Bar 14.5038
(psi)
Pound force per square inch (psi) MPa 0.006895
Pound force per square inch
MPa 145.038
Pressure (psi)
MPa Bar 10
Bar MPa 0.1
Pa Bar 10-5
Bar Pa 105
Foot per second (ft/s) Meter per second (m/s) 0.3048
Speed
Meter per second (m/s) Foot per second (ft/s) 3.28084
UK gallons per minute (gal/min) Liter per minute (l/min) 4.54609
UK gallons per minute (gal/
Liter per minute (l/min) 0.219969
min)
Flow
US gallons per minute (gal/min) Liter per minute (l/min) 3.78541
US gallons per minute (gal/
Liter per minute (l/min) 0.264172
min)
Fahrenheit degree ºF Celsius degree ºC 5/9*(Fahrenheit degree ºF-32)
Temperature
Celsius degree ºC Fahrenheit degree ºF Celsius degree °C*9/5+32
1-23
April 17, 2019 Purpose and Main Technical Parameters of Complete
Vehicle
Purpose and Main Technical

Parameters of Complete
Vehicle
Purpose and Working

Environment Requirements
Purpose: this grader is used to level road surface

and reshape road section and embankment. It is
used to level roads, squares, etc. This grader is a
common construction machine, therefore it is not
used in the presence of flammable and explosive
hazard, excessive dust and toxic gas.
Working environment requirements:
1. Altitude: ≤ 3048m
2. Ambient temperature: -15°C~40°C (without
auxiliary cooling start device)
3. Fording depth: ≤ 430mm
1-24
Purpose and Main Technical Parameters of Complete Vehicle April 17, 2019
Main Technical Parameters CLG4215
Main Technical Parameters
Overall dimensions drawing
Overall dimensions drawing (standard configuration)
警告
皮带缠绕能导
致人身伤害，与皮
带保持距离。发动
机熄火后才能进行
维修。
注意
上下机器时，应先清
理干净踏板，面向机器，
保持三点接触，禁止从机
器上跳下。
A
4
7 6
2
3 -4 G
B
警告
容器内有高压气体，
C RUSH HAZ A RD 为了避免爆炸和人身伤
害，不得对容器进行加
En g a g e a rt i c u l a it o n 热、焊接、钻孔。在释
lo c k b e fo r e se rv i c e 放气体前，应先释放液 C LG 41 80 142 kW
压油的压力。
or t ra n s p o r t.
155 00 kg
警告
压力系统
在维修前必须释
放压力。
柴油
柴油
1-25
Vehicle
Overall dimensions drawing (optional front blade)
警告
皮带缠绕能导
维修。
注意
器上跳下。
A
4
7 6
2
3 4
- B
G
警告
C RUS H HAZ A RD 为了避免爆炸和人身伤
En g a g e a r ti c u l a it o n 热、焊接、钻孔。在释
C LG 4 180 142 kW
放气体前，应先释放液
ol c k b e fo er se rv i c e 压油的压力。
or t ra n s p o r t.
155 00 kg
警告
压力系统
放压力。
柴油
柴油
1-26
Overall dimensions drawing (optional rear ripper)
警告
皮带缠绕能导
维修。
注意
器上跳下。
4
7 A 3
6
2 4
-G B
警告
E n g a g e a rt ic u la ti o n 热、焊接、钻孔。在释
l o c k b e f o r e se r v i c e 放气体前，应先释放液 C LG 4 18 0 14 2 kW
压油的压力。
o r rt a n s p o rt .
15 500 kg
警告
压力系统
放压力。
柴油
柴油
1-27
Vehicle
Overall dimensions drawing (optional front blade and rear ripper)
警告
皮带缠绕能导
维修。
注意
器上跳下。
A
4
7 6
2
3 4
-G B
警告
En g a g e a tr i c u l a it o n 热、焊接、钻孔。在释
CL G4 1 8 0 1 42 kW
放气体前，应先释放液
ol c k b e fo r e se rv i c e 压油的压力。
or tr a n s p o r t. 1 550 0 kg
警告
压力系统
放压力。
柴油
柴油
1-28
Completed vehicle parameters
Main technical parameters

Weight of completed vehicle kg 16500
Front wheel kg 4950
Complete vehicle Rear wheel kg 11550

parameters Maximum traction (wheel skid) kN 90
Ground pressure of blade kg ≥7820
Minimum turning radius mm 7820

Dongfeng Cummins
Diesel engine
6CTAA8.3-C215
Rated power Kw 160
Rated speed rpm 2200
Number of cylinders In-line 6 cylinder
Cylinder diameter X stroke mm 114×135
Engine system Total displacement of pistons L 8.3
Maximum torque N.m 980N.m/1500r/min
Torque reserve 41%

g/
Rated fuel consumption (bench test) 223
Kw.h
Fuel 0 or-35 light diesel oil
Fan diameter mm 762
Model ZF 6WG200
Single-turbine and three-
Type
Torque converter component
Torque ratio 2.15
Cooling method Air-cooling pressure circulation type
Model ZF 6WG200
Transmission Type Fixed shaft power gearshift
Gearshift 6 gear forward, 3 gear backward

Transmission oil pump
Working pressure MPa 1.6-1.8
(gear pump)
1-29
Vehicle
Main technical parameters

Forward VI gear km/h ≥42
Forward V gear km/h ≥26.2
Forward IV gear km/h ≥21.2
Forward III gear km/h ≥12.4

Highest speed at different
Forward II gear km/h ≥10.7
gears
Forward I gear km/h ≥6.2
Backward I gear km/h ≥6.2
Backward II gear km/h ≥12.4
Backward III gear km/h ≥26.2
Main transmission mode Spiral bevel gear one-stage reducer

Differential and final drive Super gear and planetary gear
Wheel speed reduction mode
speed reduction.
Type Four-wheel drive
Drive shaft and wheels Tire 17.5-25
Tyre Pressure MPa 0.35
Major technical parameters

Brake pump MICO
Driving brake (foot-operated braking Wholly hydraulic shoe brake
Brake oil pressure MPa 10±0.3
Opening pressure of charge valve MPa 12.3±0.35
Shut-off pressure of charge valve MPa 15±0.35
Brake system Low pressure alarm pressure of driving braking MPa 11.5
Accumulator air pre-compression MPa 9.2
Parking brake and emergency brake Manual and electric disc types
Oil pressure of system MPa 15
Low pressure alarm pressure of parking brake MPa 3.5
Type Load sensing steering gear

Number of steering cylinder-- internal radius X
Steering hydraulic mm 2-φ32×275
stroke
system
System working pressure MPa 15-17
Steering angle ° 45°±1°for both left and right sides

1-30
Major technical parameters

Working pump Permco gear pump
Work hydraulic Multiple valve husco

system Maximum flow L 126L/2200r/min
Maximum working pressure of system MPa 18
Length X Width X Thickness mm 4272×610×19
Shovel blade Maximum lifting height of the blade mm 450
Maximum shovel depth of the blade mm 555
System voltage V 24
Battery 2-6-QW-120T
Electrical system
bulb voltage V 24
Diesel engine start Start at 24V
Fuel L 270
Hydraulic oil L 186

22(Actual amount of oil filling
Crank case L
Oil fill capacity according to oil-ruler scale)
Transmission system L
according to oil-ruler scale)
Worm box, rear axle and tandem L
according to oil-ruler scale)
Warm wind
Working medium Engine coolant

kilocal
Heating capacity orie/ 5000
hour
A/C System Cold air
Working medium R12A

kilocal
Refrigerating capacity orie/ 3500
hour
System voltage V 24
1-31
April 17, 2019 Tire Inflation Pressure
CLG4215 Main Technical Parameters
Tire Inflation Pressure
Liugong recommended to inflate the tires with dry nitrogen and adjust the tire pressures. This is applied
to all the machines equipped with rubber tires. Since nitrogen is a type of inert gas, it will not help to
combust in the tires.
Using nitrogen (N2) can not only reduce risk of explosion but also help to prevent oxidation and rubber
ageing as well as corrosion of rim parts. This prolongs the service life of the tires up to more than four
years.
It is necessary to train the operators to use the inflatable equipment. Using improper tire inflation
technique can cause personal injury or even death.
Don’t set the pressure of the inflatable equipment to be higher than the recommended tire
pressure by 140kPa (20 psi).
Check and adjust tire inflation pressure. This should be done when tires are fully cooled. Keep all
other person away from the dangerous area (around the tires).
The pressure of the nitrogen–inflated tires is the same as that of the air-inflated tires. It is
recommended to select the tire inflation pressure listed in the table means the one at normal
temperature based on the machine operating conditions.
*
MPa Psi
17.5-25 0.35±0.01 50±1.5
When driving in very cold environment, the tire pressure will tremendously change. Even if the tire has
been inflated to the correct pressure at normal temperature, it will be under-inflated at freezing
temperature. Low tire pressure can shorten the tire’s service life.
1-32
Pressure Release April 17, 2019
Pressure Release
The hydraulic oil lines are under pressure all the time. Therefore, it is necessary to release the
pressure in the lines when to check or replace the lines. If not, the high-pressure oil will spout out
and lead to severe personal injury.
Though the engine is shut down, yet the parts and oil as well as the cooling water in the radiator
are at high temperature and lead to severe burns. Wait for the temperature to drop down prior to
the operation.
When to dismantle the filling oil port cover and the filling oil port cover of the radiator, the oil or
water may spout out. Therefore, move the covers slowly to release the internal pressure.
*
Specific operation methods of pressure release:
1. Park machine on a firm level ground. Lower all work implements down to the ground.
2. Within 15 seconds after the machine shuts down, turn the switch to the "ON" position, and operate
the operation levers (of Work implements and driving devices) to different directions fully to release
the pressure inside the work implements.
3. Slowly release the filling oil port cover A or filling water port cover B of the radiator at the top of the
hydraulic oil tank to release the internal pressure.
LG421503001 LG421503002
4. Loosen the locking nuts between the hydraulic lines to release the residue pressure inside the
hydraulic devices and then screw them up. In the meantime, collect the residue oil inside the work
implements.
5. Please refer to the "Accumulator Maintenance" section in the Grader User Manual for details about
the release of pressure of the accumulator.
1-33
April 17, 2019 Technical Specifications for Lubricant
Technical Specifications for Lubricant
Time interval of oil change and approximate filling volume
During the check, maintenance, test and adjustment of the machine, when to remove any
hydraulic oil lines or dismantle any parts that contain liquid, prepare proper containers to collect
such liquid. Dispose all liquid properly as per local law and regulation.
Oil change interval (working Approximate filling volume
Category
hours) (litre)
Engine crankcase 250 (or 1 months) 22
Transmission system 1000 (or 6 months) 45
Hydraulic oil 2000 (or 1 year) 186
Axle, balancing tank and worm tank 1000 (or 6 months) 80
Fuel 230 (per shift)
Note: oil change interval, first to shall prevail.

1-34
Technical Specifications for Lubricant April 17, 2019
Technical specification for oil
Name
Category Application parts
Oil for summer Oil for winter
For roller bearing, slide bearing, pins of work
implement, pins of steering cylinder, pins of
★ Molybdenum disulfide lithium-based grease
Grease frames, swing frame of rear axle, spline of
2#
drive shaft, universal joints, and water pump
shafts
Torque converter Engine oil above Mobil Delvac 1300 or For torque converter and power shift
oil SAE15W-40CF gearbox
For hydraulic system, steering hydraulic
★ HM46 Anti-wear HM46 Anti-wear
Hydraulic oil system and braking system of work
hydraulic oil hydraulic oil
implements
★ 15W-30 above the 5W-30 above the
Engine oil For diesel engine
grade SAE/CF-4 grade SAE/CF-4
Engine South 0 #light fuel oil 0 #light fuel oil
For diesel engine
fuel North 0 #light fuel oil -35# light fuel oil
★ SAE85W-90GL-5 heavy-duty vehicles gear
Gear oil Drive axle, balancing tank and worm tank
oil
Notes: The oil marked with ★ is the oil filled when the machine is transported out of the factory.
The oil of the same specification but different brands cannot be used together. If another brand of
oil is to be used, please clean the system first.
● If the machine is used in low-temperature and extremely cold region, the hydraulic oil should be the
HV46 anti-corrosion hydraulic oil. The transmission oil should use ATF220
● Or DEXRON-III or Donax TC transmission oil.
● The lubricant should be changed in a timely manner. Even though the oil is very clean, yet it may
deteriorate if it is placed for a long time.
● The selection of fuel should depend on the lowest temperature of the place where the machine is
used.
1-35
April 17, 2019 Transportation of Vehicle
Transportation of Vehicle ● When the machine is moved onto a truck or a

trailer, steering operation is prohibited in the
Before the transportation, find the details about process.
the passage height, width and permissible load. ● After the machine is successfully loaded, use
The total height, width and weight after the the frame locking devices to fasten the front
machine is placed onto the transportation vehicle and rear frames.
cannot exceed those stipulated in the local
● Lower all work implements to the floor of the
relevant rules.
transportation vehicle, and change the shift
Before the loading, remove ice, snow or other control lever to the neutral.
slippery matters on platform and vehicle. This will
● Press down the parking brake button, and
help to prevent slip during the loading and the
connect the parking brake device.
movement during the transportation.
● Shut down the engine, shift all switches to
central positions or"OFF"position, and pull
out the key to the starting switch.
Observe national laws and local regulations ● Close and lock all doors, take out the key.
on height,width, length and weight during the
● Swift the negative switches of power supply
loading and transportation. If the machine is
to the shutdown position.
transported to the place of cold weather,
please ensure that there is appropriate anti- ● When use a truck or trailer transports the
freeze fluid in the cooling system. machine, use wedges to secure its wheels
and use steel wire ropes to fasten the
1. Before the loading and transportation, use machine to avoid movement during the
wedges to secure the wheels of trucks or transportation.
trailers (The figure shows a trailer).
LG421501005 LG421501006
● Cover the exhaust opening to avoid the

rotation of the turbocharger like a windmill
during the no-load transportation and
prevent the damage to the turbocharger.
1-36
Hoisting of Vehicle April 17, 2019
Hoisting of Vehicle
Lifting ring
Inappropriate hoisting and fastening will

cause the load to move and lead to death.
Install frame locking devices before the
hoisting.
● Please refer to the"main technical

parameters"section for the weight of the
machine. There should be the calculation of LG421501029
the maximum carrying capacity of the crane
and the hoisting rope to ensure the hoisting
safety.
Before hoisting, Front and rear frame was fastened
● The four hoisting ropes of the hoisting device by frame locking device so that to keep machine
should be of the same length to ensure the static.
equal forces to the four hooks.
● There should be the hoisting point marks on
the front and back frames of the machine.
In order to connect the frame locking device,
the machine must face to in the straight-
ahead position
Lifting ring
● The hoisting device should be stably
fastened to the hoisting lugs with hoisting
marks on the machine.
LG421501007
1-37
April 17, 2019 Hoisting of Vehicle
Schematic diagram of hoisting complete vehicle
LG421501009
Inappropriate hoisting may cause the deflection of the machine, and the lead to personal
casualty and damage.
1-38
Removal Process for Grader Overhaul April 17, 2019
Removal Process for Grader Overhaul CLG4215
Removal Process for Grader Overhaul
Removal Process for Grader Overhaul
Removal procedures of the machine
POSITION OF THE MACHINE
Removal for ENGINEhood
Removal for rear drive shaft
Drainage and removal for fuel tank
Removal for RADIATOR
Removal for hydraulic oil tank ASSY.
Removal for cab ASSY.
Removal for ENGINE ASSY.
Removal for rear counterweight
Removal for blade or front counterweight
Removal for blade lift cylinder

and blade swing oil cylinder
Removal for working device ASSY.
Removal for front axle ASSY.
Removal for hinge ASSY.
Removal for rear axle ASSY.

LG421501010
1-39
April 17, 2019 Removal Process for Grader Overhaul
CLG4215 Specific
Specific Removal Process and 2. Hood removal

Instruction Removal refers to section of engine hood
removal step.
1. Complete vehicle position
The blade and ripper placed in the highest point,
working device assembly placed in the lowest
point.
LG421501013
3. Removal of rear drive shaft

Removal refers to section of removal and
LG421501011
installation of rear axle drive shaft.
LG421501012 LG421501014
only remove blade cylinder and its hydraulic

lock, ripper cylinder and If its hydraulic lock,
left and right lift cylinder and its hydraulic
lock, and swing cylinder and its hydraulic
lock, lower the blade as, ripper as and work
device as to the lowest point.
1-40
Specific Removal Process and Instruction CLG4215
5. Radiator removal
Removal refers to section of adiator assembly
removal.
LG421501015
4. Draining and removal of fuel tank LG421501017
Removal refers to section of removal of fuel

6. Removal of hydraulic oil tank as
supply system.
Removal refers to section of hydraulic oil tank
remove from the machine and assembling
procedure.
LG421501016
LG421501018
1-41
April 17, 2019 Removal Process for Grader Overhaul
CLG4215 Specific
7. Removal of Cab Assembly 9. Removal of rear counterweight

Removal refer to section of cab removal. Removal refer to section of rear counterweight
removal step.
LG421501019
LG421501021
8. Removal of engine assembly

10. Remove of blade and front counterweight
Removal refers to section of engine assembly
removal. Removal refers to section of blade body
assembly removal step and front counterweight
removel step.
LG421501020
LG421501022
1-42
12. Removal of work device

Removal refers to section of release steps of
blade assembly and working device frame and
working device frame removal steps.
LG421501023
11. Removal of blade lift cylinder and circle

sideshift cylinder
Removal refers to section of left side blade lift LG421501025
cylinder remove from the machine and
assembling step and turning circle side moving
oil cylinder
If only remove worm box or blade, remove

them from the complete machine directly.
13. Removal of front axle assembly

Removal refers to section of front axle removal
and installation
LG421501024
LG421501026
1-43
April 17, 2019 New Vehicle Running-in
CLG4215 Specific
New Vehicle Running-in
Only the connecting pin between front axle New vehicle running-in is of significant role to
and front frame needs to be removed from prolong the service life of the machine, eliminate
the complete machine, other parts can be potential failures and avoid the occurrence of
removed from the complete machine directly. great failures. Users must conduct the operation
and maintenance of the machine in accordance
14. Removal of hinge assembly with the new vehicle running-in instructions as
Removal refers to section of hinge assembly stipulated in the Manual after purchasing the
removal. machine, and then use the machine normally.
Requirements of new vehicle running-in:
1. The new vehicle running-in period is 100

hours.
2. After starting, keep the machine idle away for
5 minutes at first. The machine should start
at a steady and slow speed with small
acceleration, and then its speed should be
increased gradually.
3. During the running-in period, there should be
even running-in of each gear composed of
forward I, II, III, IV, V and VI gears and
LG421501027
backward I, II and III gears.
4. Except in the urgent situations, there should
15. Removal of rear axle assembly be no sudden start, acceleration, turning or
braking.
Removal refers to section of rear axle casing
removal and assembly, adjustment of chain and 5. During the running-in period, it is better to
so on. scrape loose materials and not to conduct
heavy or quick operations. During the
running-in period, the working load should
not exceed 70 percent of the rated
requirements. The driving speed should not
exceed the 70 percent of the rated maximum
speed.
6. Pay attention to the lubrication of the
machine, and replace or add the lubricant
and grease in stipulated time and cycles.
7. Pay attention to the temperatures of the
transmission, torque converter, front and rear
axles, hubs, parking brake, central bearing
axle, hydraulic oil, engine coolant and oil. If
LG421501028
there is overheating, find out the reasons and
eliminate them.
8. Check the fastening of bolts and nuts of
different parts.
1-44
New Vehicle Running-in April 17, 2019
Conduct following operations after 8 hours of 2. Check the tightening grade of the fan belt,
the new vehicle running-in: alternator belt and the belt of compressor of
air conditioner.
1. Check the fastening of bolts and nuts of
different parts fully. Especially the bolts of 3. Check the leak proofness of the hydraulic
diesel engine cylinder head, the bolts of the system and braking system.
exhaust pipes and the captive bolts of front 4. Replace the transmission oil of the
and rear axles, the connection bolts of rim transmission and the lubricant of the drive
nut drive shaft, the captive bolts of diesel axles.
engine, the captive bolts of transmission, and
the bolts at the hinge of the front and rear 5. Replace the precision filter of the
frames. transmission and clean the rough filter of the
transmission.
2. Check the tightening grade of the fan belt,
alternator belt and the belt of compressor of 6. Wash the return oil filter element of the
air conditioner. hydraulic oil tank.
3. Check the oil level of the transmission, drive

axle and diesel engine.
4. Check whether there is any leakage with the When to replace the transmission oil of the
hydraulic system and braking system. transmission and the lubricant of the drive
5. Check the connection and fastening of the axles as well as the precision filter of the
linkage of all operation levers and transmission, the relevant procedures and
accelerators. regulations should be followed.
6. Check the temperatures and connection of

different components of the electrical
systems, the power supply of power
alternator, the lighting and the working
condition of turning signal lamps, etc.
Please follow relevant operation procedures

and regulations when checking different oil
levels.
Conduct following work when the new

vehicle running-in completes:
1. Check the fastening of different parts, i.e.

nuts and bolts. Especially the bolts of diesel
engine cylinder head, the bolts of the air
discharging pipes and the captive bolts of
front and rear axle, the nuts of rims, the
connection bolts of drive shaft, the captive
bolts of diesel engine, the captive bolts of
transmission, and the bolts at the hinge of the
front and rear frames.
1-45
April 17, 2019 Regular Maintenance
CLG4215 Specific
Regular Maintenance ● Check the air pressure and damage of tires.

● Check the working performance of the
backup alarm.
● Add the grease to drive shafts as per the
instructions of the machine lubrication figure
read and understand all safety documents, pasted onto the machine.
warnings and instructions before conducting
● Maintenance for every 50 working hours or
any operations or taking any maintenance
every week:
steps.
Firstly, conduct the above maintenance items
LiuGong requires that the maintenance work ● Check the transmission fluid level.
must be conducted according to the time cycle ● Check the gap between brake drum and
that firstly expire in the working timer or the brake shoe of the parking brake at the first 50
calendar (date, week, month, etc). working hours, and make adjustments if it is
In the working environment of extreme coldness, not proper. Conduct the check every 250
excessive dust or humidity, there should be more working hours.
lubrication maintenance stipulated in "regular ● Fasten all the binder bolts of all drive shafts.
maintenance".
● For machines equipped with air conditioner,
During the maintenance, it is better to repeat the clean the filter screens of the return air inlet
maintenance items listed in original maintenance and the fresh air gate of the evaporator;
items. For example, when conducting the check the tightening degree of the
maintenance for every 500 working hours or 3 transmission belt of the compressor. and
months, there should be the maintenance for check whether there are foreign matters such
every 250 working hours or 1month, every 50 as greasy dirt and grime that may influence
working hours or every week and every 10 the radiation of heat by the condenser.
working hour or every day.
● Keep the binding posts of the battery clean
Maintenance for every10 working hours or and apply the Vaseline to avoid the corrosion
every day: of the acid smog to the binding posts.
● Check the battery and the battery switch. ● Check the lubrications of all lubrication
points, and fill the grease to all lubrication
● Check engine oil level. points as per the instructions of the machine
● Check coolant level. lubrication figure pasted onto the machine.
● Check hydraulic oil level. ● Check the nitrogen pre-charging pressure of

the accumulator at the first 50 working hours.
● Check fuel level.
Maintenance for every 100 working hours or
● Remove the water and impurities from the oil
every two weeks:
pre-filter and the rough filter of the engine.
● Patrol inspection. (Refer to details about Firstly, conduct the above maintenance items
the"patrol inspection" in the "Important
Maintenance Programs")
● Visual inspection of the engine fan and
driving belt.
● Check the working performance of lamps and
instruments.
1-46
Regular Maintenance April 17, 2019
● At the working date of the first 100 working ● At the first 250 working hours, clean and
hours, replace the transmission box oil and wash the returning oil filter spool of the
replace it every 1,000 working hours; If the hydraulic system. Then, at every 1000
working hours are not up to the stipulated working hours, change the returning oil filter
numbers, replace the transmission box oil at spool of the hydraulic system.
least once each year. When to replace the
● Check the tension and damage of the drive
transmission box oil, change the
belt of the engine and the belt of the
transmission box oil precision filter, and clean
compressor of the air conditioner.
the rough filter inside the bottom of the
transmission box. ● For the machine equipped with air
conditioner, check whether there are
● At the working date of the first 100 working
sufficient refrigerants inside the liquid storage
hours, replace the drive shaft gear oil and
tank of the air conditioner.
change it every 1,000 working hours; If the
working hours are not up to the stipulated ● For the machine equipped with air
numbers, replace the drive shaft gear oil at conditioner, clean the air filters outside and
least once each year. inside the cab.
● Cleaning the engine cylinder head. Clean the ● Check the performance of service brake and
radiator unit. parking brake.
● Clean and wash the fuel filling filter screen of ● Check the nitrogen pre-charging pressure of
the fuel tank. the accumulator at the first 250 working
hours.
● Check the nitrogen pre-charging pressure of
the accumulator (optional) at the first 100 Maintenance for every 500 working hours or
working hours. three months:
● Operate the swing arms at least once every
100 working hours to ensure there is Firstly, conduct the above maintenance items
lubrication grease on the contact surface and ● Check the concentration of anti-freeze and
avoid excessive wear of the latch cylinder. the concentration of the coolant additive.
Maintenance for every 250 working hours or ● Check the fuel prefilter and the rough and
one month: precision filters of the engine.
● Tighten the binder bolts of the front and rear
axles and frames.
● Check the tightening torque of the rim captive
● Check whether the captive bolts of the frame
bolts.
hinge pin is loosened.
● Check the tightening torque of the mounting
bolts of the transmission and the engine.
the accumulator (optional) at the first 500
● Check whether there is crack and looseness working hours. Check the nitrogen pre-
with the force welding seams and captive charging pressure of the accumulator every
bolts of work implement and front and rear 1000 working hours.
frames.
● Check the oil level of front and rear axles. six months:
● Check the air intake system of the engine.
● Replace the engine oil and engine oil filter.
● Adjust valve clearance of the engine.
● Change the coolant filter of the engine.
1-47
April 17, 2019 Regular Maintenance
CLG4215 Specific
● Check the tension pulley bearing and fan ● Change the coolant liquid of the engine,
shaft housing of the engine. clean and washing the cooling system of the
engine, and change the engine coolant liquid
● Replace the transmission fluid & the oil filter,
filter.
and clean the filter inside the oil sump tank of
the transmission. Maintenance for every 6000 working hours:
● Change the drive shaft gear oil and the filter
element of the drive shaft gear oil filter. ● Check the shock absorber of the crank pulley
of the engine, and change it if necessary.
● Change the filter element of the returning oil
filter of the hydraulic system. ● Clean, repair or change the nozzle of the
engine.
● Clean the fuel tank.
● Clean and calibrate the fuel pump.
● Screw up the captive bolts of the battery and
clean the top of the battery. ● Check the fan hub and repair or change it if
necessary.
the accumulator (optional). ● Inspect the turbocharger.
● For the machine equipped with air

conditioner, change the air filter outside the
cab.

every year:

● Replace the hydraulic oil, clean the oil tank
and the oil suction filter screen and check the
oil suction pipes.
● Check the working performance of the
service brake system and the parking brake
system. Remove the friction plate and check
it for damage if necessary.
● Check the tightness of the control valve and
the working cylinder through the
measurement of the natural settlement of the
cylinder.
● For the cab equipped with air conditioner,
check whether there is rupture and wear with
the cooling pipes and water pipes of the air
conditioning system or the oil immersion of
such system, and check whether pipe joints
and clamps are loosened.
● For the cab equipped with air conditioner,
change the air filter inside the cab.
● Check the flexibility of the steering system.
1-48
Important Maintenance Programs April 17, 2019
Patrol inspection CLG4215
Important Maintenance 9. Check steps, corridors and handrails.

Remove all scraps. Repair all damages or
Programs replace damaged parts.
10. Check whether there is any visual damage to
Patrol inspection the roll over protection system(RORS). If
there is any damage, please contact with
LiuGong's agency to repair.
11. Check all lights and replace the broken bulbs
and broken light glass.
Pay close attention to leakages. If any
12. Check the cab and keep its interior clean.
leakage, find out the leakage source and
repair it. If you have doubt about or find the 13. Check whether the instrument and indicator
leakage, please frequently check the changes lamps on the instrument panel is broken or
in the liquid level.Patrol inspection. not. Replace all broken parts.
14. Check seat safety belts, strips and mounting
1. Check whether there is leakage in the hoses fasteners, and replace all worn or broken
of the cooling system and the hydraulic parts.
system. Repair and replace the hoses timely 15. Check rearview mirror and windows to make
if necessary. sure that the driver's vision will not be
2. Check the engine chamber. Clean and affected. Clean windows if necessary.
remove the scraps and foreign matters piles
in the engine chamber. Remove the scraps
and foreign matters on the radiator.
3. Check whether there is any visual damage to
the engine.
4. Check whether there is any damage to tires.
Check whether the valve caps are missed or
not.
5. Check whether there is any leakage in the
drive axle, differential, wheel brakes and
transmission. If any, fix the problem.
6. Check whether there is any leakge in the
hydraulic oil tank, all hoses and pipes. In the
meantime, check whether there is any
leakage in all blockage, seals, joints and
nozzles. Fix the problem and replace hoses if
necessary.
7. Check whether there is any wear and
damage to all work implements and links.
8. Ensure all doors, inspection covers and
protection plates are solid. Check whether
there is any damage to doors, inspection
covers and protection plates.
1-49
April 17, 2019 Complete Machine Inspection Table
CLG4215 Patrol inspection
Complete Machine Inspection Table
Inspection
No. Inspection method and acceptance criteria
item
Complete machine information: visually check the complete machine number for compliance
1
with description of model;
2 Fastening bolt: visual check whether the mounting bolts of the frame hinge are tightened;
3 Fastening bolt: visual check whether the mounting bolts of the engine are tightened;
4 Fastening bolt: visual check whether the mounting bolts of transmission are tightened;
5 Fastening bolt: visual check whether the mounting bolts of rear axle are tightened;
6 Fastening bolt: visually check whether mounting bolts of tire & rim are tightened;
Water level: anti-freeze level shall be over the middle line in the level window of expansion
7
tank;
Inspection
before test Engine oil: pull out the oil dipstick and the engine oil level shall be between the MIN and MAX
8
run marks of the dipstick, and the oil is not in white;
Hydraulic oil: visually check whether the oil level of the hydraulic oil tank is within the green
9
scale and the oil is not in white;
Transmission fluid: when the engine is idling and the transmission fluid temperature does not
exceed 40°C, check that the level shall be between cold fluid MAX and MIN marks. Then, put
the shift lever to 4th gear and depress the brake, then the accelerator to run the transmission for
10
5~8min resulting in the transmission fluid temperature reaching 100~110°C. Release the
accelerator and put the shift lever to 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: visual 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 and tape player, sunshade, cigarette lighter, and they should
3
function normally;
Seat adjustment: the height and front & rear adjustment distance of the seat is obvious;
4 adjustment angle of left and right backrest armrest is obvious; move upward the handle at the
front of suspension, the suspension rises, otherwise goes down;
Turning on the electric lock: turn on the front floodlight, work light, warning lamp, parking light
5
Climbing up orderly and get off the vehicle to check if they function normally;
the cab Starting the complete machine: depress the accelerator pedal and visually check the
6
corresponding change to the speed of the tachometer on the instrument panel;
Starting the complete machine: operate the switch of LCD to switch the voltage and timing
7
display;
8 Visually check: timer display and record the time;
Steering wheel: Steering gear can be adjusted front and rear normally; no looseness after
9
locking. Lift the steering wheel upwards by hand and no axial runout occurs (≤3mm);
Horn: press the horn button on the combination lever/steering wheel and listen for the horn, no
10
abnormal sound and failure shall occur;
Air condition The air volume switch, temperature mode switch on the A/C panel functions normally and is
1
system indicated; the air outlet shall be operated normally;
1-50
Complete Machine Inspection Table April 17, 2019
Inspection
item
Start the complete machine: it is started normally, and no abnormal sound is heard from the
1 engine and air filter, and it turns off normally without delay; observe the engine under the diesel
engine idling and top speed, it shall not stall;
Start the complete machine: adjust the complete machine operating idle speed to a level of
2 more than 950 rpm, and under the working condition of the blade pressing the ground, the
engine does not stall;
Starting the complete machine: visually check that no trouble code appears on the LCD of
3 instrument panel, and no indicating identification, no alarm flashing or constant lighting appears
on the instrument panel;
4 Control lever: there is no seizing and interference with other parts when operating the lever;
Inspection of work implement operation: no abnormal sound shall occur during cylinder
5
lifting; no abnormal sound shall occur during the rotation process of the swing circle;
Visual check and listening: visually check that there is no interference between front and rear
6 frame when turning to the maximum left and right steering angle; there is no interference and
pulling between hydraulic line&electrical circuit when the steer action occurs for the hinge;
Gear inspection: Operate the shift lever, and all the gears shall be available freely for the
7
complete machine;
Driving test
Backup alarm: when the shift lever is placed at reverse gear, the backup alarm begins to
8
perform buzzing alarm immediately;
Drive the vehicle for 10 laps, during which depress the brake pedal and the complete machine is
9 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 alarm indicator on instrument panel indicates alarm
10 during driving; visually check that oil and water temperature of the torque converter are
displayed at green area;
Steering during driving: no seizing, heavy or floating is felt when turning to the left and right
11
during driving;
Power train system inspection: listen to the diesel engine operation for abnormal sound
12 during driving; front and rear axles have no abnormal sound; transmission & torque converter
assembly has no abnormal sound;
Emergency brake: apply hand brake after climbing 15% of slope, and then release the brake
13
valve, the complete vehicle shall stay for 5 seconds and remain stationary;
Pressure maintaining of hydraulic system: work implements are lifted to the maximum,
14
visually check dropping off doesn’t occur during lifting the cylinder;
1-51
April 17, 2019 Complete Machine Inspection Table
CLG4215 Patrol inspection
Inspection
item
Touch: there is no oil leakage for fuel pipe joints from front wheel steering cylinder, front wheel
1 tilt cylinder, traction frame swing oil cylinder, frame hinge steer cylinder, blade lead-out cylinder
and blade angle cylinder;
Touch: there is no oil leakage for fuel pipe joints from hydraulic pump, multiple-way valve, worm
2
box drive motor and swing joint;
Touch: there is no oil leakage for joints from the accumulator, the brake steel tube and the
3
brake;
Touch: there is no oil leakage for flanges, plugs, dipstick and fuel pipe joint in the hydraulic oil
4
tank;
Touch: there is no oil leakage for joints from blade cylinder (if configured), ripper cylinder (if
5
configured) and latch cylinder (if configured);
Touch: there is no oil leakage at diesel tank and outlet pipe joint, diesel tank body and flange,
6
plug;
Visual check: rear cover with lifting mechanism is raised smoothly during which there is no
7 interference with other parts; there is no interference between lifting jack and frame, radiator;
there is no oil leakage at lifting cylinder joint;
Static check
Visual check: rear cover is symmetrical at left and right sides; bottom of rear cover is attached
8
with counterweight, rear frame, left and right plate;
Visual check: diesel engine mounting bolt is fastened and there is no oil leakage at parts on
9
diesel engine and oil pan;
Visual check+touch: there is no water leakage at upper and lower water pipe, cool and warm
10 water pipe and water valve; there is no oil leakage at pipe joints of filter, high pressure oil pump,
flywheel housing cover;
Visual check: A/C pipe runs smoothly and is not interfered with other components, diesel
11 engine high temperature area and the exposed A/C aluminum pipe is not interfered with other
components;
Visual check: the pulley belt is not twisted and peeled off; and the A/C compressor pulley is in
12
the same horizontal plane with diesel engine pulley;
Visual check: clearance between engine fan and shroud is ≥10mm, clearance between the
13
engine and the fan guard is ≥15mm;
Visual check + touch: there is no water and oil leakage at radiator assembly and its radiator
14
pipe joint;
1-52
Complete Machine Inspection Table April 17, 2019
2-1
April 17, 2019 Power System
CLG4215
Power System
Overview of Engine .........................................................................................................2-1
Basic Parameters of Engine ...........................................................................................2-1
Removal and Installation of Intake and Exhaust System ............................................2-3
Introduction of Intake and Exhaust System ...........................................................................................2-3
Removal and Installation of Intake and Exhaust system........................................................................2-4
Removal of Air Filter ........................................................................................................................2-4
Installation of Air Filter......................................................................................................................2-5
Removal and Installation of Fuel Supply System.........................................................2-6

Introduction of Fuel Supply System .......................................................................................................2-6
Removal and Installation of Fuel Supply System...................................................................................2-7
Removal of Fuel Tank ......................................................................................................................2-7
Installation of Fuel Tank .................................................................................................................2-17
Cleaning of Fuel Tank ..........................................................................................................................2-18
Removal and Installation of Cooling System..............................................................2-19

Working Principle of Cooling System ...................................................................................................2-19
Removal and Installation of Fan Components .....................................................................................2-20
Removal of Radiator Fan ...............................................................................................................2-20
Installation of Radiator Fan ...........................................................................................................2-20
Removal and Installation of Radiator Assembly...................................................................................2-21
Removal of Radiator Assembly ......................................................................................................2-21
Installation of Radiator Assembly...................................................................................................2-23
Removal and Installation of Engine Assembly...........................................................2-24

Removal and Installation of Engine Assembly .....................................................................................2-24
Removal of Engine Assembly ........................................................................................................2-24
Installation of Engine Assembly .....................................................................................................2-34
Removal and Installation of Engine and Gearbox & Torque Converter Assembly...............................2-35
Removal of Engine and Gearbox & Torque Converter Assembly ................................................2-35
Installation of Engine and Gearbox & Torque Converter Assembly ...............................................2-40
Common Faults and Reasons Analysis of Engine.....................................................2-41

Common Simple Fault Diagnosis Methods of Engine..........................................................................2-41
Daily Maintenance and Tips for Engine ...............................................................................................2-47
2-2
Power System April 17, 2019
CLG4215
Maintenance and Replacement of Engine Quick-wear Parts ....................................2-47

Replacement of Fuel Filter ...................................................................................................................2-47
Replacement of Fuel Prefilter ..............................................................................................................2-48
Replacement of Oil Filter .....................................................................................................................2-49
Maintenance of Air Filter ......................................................................................................................2-49
Replacement of Air Filter Safety Filter Element ...................................................................................2-51
2-1
April 17, 2019 Overview of Engine
CLG4215
Overview of Engine
CLG4215 adopts Dongfeng Cummins fuel engine (6CTAA8.3-C215) with four strokes, in-line 6
cylinders and displacement of 8.3L as its power system, which meets the emission requirements of
China II stage.
This fuel engine adopts the air intake type of turbo charger and air-air intercooler to make the air intake
adequate, combustion more sufficient and power greater. Use air as the heat exchange medium, cool
the air intake with high temperature after supercharged to the required temperature through the air-air
intercooler to meet the requirements of emission regulation, and improve the engine power performance
and economy.
Fuel system adopts WUXIWEIFU PW2000/RSV speed regulator and has higher fuel economy.
It adopts integrated design. Water pump housing, oil pump housing, water intake pipe of water pump, oil
cooler housing, air intake manifold, thermostat seat, small coolant circulating pipe and fuel filter base,
etc. are cast directly onto the cylinder block and cover to decrease components, which reduces faults,
makes maintenance easier and cost less.
Basic Parameters of Engine
Basic Parameters of Engine
Fuel engine Dongkang 6CTAA8.3-C215

Rated power Kw 160
Rated speed Rpm 2200
Number of cylinders In-line 6 cylinder
Cylinder bore X stroke mm 114X135

Engine system
Total displacement of pistons L 8.3
Maximum torque N.m 980N.m/1500r/min
Specific fuel consumption (stand test) g/Kw.h 223
Fuel 0 # or -35 # light fuel
Fan diameter mm 762
Typical Data of Engine

Dry weight (with flywheel and alternator, without
kg 604
starter and air compressor)
Instantaneous inertial of rotating components (without
kg.m2 0.72
flywheel)
Typical data
Distance from center of gravity to front end surface of
mm 427
cylinder block
Distance from center of gravity to center line of
mm 163
crankshaft (on the crankshaft)
2-2
Basic Parameters of Engine April 17, 2019
CLG4215
Performance Parameters of Engine

Min. idle speed rpm 900
Max. speed regulation speed (10% of rated load) rpm 2450
Max. over-speed performance rpm 3500
Max. height allowable for continuous running m 3000
Max. torque during full-shutdown of accelerator N.m 510

Performance
Speed regulation ratio % ?8
parameters
High idle Deg 103±10°
Accelerator handle
Low idle Deg 70±10°
angle
Rotation angle Deg 35±5°
Shutdown handle Free position Deg 316±5°

angle Parking position Deg 15±5°
2-3
April 17, 2019 Removal and Installation of Intake and Exhaust System
CLG4215 Introduction of Intake and Exhaust System
Removal and Installation of Intake and Exhaust System
Introduction of Intake and Exhaust System
Intake and exhaust system is like human respiratory system, which is in charge of the intake an exhaust
of fuel engine. Its main functions are: filter the impurity in the air to supply adequate and clean air to fuel
engine; at the same time, reduce noise of fuel engine to ensure smooth exhaust. Main components of
intake and exhaust system include: air prefilter, air filter, turbocharger, muffler, air intake manifold and
exhaust manifold.
Intake process:
Impurity of large particles is removed from the air through prefilter, then the air enters the filter to remove
unnecessary impurity of 99.5%; after the air is supercharged through turbocharger, it enters the
intercooler to cool down, then it flows into the cylinder of fuel engine through intake manifold.
Main function of intercooler is to cool the air intake with high temperature after supercharged to the
required temperature to meet the requirements of emission regulation, and improve the engine power
performance and economy. High intake temperature indicates that the density of air into the engine
decreases, which will cause increase of exhaust smoke, reduction of power, increase of heat release to
cooling system and raise of engine temperature. Too low intake temperature will cause the non-
compression ignition of fuel engine, ignition lag and abnormal combustion, which will generate black
smoke, knock, unstable running and diluted oil due to fuel penetration. So intercooler is an indispensable
part .
Exhaust process:
Air in the cylinder is mixed with fuel, then it becomes exhaust gas after burning; the gas is back to the
atmosphere after passing through exhaust manifold, turbocharger and muffler.
Air flow route
COMPRESSED AIR FLOW
TURBOCHARG
ENGINE ER OIL INLET
CYLINDER
AIR INLET COOLER TURBINE
COMPRESSOR
EXHAUST
AIR INLET EMISSION
COMPRESSOR BLADE
EXHAUST
OIL OUTLET EMISSION VALVE
LG421504001
2-4
Removal and Installation of Intake and Exhaust System April 17, 2019
Removal and Installation of Intake and Exhaust system CLG4215
Removal and Installation of Intake and Exhaust system
Removal of Air Filter
Figures Operation instructions

1. Loose the lock on the fixed guard to open the
cover plate;
LG421504002
2. Separate six fasteners by the thumb;
LG421504003
3. Hold up the fasteners and pull the cover open in

the direction as above;
LG421504004
2-5
April 17, 2019 Removal and Installation of Intake and Exhaust System
CLG4215 Removal and Installation of Intake and Exhaust system

4. Shake main filter element to the left and right by
hand slightly, and pull out main filter element
slowly. Clean or replace main filter element
according to the requirements. For cleaning of air
filter and replacement of filter element, please
refer to 4.8.4-Maintenance of air filter and 4.8.5-
Replacement of air filter element.
LG421504005
Installation of Air Filter
Install the filter according to reverse steps of removal.

2-6
Removal and Installation of Fuel Supply System April 17, 2019
Introduction of Fuel Supply System CLG4215
Removal and Installation of Fuel Supply System
Introduction of Fuel Supply System
Fuel supply system supplies clean fuel to engine and it is the key part for engine to work normally. Fuel
supply system mainly includes fuel tank, suction filter screen, oil pipe lines, oil-water separator and fuel
filter, etc.
Fuel filter device is the best guarantee for long-time continuous running of engine. Water is the most
important affecting factor in all the pollutants of the fuel, which can enter fuel when filling fuel. When the
moisture in the air is condensed on cold metal wall of fuel reservoir, or inappropriate cleaning is
conducted, water will be generated. The water in the fuel has serious affect. It can damage the injector
nozzle or decrease the fuel unctuosity. Exceeding impurity and water in the fuel is the main reason to
damage and wear the high pressure oil pump and injector. So oil-water separator and fuel filter should
be installed on the front engine to separate fuel and water, and remove most impurity in the fuel.
1
1 2
LG421504006
1. fuel filter
2. oil-water separator
2-7
April 17, 2019 Removal and Installation of Fuel Supply System
CLG4215 Removal and Installation of Fuel Supply System
Removal and Installation of Fuel Supply System
Removal of Fuel Tank
Remove the hood assembly before removing the fuel tank;please refer to chapter "removal steps of
hood" to conduct the removal, after this removal, remove the fuel tank as the following steps.

1. Remove the return tube clamp bolts on the fuel
tank (Removal wrench specification10mm);
LG421504007
2. Remove the return tube connector on the engine

side;
LG421504008
2-8
Removal and Installation of Fuel Supply System CLG4215

3. Bypassing the engine, put the return tube into the
waste fuel bucket on the other side;
LG421504009
4. Shield the fuel hose after draining fuel;
LG421504010
5. Remove the screw on the other side of fuel hose

(wrench specification 19mm) and take down the
fuel hose;
LG421504011
2-9

6. Install the screw onto the oil drain hole of fuel
tank;
LG421504012
7. Unscrew the clamp bolts of rubber hose spread

water to lower hose (removal wrench specification
10 mm );
LG421504013
8. Remove the clamp fixing rubber hose on the water

spreading side (removal socket specification
10mm);
LG421504014
2-10

9. Pry the rubber hose out with crowbar;
LG421504015
10. Lift the rubber hose to the highest position and

bend the hose into 2 sections; Move the rubber
hose in front of the waste oil bucket, put the hose
into the bucket to drain the coolant.
LG421504016
2-11

Remove the intercooler steel tube on the left
machine, the detailed steps are as follows:
11. Remove the 4 bolts fixing the steel tube clamp of

the intercooler ( wrench or socket specification
16mm);
LG421504017
LG421504018
12. Remove the clamp close to the radiator side on

the intercooler with long type socket (specification
10mm);
LG421504019
2-12

13. Remove the clamp near close to the engine side;
take down the steel tube of intercooler;
LG421504020
Remove the intercooler steel tube on the right

machine, the detailed steps are as follows:
14. Remove the 4 bolts fixing the steel tube clamp of

the intercooler (removal wrench or socket
specification 16mm);
LG421504021
×4
LG421504022
2-13

15. Remove the clamp on the intercooler steel tube
sides with long type socket;
LG421504023
16. Take down the intercooler steel tube;
LG421504024
2-14

17. Remove clamps of warm water hose and breather
hose of A/C on the end of the engine;
LG421504025
LG421504026
18. Remove the clamp of big and breather rubber

tube close to the radiator side;
×2
LG421504027
2-15

19. Take down the big and small rubber tube
assembly;
LG421504028
20. Cut off the harness tie of fuel tank level sensor
with scissor;
LG421504029
21. Remove the harness connector of fuel tank level

sensor;
LG421504030
2-16

22. Unscrew the fuel hose (wrench specification
19mm);
LG421504031
23. Bend the fuel hose into two sections and bind
them with 1 tie;
LG421504032
24. Remove the 4 bolts on both sides of fuel tank

( removal socket specification 24mm);
×4
LG421504033
2-17

25. Install 2 lifting rings on the 2 lifting lug on the top
fuel tank (thread specification M16); use 2 lifting
rope to lift the fuel tank.
LG421504034
Installation of Fuel Tank
Assemble according to reverse steps of removal.

Installation of fuel tank has the following requirements: oil inlet and return port must be separated and
the return port must be below the oil level ; oil inlet port must be 25 mm away from the tank bottom. The
bottom is the sediment space of water and impurity and the lowest bottom must be installed with
blowdown valve, reserve 5% of expansion space to avoid overflow after fuel expansion and has the
ventilatory function to avoid too high pressure of internal tank; the ventilatory hole should be dust proof
and water proof.
2-18
Cleaning of Fuel Tank CLG4215
Cleaning of Fuel Tank
Sometimes, we should clean the removed fuel tank; here we will introduce the cleaning steps of fuel tank
briefly.
1. 1. Remove the flange cover on the front end of fuel tank, use clean fuel to wash the inner oil tank
surface.
2. 2. Unscrew the drain plug under the fuel tank to drain the oil.
3. 3. Wash the surface repeatedly until the oil is exhausted.
FLANGE
COVER
DRAIN PLUG
LG421504035
2-19
April 17, 2019 Removal and Installation of Cooling System
CLG4215 Working Principle of Cooling System
Removal and Installation of Cooling System
Working Principle of Cooling System
Main function of cooling system is to emit the heat from the main components during operating process
of grader to the atmosphere to make sure normal running of machine.
Main components of cooling system include water radiator (water tank), hydraulic oil cooler, torque
converter oil cooler and fan,etc. CLG4215 grader adopts the arrangement form of post cooling system to
make maintenance easier and independent hydraulic motor drive fan to ensure high efficiency cooling;
the fan speed is adjustable and without noise.
AIR COOLER
WATER
RADIATOR
HYDRAULIC OIL TORQUE CONVERTER

BULK HEATING OIL RADIATOR
LG421504036
Coolant in the radiator is pressed into the cylinder block and cylinder cover water sleeve through the inlet
hole of cylinder block after supercharged; the coolant returns to cooler through the cylinder cover outlet
hole after absorbing large amount of heat from the engine. Due to the strong suction of fan, air flow
passes through the cooler with high speed from the front to rear. Therefore, in the process of heated
coolant flowing through the radiator core, heat is emitted to the atmosphere constantly; cooling water
flows through the radiator bottom, and then it is pumped out by water pump and pressed into the water
sleeve of engine. This is how the cycle works to emit heat into the atmosphere and make the fuel engine
cool down constantly.
2-20
Removal and Installation of Cooling System April 17, 2019
Removal and Installation of Fan Components CLG4215
Removal and Installation of Fan Components
Removal of Radiator Fan
Figures Operation instruction

1. Open left and right doors of engine hood to see 4
mounting bolts from the inside referred by P1
P2 and P2; Hang the 2 handrails by lifting rope;
Remove the 2 bolts P1 under the rear hood firstly(
socket specification 13 mm), then remove the 2
P1
bolts P2 above the hood; Take down the rear
hood; unplug the harness connector of plate
license light during this process;
Caution: please use lifting rope to lift rear
hood and avoid potential hazard due to manual
materials handling(such as bruised, injured by a
LG421504037
crashing object)!
×4
LG421504038
2. Remove the 6 bolts(socket specification13mm)

and take dowm the fan;
LG421504039
Installation of Radiator Fan

2-21
CLG4215 Removal and Installation of Radiator Assembly
Removal and Installation of Radiator Assembly
Removal of Radiator Assembly
Please remove the engine hood, fuel tank and fan firstly according to steps of Engine hood remove
steps, Removal of fuel supply system and Removal of fan components;

1. Remove 2 oil pipes of torque converter and 2
hoses of hydraulic oil cooler;
×2
×2
LG421504040
2. Remove 3 oil pipes on the cooler motor;

×3
LG421504041
2-22
Removal and Installation of Cooling System April 17, 2019
Removal and Installation of Radiator Assembly CLG4215

3. Refer to "Radiator control valve" to mark and
remove the hoses;
LG421504042
4. Loose the rubber hose clamp P1; Loose P2 clamp

bolts at the lower water pipe 2;
P1
P2
LG421504043
5. Pull out the hose and screw 2 lifting rings into the
radiator assembly, hang the rings by 2 steel cable
and lift it up slowly until the cable is exactly
tensioned;
LG421504044
2-23
CLG4215 Removal and Installation of Radiator Assembly

6. Unscrew 4 fastening bolts of radiator
assembly(socket specification 24 mm); Lift slowly,
check whether there are non-removed hoses and
rubber hoses around the radiator during lifting
process; if yes, remove them before lifting,
otherwise, components will be damaged or
accidents will be caused; Put the radiator onto firm
ground and shield all oil ports;
LG421504045
Installation of Radiator Assembly

2-24
Removal and Installation of Engine Assembly April 17, 2019
Removal and Installation of Engine Assembly CLG4215
Removal and Installation of Engine Assembly
Removal and Installation of Engine Assembly
Removal of Engine Assembly
Please remove the above parts according to Discharging refrigerant in A/C system (Chapter 8 Removal
and Installation for A/C), Removal for pipe of the compressor, Removal procedures of engine hood,
Removal and installation for fuel supply system, Removal and installation for fan components, Removal
and installation for radiator assembly, Removal and installation for pump drive shaft, then remove the
engine according to the following steps.

1. Remove the throttle cable;
LG421504046
The components below are on the right side of

engine:
2. Remove all the wires on the alternator;
LG421504047
2-25
April 17, 2019 Removal and Installation of Engine Assembly
CLG4215 Removal and Installation of Engine Assembly

3. Remove the wires connecting with the
transmission;
LG421504048
4. Unplug all the wires of air filter blockage sensor;
LG421504049
5. Remove all the wires on the alternator;
LG421504050
2-26

6. Unscrew the clamp of A/C return pipe and unplug
the water pipe;
LG421504051
7. Remove water intake pipe of A/C on the engine;
LG421504052
2-27

8. Unplug the sensor wire harness on the
transmission;
LG421504053
LG421504054
The components below are on the left side of

engine:
9. Unplug the wires on the transmission oil pressure

switch;
LG421504055
2-28

10. Unplug the transmission wire harness and cut off
the fixed ties of harness;
LG421504056
11. Unplug the wires on the torque converter oil

temperature sensor;
LG421504057
12. Unplug the harness on the shutdown

electromagnet;
LG421504058
2-29

13. Unplug the wires on the oil pressure alarm switch;
LG421504059
14. Unscrew the wire nuts and unplug the wires;
LG421504060
15. Unscrew fastening bolts of pipe clip (socket

LG421504061
2-30

16. Unplug the wire harness;
LG421504062
17. Remove the cooling pump hydraulic hose;
LG421504063
18. Check the pump drive shaft for separation; if not,

please refer to the steps of 5.6.2-removal and
installation of pump drive shaft to separate the
shaft;
LG421504064
2-31

19. Unscrew the 2 bolts on upper side of shock
absorber (removal socket specification 19mm);
LG421504065
20. Loosen the rubber hose clamp on the engine side

and unplug the rubber hose;
LG421504066
21. Unscrew the 4 fastening bolts on transmission

bracket (removal socket specification 33mm);
LG421504067
2-32

22. Loosen the hose bolts and take down the hose;
LG421504068
23. Unplug the dipstick on the filler tube;
LG421504069
2-33

24. Hang the engine with 2 steel cables (lifting weight
of the cables must be over 1t);
LG421504070
LG421504071
25. Lift the engine slowly, check whether there are

non-removed harness and pipes around the
engine during the lifting process; if yes, remove
them before lifting, otherwise, components will be
damaged;
LG421504072
2-34

26. Put the engine assembly onto firm ground;
support the front end of engine with bracket; make
sure the engine assembly is placed stably and
then loosen the steel cables;
LG421504073
LG421504074
27. Screw the dipstick onto the filler tube.
LG421504075
Installation of Engine Assembly
Install according to reverse steps of removal.

2-35
CLG4215 Removal and Installation of Engine and Gearbox & Torque Converter Assembly
Removal and Installation of Engine and Gearbox & Torque Converter

Assembly
Removal of Engine and Gearbox & Torque Converter Assembly

1. Remove the hose on the transmission bracket
(open-end wrench specification 55mm).
LG421504076
2. Remove the hose on the left side of transmission

(open-end wrench specification 50mm);
LG421504077
2-36
Removal and Installation of Engine and Gearbox & Torque Converter Assembly CLG4215

3. Unscrew the connector (open-end wrench
LG421504078
4. Unscrew the 4 fastening bolts on transmission

bracket ( removal socket specification 30mm);
LG421504079
2-37

5. Lift the engine assembly, put the transmission
bracket under it;
LG421504080
LG421504081
6. Unscrew 1 bolt on the viewport cover of flywheel

housing left side of the engine, and loosen the
other one (open-end wrench specification 16mm);
LG421504082
2-38

7. Screw bolts or 4 M10 screw with length of 50mm
on the front end flange of engine; One person
rotate the flange clockwise or anticlockwise with
crowbar and the other person observes whether
the screw on the flywheel is rotated into the
viewport;
LG421504083
LG421504084
8. Stop rotation after the screw is in the viewport;

Unscrew the screw with inner hexagon wrench;
Repeat the steps above for 4 times;
LG421504085
2-39

9. Unscrew the 12 bolts connecting the engine and
transmission (removal socket specification
15mm);
LG421504086
10. Separate the engine from the transmission;
LG421504087
11. Remove the connecting flange;
LG421504088
2-40

12. Remove the flange.
LG421504089
Installation of Engine and Gearbox & Torque Converter Assembly

2-41
April 17, 2019 Common Faults and Reasons Analysis of Engine
CLG4215 Common Simple Fault Diagnosis Methods of Engine
Common Faults and Reasons Analysis of Engine
Common Simple Fault Diagnosis Methods of Engine
There are various engine faults, and the reasons are different. The following will introduce common
faults and make a simple analysis of causes for reference of readers. It is suggested to do fault diagnosis
according to the following principles:eradicate faults by the sequence of conducting before thinking, from
simple work to tedious work, from surface to inside. Don't remove and dismantle the machine to a large
extent blindly.
Please contact with the authorized maintenance point if reasons still can not be found out after simple
diagnosis method. Please don't remove blindly!
Idle Running is not Stable and the Engine Warms Up
REASON CORRECT
SUPPLY OIL FROM
TEMPORARY TANK TO
FUEL HAS IMPURITIES START THE ENGINE FOR
VERIFICATION.
OK
DISCHARGE AIR OUT OF
FUEL SYSTEM HAS AIR FUEL SYSTEM AND CHECK IF
SUCTION PIPE LEAKS
OK
FUEL INJECTION CHECK /REPLACE
PIPE LEAKS DAMAGED PIPE.
OK
FUEL RETURN OVERFLOW CHECK /REPLACE OIL
VALVE FAULT RETURN OVERFLOW VALVE.
OK
FUEL DELIVERY CHECK/REPLACE

PUMP FAULT DELIVERY PUMP.
OK
CHECK PUSH ROD
VALVE ADJUSTMENT
SPRING AND
IS INCORRECT ADJUST VALVE.
OK
INJECTOR NOZZLE IS
BLOCKED OR REPLACE INJECTOR
DOES NOT WORK
OK
CHECK AND
FUEL INJECTION PUMP CORRECT
TIMING IS INCORRECT INJECTION
PUMP TIMING.
OK
CONTACT WITH
SERVICE STATION OF
DONGKANG CUMMINS
LG421504092
2-42
Common Faults and Reasons Analysis of Engine April 17, 2019
Common Simple Fault Diagnosis Methods of Engine CLG4215
Engine Flameout
REASON CORRECT
SUPPLY OIL FROM
TEMPORARY TANK TO
FUEL HAS IMPURITIES START THE ENGINE FOR
VERIFICATION.
OK
FUEL SYSTEM HAS AIR FUEL SYSTEM AND CHECK IF
SUCTION PIPE LEAKS
OK
FUEL INJECTION CHECK /REPLACE
PIPE LEAKS DAMAGED PIPE.
OK
FUEL RETURN OVERFLOW CHECK /REPLACE OIL
VALVE FAULT RETURN OVERFLOW VALVE.
OK
FUEL DELIVERY CHECK/REPLACE

PUMP FAULT DELIVERY PUMP.
OK
CHECK PUSH ROD
VALVE ADJUSTMENT
SPRING AND
IS INCORRECT ADJUST VALVE.
OK
INJECTOR NOZZLE IS
BLOCKED OR REPLACE INJECTOR
DOES NOT WORK
OK
CHECK AND
FUEL INJECTION PUMP CORRECT
TIMING IS INCORRECT INJECTION
PUMP TIMING.
OK
CONTACT WITH
SERVICE STATION OF
DONGKANG CUMMINS
LG421504092
2-43
Fuel or Engine Oil Leaks a lot into Exhaust Manifold
REASON CORRECT
AIR INTAKE CHECK/REPLACE

LIMITED FILTER ELEMENT
OK CHECK IF THERE ARE

MUCH IDLE RUNNING
INJECTOR NEEDLE
VALVE IS STUCK LOOK FOR AND REPLACE
AT STARTING FAULTY INJECTOR
POSITION
OK
TURBOCHARGER
OIL RETURN PIPE CHECK/CLEAN OIL
IS BLOCKED RETURN PIPE
OK
TURBOCHARGER CHECK/REPLACE
SEAL LEAKS TURBOCHARGER
OK
CONTACT WITH
SERVICE STATION OF
DONGKANG CUMMINS
LG421504093
2-44
There is Too Much Smoke with Load
REASON CORRECT
ENGINE LOAD SHIFT TO

IS HIGH LOW GEAR
OK
FUEL SYSTEM FUEL SYSTEM AND
HAS AIR CHECK IF SUCTION PIPE
LEAKS
OK
AIR FILTER CHECK IF AIR FILTER IS

IS CLOGGED CLEAN AND REPLACE IT
OK
THERE IS AIR LEAKAGE
BETWEEN TURBOCHARGER AND
CORRECT LEAKAGE
INTAKE MANIFOLD OR EXHAUST
MANIFOLD
OK
CHECK AIR COOLER; IF

AIR FLOW IN AIR
NECESSARY, CLEAN OR
COOLER IS LIMITED
REPLACE IT
OK
INJECTION PUMP CHECK AND ADJUST
TIMING IS INCORRECT INJECTION PUMP TIMING
OK
THERE ARE TWO OR
MORE THAN SEAL REMOVE EXCESSIVE
WASHERS UNDER WASHER
INJECTOR NOZZLE
OK
REMOVE AND TEST
INJECTOR INJECTOR NOZZLE. IF
NOZZLE FAULT NECESSARY, REPLACE
INJECTOR
OK
TURBOCHARGER REPLACE
FALUT TURBOCHARGER
OK
ENGINE RUNNING
TEMPERATURE IS TOO CHECK THERMOSTAT
LOW (BELOW 60 AND COOLING SYSTEM
DEGREE)
OK
CONTACT WITH
SERVICE STATION OF
DONGFENG CUMMINS
LG421504094
2-45
Lubricating Oil Consumption
REASON CORRECT
EXTERNAL CHECK IF THERE IS

LEAKAGE ENGINE OIL LEAKAGE
VISUALLY
OK
ENGINE OIL OF VERIFY DIPSTICK

CRANKCASE IS IS AT RIGHT
EXCESSIVE POSITION.
OK
ENGINE OIL IS
INCORRECT MAKE SURE ENGINE
OIL SPECIFICATION
(SPECIFICATION IS CORRECT.
OR VISCOSITY)
CHECK IF ENGINE
OIL VISCOSITY IS
LOW DUE TO
DILUTED FUEL.
OK
CHECK / SHORTEN
ENGINE OIL
REPLACEMENT
PERIOD.
ENGINE OIL CHECK IF THERE IS

ENGINE OIL IN
COOLER LEAKS COOLANT.
OK
IF IT IS EQUIPPED, CHECK /
AIR COMPRESSOR REPLACE AIR
PUMPS ENGINE OIL. COMPRESSOR.
OK
HIGH BLOW-BY CHECK IF THERE IS ENGINE OIL
FORCED ENGINE OIL CONSUMPTION AROUND BREATHER
OUT OF BREATHER PIPE. MEASURE BLOW-BY AND MAKE
PIPE NECESSARY REPAIR.
OK
ENGINE OIL LEAKS CHECK IF THERE IS
FROM TURBOCHARGER ENGINE OIL LEAKAGE AT
TO INTAKE OR INLET AND OUTLET OF
EXHAUST SYSTEM
TURBOCHARGER.
OK
CONTACT WITH SERVICE

STATION OF DONGFENG
CUMMINS
LG421504095
2-46
Overhigh Coolant Temperature
REASON CORRECT
COOLANT FILL
LEVEL TOO LOW COOLANT
OK
WATER TANK CHECK WATER TANK
COOLING FIN IS
DAMAGED OR RADIATOR — IF
BLOCKED BY NECESSARY, CLEAN OR
IMPURITIES REPAIR IT.
OK
CHECK HOSE — IF
WATER TNAK
NECESSARY, REPLACE
HOSE BROKEN
HOSE.
OK
COOLING FAN CHECK THE COVER,

COVER IS REPAIR, REPLACE
DAMAGED OR LOST OR INSTALL IT.
OK
FAN DRIVE CHECK BELT

BELT LOOSE TENSIONER.
OK
CHECK IF FAN IS
FAN DAMAGED DAMAGED,
OR NOT USED REPLACE IT.
OK
MEASURE
TEMPERATURE TEMPERATURE
GAUGE — IF
GAUGE FALUT NECESSARY, REPAIR
OR REPLACE IT
OK
THE THERMOSTAT CHECK /REPLACE

DOES NOT WORK THERMOSTAT.
OK
VEHICLE LOAD REDUCE LOAD.

IS HEAVY USE LOWER GEAR.
OK
MEASURE CYLINDER
WATER PUMP BLOCK COOLANT
FAULT
PRESSURE.
OK CHECK/REPLACE
WATER PUMP.
CHECK IF THERE IS
COOLING THE LEAKAGE FROM HOSE
SYSTEM HAS AIR CLAMP AT THE SIDE OF
SUCTION PIPE.
CHECK IF THERE IS
OK LEAKAGE FROM
CYLINDER HEAD
GASKET.
WATER TANK, CYLINDER

HEAD, COVER GASKET WASH COOLING
OR CYLINDER BLOCK SYSTEM, AND FILL
COOLANT PIPE ARE NEW COOLANT.
BLOCKED
OK
INJECTION PUMP CHECK

HAS MUCH FUEL CALIBRATION
OK
CONTACT WITH
SERVICE STATION
OF DONGFENG
CUMMINS
LG421504096
2-47
April 17, 2019 Maintenance and Replacement of Engine Quick-wear
Parts
Daily Maintenance and Tips for Maintenance and

Engine Replacement of Engine
Quick-wear Parts
Make routine maintenance and inspection before
fuel engine works; the contents and procedures
of routine maintenance and inspection as Working condition of most construction
follows: machinery is: frequent work, too much work and
rugged environment; this condition makes
Oil level-coolant level-cooling fan-exhaust oil- relevant components easily damaged. Engine
water separator-visual inspection on the system quick-wear parts of CLG4215 grader
respirator tube of crankcase-air filter resistance mainly include: fuel pre-filter, oil-water separator,
indicator. fuel filter, oil filter, air filter, fuel injection pump
and turbocharger, etc. The following introduces
the maintenance and replacement method of
some quick-wear parts.
exhaust water and sediment from the oil-
water separator of engine frequently. Replacement of Fuel Filter
Maintain periodically fuel prefilter element
and replace it. Keep the fuel tank and pipeline
clean. Keep the fuel tank ventilation hole and 1. Clean the nearby area of fuel filter and the
its nearby clean, avoid pollutant, dust and mounting bracket firstly.
water entering the fuel tank. Never use water 2. Remove the filter from the mounting bracket
to clean the engine. with belt wrench.
Remove the filter
LG421504097
2-48
Maintenance and Replacement of Engine Quick-wear Parts April 17, 2019
Replacement of Fuel Prefilter CLG4215
3. Wipe off the filter base with clean cloth, 5. Keep the filter upright, and install it on
especially impurities on mounting surface of threads of the base; when top end surface of
the base. the filter touches mounting surface of the
base and tighten it counter clockwise by 3/4
turn.
Install the filter
Don't fill fuel before installing the fuel filter.
Polluted fuel will accelerate wear of fuel
system components.
Clean the seal surface of mounting bracket
LG421504100
LG421504098 Replacement of Fuel Prefilter

4. Install cleaned water collector onto a new oil- 1. Clean the nearby area of prefilter and the
water separator and then pour fuel into the mounting bracket firstly.
new oil-water separator until it is full. Note:
fuel shall be filled through 8 oil inlet holes on 2. Remove the prefilter from the mounting
oil-water separator, and not be poured bracket and then clean the seal surface of
directly through middle thread hole to avoid mounting bracket with a piece of non-fibre
unfiltered fuel from going into the engine. cloth.
Apply a small amount of engine oil on seal 3. Remove the transparent water cup on the
ring by brush. lower side of fuel prefilter.
Prepare a new filter
4. Clean the cup and then install it onto the new
fuel prefilter element.
5. Fill the fuel prefilter with oil, and coat a layer
of engine oil onto the seal gasket, then install
it onto the mounting bracket.
LG421504099
2-49
Parts
Replacement of Oil Filter
1. Clean the nearby area of oil filter mounting

Before installation, fill the oil filter with clean
bracket .
oil. If an empty oil filter is installed, engine
2. Remove the oil filter with belt wrench. will be damaged for lack of lubricant.
3. Clean the contact surface of seal gasket on 5. Install the oil filter onto the mounting bracket,
the mounting bracket with a piece of non- tighten it to the surface of seal gasket of filter
fibre cloth If the old O-ring is sticked onto the to contact with the mounting bracket; then
mounting bracket, remove it. . use belt wrench to tighten the oil filter to the
Clean the mounting bracket specified requirements.
Excessive mechanical tightening may be

damage the thread or the seal of oil filter
element.
Maintenance of Air Filter
Air filter is located under the fixed hood(as the

arrow indicated area in the figure)..
LG421504101
4. Install the new O-ring; fill the oil filter with

clean oil and coat a layer of clean oil onto the
surface of seal gasket.
Install the oil filter
LG421504103
maintain the air filter if the alarm light goes

on due to blockage of air filter. Engine must
LG421504102
be shut down to avoid being damaged when
maintaining the air filter.
2-50
Maintenance of Air Filter CLG4215
1. Removal for air filter has been described in 4. After cleaning the main filter element, use the
“Removal and installation for intake and electric light to inspect. If small hole or
exhaust system”; refer to “Removal particle is found,or the gasket or seal is
procedures for intake and exhaust system” in damaged, replace with a new main filter
this section to remove main filter element. element.
2. Clean the inner wall of air filter housing
3. Clean main filter element, back purge main
filter element with compressed air (pressure
not greater than 300 kPa)wash the filter
element along diagonal direction from inside
to outside.
To avoid damage to the engine, don’t strike

the filter element when cleaning the filter
element.
LG421504105
5. Install the clean main filter element to the air

filter housing to make sure the element end
seal is contacted evenly.
6. Clean and install the air filter cover to make
sure the seal gasket in the filter inner cover is
contact with the filter housing evenly.
7. After cleaning the main filter element, start
the engine; if the alarm light for blockage of
air filter is still on, or black smoke is emitted,
LG421504104
replace with a new main filter element and
safety filter element.
8. Replace the main filter element after being
cleaned for 6 times; at least replace once per
year. Replace the main filter element and
safety filter element at the same time.
2-51
Parts
Replacement of Air Filter Safety

Filter Element
1. Shut down the engine and open the engine

hood.
2. Open the air filter cover.
3. Remove the main filter element.
4. Remove the safety filter element.
Replace safety filter element with a new one

and don't instead of an old cleaned one.
SAFETY FILTER
ELEMENT
LG421504106
5. Clean the inner wall of air filter.

6. Install a new safety filter element; make the
seal ring on the end face of safety filter
element contact evenly and the seal good.
7. Install the main filter element and air filter
cover.
Replace the main filter element and safety

filter element at the same time.
After cleaning the main filter element, start
the engine; if the alarm light for blockage of
air filter is still on, or black smoke is emitted,
replace with a new element.
2-52
Replacement of Air Filter Safety Filter Element CLG4215
3-1
April 17, 2019 Power Train System
CLG4215
Power Train System

Drive System Parameters ...............................................................................................3-1
Torque Converter and Transmission Assembly ...........................................................3-3
Rear Axle and Tandem....................................................................................................3-3
Working Principle of Rear axle Casing and Tandem .............................................................................3-3
Removal and Installation of Rear Axle and Tandem..............................................................................3-4
Remove the Rear Axle from Rear Frame.........................................................................................3-5
Installation of Rear Axle and Rear Frame ........................................................................................3-9
Remove the Rear Axle from Complete Vehicle..............................................................................3-12
Rear Axle is Re-installed on the Complete Vehicle .......................................................................3-16
Front Axle.......................................................................................................................3-19
Function of Front axle ..........................................................................................................................3-19
Structural Drawing of Front Axle ........................................................................................................3-19
Removal and Installation of Front Axle ................................................................................................3-20
Removal of Front Axle Assembly .................................................................................................3-20
Installation Steps of Front Axle Assembly ......................................................................................3-25
Removal and Installation of of Front Axle Hub.....................................................................................3-26
Removal of Front Axle Hub ............................................................................................................3-26
Installation Steps of Front Axle Hub ...............................................................................................3-33
Adjustment of Front Axle Steering Linkage .........................................................................................3-37
Adjustment of Clearance and Torque after Assembly of Hub .............................................................3-38
Adjustment of Pre-tightening Torque for Hub Inner Bearing ................................................................3-44
Tire ..................................................................................................................................3-45
Function of Tire ....................................................................................................................................3-45
Structure of Tire Assembly and Its Related Parameters ......................................................................3-45
Structure of Tire Rim Assembly .....................................................................................................3-45
Structure of rim assembly ..............................................................................................................3-45
Related technical parameters of tire assembly ..............................................................................3-46
Tire common Fault Mode .....................................................................................................................3-46
Drive Shaft......................................................................................................................3-47
Structure of Pump Drive Shaft ............................................................................................................3-47
Removal and Installation of Pump Drive Shaft.....................................................................................3-48
Removal of Pump Drive Shaft As .................................................................................................3-48
3-2
Power Train System April 17, 2019
CLG4215
Installation Steps of the Pump Drive Shaft As ..............................................................................3-50

Structure of Rear Axle Drive Shaft .......................................................................................................3-51
Removal and Installation of Rear Axle Drive Shaft ..............................................................................3-51
Removal of Rear Axle Drive Shaft ..............................................................................................3-51
Installation Steps of the Rear Drive Shaft As .................................................................................3-51
Worm Box.......................................................................................................................3-52
Function of Worm Box .........................................................................................................................3-52
Structure of Worm Box ........................................................................................................................3-52
Removal of Worm Box .........................................................................................................................3-53
Installation of Worm Box ......................................................................................................................3-60
Adjustment of Worm Box Assembly.....................................................................................................3-73
Test and oil Filling of Worm Box ....................................................................................................3-73
3-1
April 17, 2019 Drive System Parameters
CLG4215
Drive System Parameters
17
45
36
LG421505001
When the front axle turns, the maximum steering angle of the inside corner is 45°, and the maximum
steering angle of the outside corner is 36°; the inside swing angle of the right and left lean-joints is 17°;
3-2
Drive System Parameters April 17, 2019
CLG4215
Maintechnical parameters table roe the power train system
Model ZF 6WG200
Type Single-turbo three elements

Torque converter
Torque ratio 2.15
Cooling mode Air-cooling pressure circulation type
Model ZF 6WG200
Transmission Type Counter shaft power shift
Shift gear 6 gear forward, 3 gear backward
Forward VI gear ≥ 42km/h
Forward V gear ≥ 26.2km/h
Forward IV gear ≥ 21.2km/h
Forward III gear ≥ 12.4km/h

Highest speed at
Forward II gear ≥ 10.7km/h
different gears
Forward I gear ≥ 6.2km/h
Backward I gear ≥ 6.2km/h
Backward II gear ≥ 12.4km/h
Backward III gear ≥ 26.2km/h
Differential and Main transmission mode Bevel gear 1st reduction

final drive Wheel speed reduction mode Super gear and planetary reduction
3-3
April 17, 2019 Torque Converter and Transmission Assembly
CLG4215 Working Principle of Rear axle Casing and Tandem
Torque Converter and Transmission Assembly
Please refer to maintenance manual and guidance for ZF torque converter and transmission.
Rear Axle and Tandem
Working Principle of Rear axle Casing and Tandem
1. Main function: drive axle of grader is a key part of chassis drive system. Its major functions are to
enlarge the torque transmitted from the engine (decrease rotate speed), distribute the torque to the
left and right sprocket and then cause differential speed for wheels on both sides. At the same time,
drive axle still bears various acting forces from the road and frame. Provide service brake function;
left and right tandems can swing up and down by 15°.
2. Working principle: the transmission transfers power through drive shaft, and then transfers to drive
wheels through 7C flange, main reducer (large and small spiral bevels, differential), half shaft gear,
half shaft, wheel-side planetary reducer, double-row sprocket wheel, and chain to achieve
mechanical driving. Rear axle is equipped with service brake, and provides power through hydraulic
brake system. During the course of driving, necessary service brake is executed.
HUB SUPPORT AND BRAKE
TANDEM
MAIN DRIVE AND LIMITED SLIP

7C FLANGE DIFFERENTIAL (OR DIFFERENTIAL LOCK)
PLANETARY
REDUCER TYRE
DRIVE CHAIN
LG421505002
3-4
Rear Axle and Tandem April 17, 2019
Removal and Installation of Rear Axle and Tandem CLG4215
Removal and Installation of Rear Axle and Tandem
1. If only the rear axle tandem needs to be repaired, it is not necessary to remove the rear axle from the
machine.
2. If the middle of the rear axle needs to be repaired, it is necessary to remove the rear axle from the
machine or rear frame. There are two circumstances:
a. If the machine needs to be overhauled, remove according to the removal steps of main
components from front frame and rear frame. After removal, only the rear frame, rear axle and
tires are reserved. The final state is:
LG421505003
Operate according to the steps of "Removal of Rear Axle from Rear Axle Stand";
b. If the machine does not need to be overhauled, only the middle section of the rear axle needs to
be repaired, operate according to the steps of "Removal of Rear Axle from Machine";
3. Repair the components of the rear axle according to the Maintenance Manual of Xuzhou Meritor
Rear Axle;
3-5
April 17, 2019 Rear Axle and Tandem
CLG4215 Removal and Installation of Rear Axle and Tandem
Remove the Rear Axle from Rear Frame

1. Remove the 4 fastening bolts on the 2 bottom
plates of the rear frame, and remove the 2 bottom
plates;
LG421505004
2. Thread the lifting rope through both sides of the

front end and rear end of the rear axle, at 3
positions in total as shown in the figure; lift the
rope slowly till it is stretched tight;
LG421505005
LG421505006
3-6

3. Use an air gun and open-end wrench to screw the
8 fastening bolts and nuts out connected with the
rear axle and rear frame(nut specification: M20,
socket specification: 30mm); suspend the rear
frame slowly;
LG421505007
LG421505008
3-7

4. Use a wire rope to suspend the 2 lifting eyes in the
middle of the rear axle; loosen the top nut of the
tire, but do not screw it out; alternately remove the
other 9 fastening nuts on the tires; remove other
three fastening nuts by the above steps;
LG421505009
LG421505010
3-8

5. Loosen nuts on the top of one tire, and shake it
ffrom inside of the tire to separate one tire from
rear axle; repeat the above procedures to
separate other tires from rear axle; Caution During
detachment, nobody is allowed to stand within
1.5m from the tires; otherwise, the tire may hit
him/her
LG421505011
LG421505012
6. For removed rear axle, see the left -hand figure.
LG421505013
3-9
Installation of Rear Axle and Rear Frame

1. Lift rear axle that has been maintained, and place
it on four equal-height supports; keep the hub
center 700~710mm above the ground (the tire is
30~40mm above the ground); 4 supports are
under tandem that the hub faces to ensure rear
axle does not shake.
2. Lift tire assembly. by lifting equipment and then
put it onto the hub of rear axle; at the same time,
align mounting hole with hub bolt, tighten hub
bolts and then tighten hub nuts diagonally
(specification M22x1.5-10-Zn.D, socket
specification 36mm, tightening torque is
LG421505014 700~800N.m). According to the above
procedures, install other three tires.
LG421505015
3-10

3. Thread the lifting rope through both sides of the
front end and rear end of the rear axle, at 3
positions in total as shown in the figure; lift the
rope slowly till it is stretched tight;
LG421505016
LG421505017
4. Lift rear frame above rear axle, and put it down

slowly; align their bolt holes, and install 8 bolts and
nuts, then tighten them. (Bolt specification M20:
socket specification 30mm: tightening
torque:800±80N.m)
LG421505018
3-11

5. Unlash lifting ropes in the above procedures, lift
the assembly by 2 lifting eyes in the middle of rear
axle, remove four equal-height supports, and
place the assembly onto appropriate position.
Final state is as shown in the left-hand figure.
LG421505003
3-12
Remove the Rear Axle from Complete Vehicle

1. Park the machine in maintenance workshop with
lifting equipment (above 15T), or lift the grader to
a flat ground. Keep the shovel blade touch the
ground and keep it at middle position.
LG421505019
2. After flame out, discharge the pressure from brake

system completely (see 6.5.4.2 Removal and
installation for service brake valve); remove brake
hose on rear axle tandem and shield both ends to
prevent pollution.
3. Remove fastening bolts of rear drive shaft and
transmission, to separate drive shaft and
transmission (see 5.6.4 Removal and installation
for rear axle drive shaft).
LG421505020
4. Open engine hood, and remove bolts and nuts of

rear axle and rear frame (nut specification: M20,
socket specification: 30mm).
LG421505021
3-13

5. Lock hitch limit safety lever to prevent rear frame
from swinging when lifting the complete vehicle.
LG421505022
6. Lifting cable goes through traction pin of rear

counterweight (or rear frame ) and is locked;

LG421505023
LG421505024
3-14

7. Lift the complete vehicle slowly until the lowest
point of rear counterweight (or ripper) is higher
than the tire and keep the machine in static state.
LG421505025
8. Push out rear axle and trye assembly and make

follow-up maintenance and repair at a suitable
place; [for separating tire assembly from rear axle,
see ‚"Remove the rear axle from rear frame”‚
(4)(5)(6)]
LG421505026
LG421505027
3-15

9. With counterweight of the complete vehicle or rear
frame, place equal-height supports, and slow
down the machine to keep the complete vehicle at
the height when rear axle is not removed.
10. Final state of rear axle removed from the
complete vehicle [see ‚"Remove the rear axle from
rear frame”‚ (6)].
LG421505028
LG421505029
3-16
Rear Axle is Re-installed on the Complete Vehicle

1. Install tire assembly onto rear axle that has been
maintained[ see “Assembly of rear axle”(1)(2)].
2. Lift rear axle with tire assembly off the support,
and place it on a flat ground behind the complete
vehicle, align rear axle with the complete vehicle
(pay attention to the direction of flange 7).
LG421505030
3. Lift the complete vehicle slowly until the lowest

point of rear counterweight (or scarifier) is higher
than the tire and keep the complete vehicle in
static state, then remove equal-height supports.
LG421505031
3-17

4. Push rear axle under the complete vehicle until
rear axle is at mounting position; put down the
complete vehicle slowly and align mounting holes
of rear axle and rear frame (install bolt onto rear
frame). If it is impossible to align them, loosen
hitch limit safety lever is loosen, start the machine
and operate hitch to rotate slightly to align them.
5. Install and tighten 8 nuts (nut specification M20:
socket specification 30mm: tightening
torque:800±80N.m).
6. Remove the sling.
LG421505032
LG421505033
LG421505034
3-18

7. Install brake hose to make sure no leakage.
8. Install rear drive shaft(see “Removal and
installation for rear axle drive shaft”).
LG421505035
3-19
April 17, 2019 Front Axle
CLG4215 Function of Front axle
Front Axle
Function of Front axle
The front axle as is installed on the front frame by being connected with the front frame via a pin and it is
used to carry the weight on the complete vehicle; when driving the grader, steer the grader and
guarantee its stable operation under the forces of the steering cylinder and the tilt cylinder.
Structural Drawing of Front Axle
01
02 01 45
03 46
04
06 05 47
22 48
08 07 49
21 50
20
49
23 51
09 04 54
03 53
10
02
11 24
01 1718 25 55 56
16 19
15 57
14 19 58
12 26 59
35 19 19 27 60
13 28 52 49
29 72
47 71
06 01 70
34 46
28 61
45 62
33 32 27 70 69 63
19 26 64
29 68 67
31
01
38 30 66
65
39
36 37 37 29
40
38
41
42 44
43
LG421505036
1. Grease fitting 20.Shaft end baffle 39.Ball joint seat 57.Hub bolt
2. V-ring 21.Washer 40.Ball pivot 58.Front hub
3. Thrust washer 22.Bolt 41.Lock ring 59.Washer
4. Self-lubricating bearing 23.Pin 42.Dust cover 60.Nut
5. Shaft 24.Nut 43.Nut 61.Locking piece
6. Bolt 25.Washer 44.Pin 62.Bolt
7. Front axle 26.V-ring 45.Dust ring 63.Washer
8. Inclination knob 27.Thrust washer 46.COB052 bearing 64.Bolt
9. Left steering knuckle 28.Knuckle bearing 47.V-ring 65.Cover
10.Adjusting shim 29.Grease fitting 48.Adjusting shim 66.Gasket
11.Linkage 30.Lean-joint 49.Thrust washer 67.Bolt
12.Pin shaft 31.Pin shaft 50.Thrust roller needle 68.Cover
13.Ring shim 32.Pin bearing 69.Adjusting shim
14.Pin shaft 33.Cap 51.Steering pin 70.Tapered roller bearing
15.Bolt 34.Linkage 52.Right steering knuckle 71.Oil seal
16.Washer 35.Left ball joint assembly 53.Screw 72. Check ring
17.Washer 36.Pin 54.Nut
18.Disk 37.Clamp ring 55.Shaft bushing
19.Nut 38.Ball seat 56.Screw
3-20
Front Axle April 17, 2019
Removal and Installation of Front Axle CLG4215
Removal and Installation of Front Axle
Removal of Front Axle Assembly

1. Use M12 bolts in the middle of the axle stand and
tilt rod, and screw on the nuts, wherein, the length
of the M12 bolts is more than 95 and the strength
of the M12 bolts is Grade 10.9;
Proceed with the next steps after the axle
stand and the tilt rod are connected via bolts;
otherwise, potential safety hazard may occur
because of tilt tires during removal;
LG421505037
2. Remove the 2 hydraulic hoses of the right steering

cylinder and the 2 hydraulic hoses of the tilt
cylinder;
Because certain pressure exists in the
hydraulic hoses, you can unscrew the hydraulic
hoses only after the pressure is totally released
by unscrewing the hose nuts for one to two
circles and knocking the connectors; otherwise,
hydraulic fluid may spray out;
LG421505038
3. Shield the fillers of the above 4 hoses and insert

the hoses into the front frame holes;
LG421505039
3-21
CLG4215 Removal and Installation of Front Axle

4. Remove the 2 hydraulic hoses of the left steering
cylinder;
×2
LG421505040
5. Shield the fillers of the above 4 hoses and insert

the hoses into the front frame holes;
LG421505041
6. Screw out the 2 bolts on the stop plate (Parts

specification:M16×40-8.8-Zn., wrench or socket
specification:24mm), and remove the stop plate;
LG421505042
3-22

7. Use a wire rope to suspend the front frame till the
tires are lifted off the ground;
LG421505043
8. Use an iron bar to knock the pin shaft that

connects the front axle with the front frame;
LG421505044
9. Suspend the front frame slowly to detach the front

axle from the front frame;
LG421505045
3-23

10. 2 persons respectively push the tires to roll them
forward;
LG421505046
11. Lay down the front frame; use hooks to hook on

the 2 lifting holes in the middle of the front axle
and lift the front frame to a wide field;
LG421505047
12. Loosen the top nut, but do not screw it out;

remove the other 9 fastening nuts on the tires;
remove the fastening nuts on the other side by the
above steps;
LG421505048
3-24

13. Screw out the top nuts to detach the tires from the
front axle;
During detachment, nobody is allowed to
stand within 1.5m from the tires; otherwise, the
tires may hit him/her;
LG421505049
14. Lay the axle carrier on the ground; thread the

lifting rope through the front axle;
LG421505050
15. Lift the axle carrier to overturn the axle carrier;
LG421505051
3-25

16. Lift the axle carrier on the bracket.
LG421505052
Installation Steps of Front Axle Assembly

3-26
Removal and Installation of of Front Axle Hub CLG4215
Removal and Installation of of Front Axle Hub
Removal of Front Axle Hub
Method 1: remove the axle as and put it in place according to the steps of "Removal of Front Axle As".
This method is suitable for overhaul of the front axle, such as overhaul of the connecting pin between the
front axle and the front frame, replacement of the front axle hub as and lean-joint as, etc.
Method 2: If only the front axle hub as and lean-joint as need to be repaired, the steering cylinder and the
tilt cylinder can be replaced directly on the machine; the replacement steps are:

1. Place the machine: place 2 approximately 50mm-
thick wooden strips on the ground to support the
blade, adjust the lift cylinder, descend the blade
body till it contacts the wooden strips, and
suspend the front wheels 10~30mm.
LG421505053
3-27
CLG4215 Removal and Installation of of Front Axle Hub

2. Remove the tires: use a crowbar and a hex socket
to remove the 10 nuts (Parts
specification:M22×1.5-10-Zn.D, removal socket
specification:33mm), and use a lifting tool to drop
down the tires;
LG421505054
LG421505055
Removal of Front Axle Hub Assembly:
3. Remove the cover: use a wrench or open-end

wrench to screw off the bolts (Part specification:
M6×16-8.8-Zn.D,removal wrench specification:
10mm) of the cover on the hub.
LG421505056
3-28

4. Remove the lock plates: use a slotted screwdriver
and a hammer to remove the 3 lock plates.
LG421505057
5. Remove the bolts: Use a wrench or open-end

wrench to remove 6 M12 bolts (parts specification:
M12×45-8.8-Zn.D, removal wrench specification:
18mm).
LG421505058
6. Remove the bolts: use an inner hexagon socket to

remove M20 bolts (parts specification: M20×50-
10.9-Zn.D, removal wrench specification: 30mm).
LG421505059
3-29

7. Use M20 bolts to remove the cap. There are the
adjusting shims on the cap. Avoid losing the
shims.
LG421505060
8. Remove the hub: use a copper bar to knock on

the circumference of the inner side of the hub
uniformly (rotate and knock the hub
simultaneously) till the hub is removed.
LG421505061
3-30

9. Remove the bearing cone: use a puller and
wrench to remove the bearing cone from the axle
by the following steps: Adjust the puller, fix the
screw rod of the puller in the threaded holes of the
M20 bolts (arrange a washer on the threaded end
of the puller to protect the threads from damage),
fix the pulling end of the puller on the snap ring,
and pull out the bearing cone and the snap ring by
rotating the screw rod on the puller with a wrench.
LG421505062
LG421505063
10. Assemble the snap ring: after the bearing cone

and the snap ring are pulled out, detach the
bearing cone from the snap ring and install the
snap ring on the axle immediately.
LG421505064
3-31

11. Clean up the grease: Clean up the grease in the
axle and the hub.
LG421505065
LG421505066
3-32

12. Remove one bearing cup: use a copper bar and a
hammer to remove one bearing cup in the hub by
the following steps: Connect the edge of the
copper bar with the bearing cup, knock the copper
bar (change the position of the copper bar at the
symmetry point of the circumference of the
bearing cup to ensure that the bearing can be
knocked out more easily) with the hammer till the
bearing cup is knocked out, erect the hub and
continue to knock the hub when the end face of
the bearing cup is flush with the end face of the
hub, till the bearing cup is completely detached
from the hub cone.
LG421505067
LG421505068
13. Detach the other bearing cup: turnover the hub,

place it on the ground, and knock out the other
bearing cup by the above steps.
LG421505069
3-33
Installation Steps of Front Axle Hub

1. Inspect the new bearing: Take out the new
bearing, check for impurities, and assemble it if no
abnormality is found. If any abnormality is found,
replace the bearing.
LG421505070
2. Make preparations prior to assembly of the

bearing cup: Apply a little grease in the place
where the bearing cup is to be assembled on the
hub.
LG421505071
3. Assemble the bearing cups: Assemble the bearing

cups on the hub, and use a copper bar to tighten
them gently.
LG421505072
3-34

4. Assemble one bearing cup: Use a tooling and
copper bar to assemble the bearing cup on the
hub (the bearing cup needs being screwed to the
bottom). Assemble the other bearing cup: Turn
over the hub on the ground, and assemble the
other bearing cup by the above steps.
LG421505073
5. Clean the external circle surface of the snap ring,

apply gear oil to the external circle, and sheath the
oil seal on the snap ring then to the steering
knuckle; apply a little grease on the axle.
LG421505074
6. Assemble the bearing cones adjacent to the snap

ring. Pay attention to the direction: The bearing
cones with bigger taper are assembled inwards.
Use a copper bar and tooling to assemble the
bearing cones in place.
LG421505075
3-35

7. The figure shows the state where the bearing
cone adjacent to the snap ring is assembled.
LG421505076
8. Assemble the other bearing cone: Two persons

assemble the hub on which the new bearing cup
is assembled on the axle. Pay attention to the hub
direction: The side of the hub that has bolt threads
faces outwards.
LG421505077
9. Assemble the other bearing cone: One person

fixes the hub, and the other person gently presses
the other bearing cone on the axle.
LG421505078
3-36

10. Assemble the other bearing cone: Gently press
the bearing cone on the axle, and use a tooling
and copper bar to assemble the bearing cone in
place.
LG421505079
11. The figure shows the state where the bearing

cone is assembled.
LG421505080
12. Check the bearing assembly: Use a copper bar to

knock on the circumference of the inner side of
the rub gently for 3 to 4 times (The positions that
are knocked should be distributed on the external
circle of the rub), rotate the rub after knocking, and
check the assembly. If there is no clamping
stagnation and abnormal sound, proceed with the
next step; if any abnormity is found, it is necessary
to remove the rub and the bearing to recheck the
bearing as, and assemble the bearing after no
abnormity is found, till the bearing as passes
examination.
LG421505081
3-37
CLG4215 Adjustment of Front Axle Steering Linkage
Adjustment of Front Axle Steering Linkage
TILT OIL
CYLINDER
STEERING
CYLINDER
6
1
2
3 4 5
LG421505082
1. Linkage 4. Clamp ring

2. Bolt 5. Ball joint seat
3. Nut 6. Cap
1. Firstly, stretch out and draw back the steering cylinder and the tilt cylinder, swing the carrier and
rotate the tires. The axle as is placed horizontally prior to use. Use a tape to measure the distance
between the right steering knuckle and the left steering knuckle and keep a record;
2. The theoretical value of the distance between the right steering knuckle and the left steering knuckle
of the front axle is:1650±10 mm;
3. Judge whether the measured distance between the right steering knuckle and the left steering
knuckle of the front axle is within the range of the design theoretical value. If the measured value
exceeds the design theoretical value, make adjustments;
4. Adjust the steering linkage distance. Unscrew the nuts (3) on the clamping rings (4) at both ends of
the linkage (1), use a handle to seize the nut blocks on the linkage (1), and slowly rotate the linkage
(1) forwards or backwards till the distance between the right steering knuckle and the left steering
knuckle of the front axle is within the range of the design theoretical value; screw the nuts (3) and the
bolts (2) on the clamping rings (4).
5. Open the glands (6) on the ball joint seats (5) at both ends of the linkage, take out the upper ball
seat, fill grease into its chamber and then cover the upper ball seat and glands;
6. Stretch out and draw back the steering cylinder and tilt cylinder and test the rotation flexibility of the
front axle.
3-38
Adjustment of Clearance and Torque after Assembly of Hub CLG4215
Adjustment of Clearance and Torque after Assembly of Hub

1. Re-assemble the glands and shims (Take care not
to miss the shims on the glands);
LG421505083
2. Assemble the glands and shims on the hub;
LG421505084
3. Use a torque wrench to tighten M20 bolts (parts

specification: M20×50-10.9-Zn.D, removal wrench
specification: 30mm) to 480Nm;
LG421505085
3-39
CLG4215 Adjustment of Clearance and Torque after Assembly of Hub

4. Use a copper bar to knock the circumference of
the inner side of the hub for four to 4-6 times (The
positions that are knocked should be distributed
on the external circle of the rub);
LG421505086
5. After knocking, grip the bolt on the hub with the

hands, rotate the hub forcefully, check the number
of turns of the hub, and 3/4-5/4 turns are qualified.
LG421505087
6. If the number of the turns is smaller than 3/4, it is

necessary to remove the M20 bolts, glands and
shims to reduce the thickness of the shims; if the
number of the turns is bigger than 5/4, it is
necessary to increase the thickness of the shims.
After adjustment, reassemble the M24 bolts,
glands and shims. After assembly, recheck the
number of turns and adjust it to 3/4-5/4 by
increasing or reducing the thickness of the shims.
LG421505088
3-40

7. After the number of turns is adjusted to 3/4-5/4,
remove the M20 bolts, apply thread locker to them
along with 6 M12 bolts (parts specification:
M12×45-8.8-Zn.D, wrench specification: 18mm)
all over the circumference;
LG421505089
8. After thread locker is applied, use the torque

wrench to tighten the 7 bolts, and the
requirements for torque are: torque for M12 bolt is
90 Nm, and for M20 bolt is 480 Nm.
LG421505090
9. Assemble the lock plates: place new lock plates

on the tooling.
LG421505091
3-41

10. Use a hammer and tooling to assemble the lock
plates on 2 adjacent bolts. Each hub needs 3 lock
plates to lock 6 M12 bolts.
LG421505092
11. The figure shows the state where the lock plates
are assembled.
LG421505093
3-42

12. Fill the grease: fill the grease until it spills over.
LG421505094
LG421505095
13. Apply a circle of seal along the mounting holes of

the cover; stick the gasket to the cover and apply
seal to the gasket;
LG421505096
3-43

14. Assemble the cover: use a 10 mm wrench to
reassemble the cover on the hub, i.e. tighten the
bolts(Part specification: M6×16-8.8-Zn.D, removal
wrench specification: 9 mm).
LG421505097
15. Assemble the tires: assemble the tires on the

hubs, assemble the bolts, and use the torque
wrench to tighten the bolts to the torque of
600Nm.
LG421505098
3-44
Adjustment of Pre-tightening Torque for Hub Inner Bearing CLG4215
Adjustment of Pre-tightening Torque for Hub Inner Bearing
17 16 15 14 13 12 11 10 9
8
7
6
5
4
3
2
1
1.COVER 7.SPRING WASHER 13.BUSHING

2.COVER 8.GASKET 14.OIL SEAL
3.BOLT 9.SHIM 15.SCREW
4.BOLT 10.TAPERED ROLLER BEARING 16.BACKUP RING
5.LOCK PLATE 11.OIL CUP 17.STEERING KNUCKLE
6.BOLT 12.FRONT WHEEL HUB LG421505099
1. Examine and repair the front axle hub. If the bearing in the hub needs replacement, when replacing
and assembling new tapered roller bearing, shaft bushing(13), tapered roller bearing (10), oil seal
(14), front wheel hub(12), tapered roller bearing(10), shim(9), cover (2), bolts (3), lock plates (5) and
bolts (4) orderly;
2. Before filling lubricant into the shaft in the chamber of the hub, make the pre-tension torque of the 2
tapered roller bearings (10) reach 7.5-9 N.m by increasing and reducing the number of the shims and
the torque of bolts (3) and bolts (4);
3. Assemble backup ring (16), screws (15), gasket (8), cover (1), spring washer (7), bolts (6) and
grease fitting (11); fill lubricant into the chamber of the hub through the grease fitting (11).
3-45
April 17, 2019 Tire
CLG4215 Function of Tire
Tire Structure of rim assembly
Function of Tire
1
The tire as is fixed on the front axle and the rear

2
axle of a grader with the hub bolts. They have
the functions of carrying the load of the grader, 3
drawing the grader to drive, absorbing shock to
keep comfort, etc.
Structure of Tire Assembly and Its

Related Parameters
LG421505101
Structure of Tire Rim Assembly

Structure Details of Rim Assembly
1. Rim base
2. Snap ring
3. Lock ring
1
LG421505100
Structure Details of Tire Rim Assembly
1. tire assembly
2. Rim assembly
3-46
Tire April 17, 2019
Tire common Fault Mode CLG4215
Related technical parameters of tire assembly
Width of
New tire
Model new tire Inflation Maximu
Parts Tire ply Tire inflation
Specific inflation pressure m load Matched rim
name rating tread diamete
ation section (Kpa) (kg)
r (mm)
(mm)
41C0167:
25-14.00/1.5
L-3 bulk 50Km/ 50Km/ 41C0166:
17.5-25- 25-14.00/1.5
Tire (corrugate h:225 h:3650
12/L-3/G- 12 1350 445
assembly d tire, i.e. 10Km/ 10Km/ 41C1389:
12TT
bias tire) h:350 h:6150 25-14.00/1.5
41C1405:
25-14.00/1.5
Tire common Fault Mode 3) Roll off at low pressure.

4. Reasons of tire surface deformation:
1. Causes of sidewall protrusion:
1) The thickness of the glue on the tread base
1) During manufacture, the density of the tire is below the standard;
cords is not uniform, and the connection
among the tire cords is poor; 2) During use, the inflation pressure is over
high or the crown is punctured.
2) During installation, the tire cords at the
bottom of the tire bead are scratched; 5. Reason of flat tire:
3) During use, the tire cords are bruised, 1) There are manufacturing defect (such as
punctured, scratched, etc. delaminating, nonuniform density of cords,
etc.);
2. Abnormal wear
2) The tires are seriously damaged under
1) Wear in the center: The tire pressure is over external force (impact, puncture, etc.);
high, and the pressure at the center of the
tread to the ground is over high; 3) Drive at excessive load or speed (design tire
speed);
2) Wear on both sides: The tire pressure is
over low, and the pressure at the two tire 4) During use, the air pressure is over low or
shoulders to the ground is over high; over high;
3) Concentrated wear: The locking and braking 6. Reasons of tire indentation:
of the brake is not uniform, the rim is 1) It is caused by poor manufacture or
deformed, the assembly parts are abnormal, improper use;
etc.
2) The tread is punctured or the sidewall is
3. Reasons of ply separation: scratched;
1) During molding, the components are not 3) The rim is deformed by impact or the iron
compacted and there is greasy dirt or foreign rim welded joint snaps;
matter on the surfaces of semi-finished
parts; 4) The sealing of the valve cock gasket or
valve core is poor.
2) Drive at excessive load or speed (design tire
speed);
3-47
April 17, 2019 Drive Shaft
CLG4215 Structure of Pump Drive Shaft
Drive Shaft
Structure of Pump Drive Shaft
15
16
18 17
14
13
12
11
10
09
08
01 07
05
06
05
04
02
03
LG421505102
1. Bolt 6. Spacer ring 11.Bolt 16.Bolt

2. Grease fitting 7. Seal ring 12.Washer 17.Bolt
3. Bracket 8. Cover 13.Washer 18.Protective cover
4. Backup ring 9. Bolt 14. Drive shaft
5. Ball brg 10.Flange 15.Washer
3-48
Drive Shaft April 17, 2019
Removal and Installation of Pump Drive Shaft CLG4215
Removal and Installation of Pump Drive Shaft
Removal of Pump Drive Shaft As

1. Screw off the 4 fastening bolts of the hood (Part
specification: M6×16-8.8-Zn.D, socket
specification: 10mm) and remove the hood;
LG421505103
2. Screw off the 4 fastening bolts of flange (Part

specification: M10×35-10.9-Zn.D, socket
specification: 16mm) and remove the hood;
LG421505104
3. Screw off four fastening bolts from the pump

bracket (Part specification: M16×40-8.8-Zn.D,
specification of remover sleeve: 24 mm);
LG421505105
3-49
CLG4215 Removal and Installation of Pump Drive Shaft

4. Screw off the two fastening bolts from the
mounting plate;
LG421505106
5. Tie the lifting rope to the pump assembly;
LG421505107
6. Pull out the pump and lift it;
LG421505108
3-50
Drive Shaft April 17, 2019
Removal and Installation of Pump Drive Shaft CLG4215

7. Lay the pump as on the ground, and shield the
filler of the steel oil filling pipe;
LG421505109
Installation Steps of the Pump Drive Shaft As
The reverse order of the removal steps.

3-51
CLG4215 Structure of Rear Axle Drive Shaft
Structure of Rear Axle Drive Shaft Removal and Installation of Rear

Axle Drive Shaft
Removal of Rear Axle Drive Shaft
2
1
LG421505110
1. Drive shaft LG421505111

2. Bolt
LG421505112
Under the rear frame, screw off the 4 fastening

bolts (Part specification: 1/2-20UNF×55, socket
specification: 16mm) connecting the rear drive
shaft and the gearbox; screw off the 4 fastening
bolts that connect the rear drive shaft with the
rear axle; remove the rear drive shaft.
Installation Steps of the Rear Drive

Shaft As
The reverse order of the removal steps.

3-52
Worm Box April 17, 2019
Function of Worm Box CLG4215
Worm Box
Function of Worm Box
This worm box is used to drive the work implement. It drives the work implement to rotate clockwise or
anticlockwise, so as to meet the work requirements of the work implement. This worm box can bear
large load and impact. It is highly adaptive to all working conditions.
Structure of Worm Box
40
39
38
02 20 24 37
05 25
36
07 21 22
35
01 23
34
03 04
33
06 32
08 19 02
09 18
08 26
31
10
11
17 30
12 16
13 29
14 28
27
15
LG421505113
1. Bolt 11.Adjusting shim 21.Round dipstick 31.Housing cover

2. Washer 12. Tapered roller bearing 22. Plug 32.Bolt
3. Cover 13.Shim 23.O ring 33.Washer
4. Sleeve 14.Oil seal 24.Screw 34.Nut
5. Support 15.Gear shaft 25. Washer 35.Gasket
6. O ring 16.Plug 26.Tapered roller bearing 36. Bolt
7. Shim 17.Washer 27.Worm gear 37.Cover
8. Tapered roller bearing 18. Plug 28.Steel sleeve 38.O ring
9. Worm 19.Washer 29.Adjusting shim 39.Sponge cushion
10.Housing 20.Screw 30.Gasket 40.Cover
3-53
April 17, 2019 Worm Box
CLG4215 Removal of Worm Box
Removal of Worm Box

1. Use a crowbar and a socket to remove the two
bolts in front of the worm box (Part specification:
M24×80-10.9-Zn.D, removal socket specification:
36mm); Use a wrench to seize the 2 bolts at the
back, and use a crowbar and a socket to remove
the 2 locknuts at the back of the worm box
(locknut part specification: M24; bolt part
specification: M24×120-8.8-Zn.D, removal socket
specification: 36mm)
LG421505114
×4
LG421505115
2. Screw in 2 lifting rings (M10 thread). 2 persons

use a crowbar to remove the worm box from the
work implement;
LG421505116
3-54
Removal of Worm Box CLG4215

3. Place a drip pan just below the oil drain hole; use
an inner hexagon spanner to remove the plug at
the oil drain hole (wrench specification: 10mm);
LG421505117
4. Drain the gear oil in the worm box body through

the oil drain hole; screw back the plug;
LG421505118
5. Use an inner hexagon spanner to remove the 2

screws that connect the hydraulic motor with the
worm box, and remove the hydraulic motor (Part
specification: M10×35-10.9-Zn.D2, removal
wrench specification: 16mm);
LG421505119
3-55

6. Use an inner hexagon spanner to remove 8
screws of the cover (Part specification: M8×16-
8.8-Zn.D, removal spanner specification:13mm);
LG421505120
7. Pry off the cover with a hammer and a straight

screwdriver;
LG421505121
8. Use a hammer and screwdriver to flatten the turn-

up of the washer, use a hammer and an iron bar to
chisel and loosen the nuts, and remove the nuts
and the washer;
LG421505122
3-56

9. Use a wrench to remove 12 cover bolts (Part
specification: M10×30-8.8-Zn.D, wrench
specification: 16mm); Screw 2 bolts into 2
fabrication thread holes, eject out the cover and
the bearing out slowly and remove them;
LG421505123
10. Take down the adjusting shim;
LG421505124
11. Turn over the worm box 90° to make the gear
shaft horizontal, put a cardboard under the top
end of the gear shaft, and use a hammer to knock
the gear shaft, loosen it and remove it;
LG421505125
3-57

12. Level the worm box and remove the steel sleeve;
LG421505126
13. Take out the worm box from housing;
LG421505127
14. Use an iron bar and a hammer to knock out the

bearing cup gently at the 2 semi-circles of the
housing;
LG421505128
3-58

15. Remove the adjusting shim from the bearing
cone;
LG421505129
16. Align the screw rod tip of the puller with the center
hole at the top end of the gear shaft, fix the pull
end of the puller on the skeleton oil seal through
the backlash, use the wrench to screw out the
screw rod of the puller, and pull out the bearing
cone and the seal ;
The skeleton oil seal and the bearing cone will
be damaged when they are pulled out, so replace
new skeleton oil seal and the bearing cone during
assembly.
LG421505130
17. Use an inner hexagon spanner to remove 8

screws that connect the support with the housing
(Part specification: M10×70-8.8-Zn.D, wrench
specification: 15mm), screw up two screws (M10,
the length of the front thread is not less than
70mm) into the fabrication thread holes on the
support to eject out the support;
LG421505131
3-59

18. Use an inner hexagon spanner to remove the
middle plug (Part specification: M18×1.5-6g, inner
hexagon spanner specification: 8mm); use a
socket wrench to remove the two right and left
plugs (Part specification: M10, socket
specification: 16mm): Use the wrench and bolts
(M18×1.5-6g, length of thread not less than
40mm) to eject out the worm assembly through
the thread holes and remove the bolts; use the
wrench and bolts (M10, length of thread not less
than 30mm) to eject out the worm bearing cup in
the chamber through the thread holes on both
sides and remove the 2 bolts;
LG421505132
3-60
Installation of Worm Box CLG4215
Installation of Worm Box

1. Use the copper bar and tooling to press in the
bearing cup into the housing hole (Notes: It is not
allowed to press in the bearing cup by knocking
the worm assembly);
LG421505133
2. Put in the worm as that is equipped with the

bearing cone, and the bearing cup orderly;
LG421505134
3. Use the copper bar and tooling to tighten the

bearing cup;
LG421505135
3-61
CLG4215 Installation of Worm Box

4. Insert screws in the two diagonal holes, assemble
the adjusting shim and the O-ring on the support,
and apply thread locker on screws;
LG421505136
5. Lay the worm box housing flat, align the support

with the thread holes and assemble it on the
housing, insert the other 6 screws (pre-apply
thread locker), and use 52±7Nm torque to screw
up the eight screws; rotate the worm, no clamping
stagnation and loosening of the worm allowed;
otherwise increase or reduce the shims;
LG421505137
6. Apply grease on the lip of the oil seal of the

skeleton;
LG421505138
3-62

7. Sheath the oil seal of the skeleton into the gear
shaft, press it to the bottom and take care not to
turn up the lip of the oil seal; the oil seal opening
should face the non-gear end, and it is not allowed
to assemble the oil seal in the reverse direction;
LG421505139
003
140J7
003
90k6
LG421505140
3-63

8. Use a hammer and a tooling to press the bearing
cone into the gear shaft; install the adjusting shim
on the gear shaft;
LG421505141
LG421505142
3-64

9. Turn over the worm box housing, and use a cotton
cloth to clean the assembly part between the
housing and the bearing cup; use a tooling and
hammer to press the bearing cup into the housing
and press it to the bottom and then place the
shims in.
LG421505143
LG421505144
3-65

10. Place the worm gear into the gear box housing; 2
persons lift the worm box housing together, align
the worm gear with the gear shaft spline, drop the
worm gear and take care not to drop out the
washers;
LG421505145
LG421505146
11. Use a copper bar and a tool to knock the turbine

to the bottom;
LG421505147
3-66

12. Sheath the steel sleeve into the gear shaft (take
care to place the side with the bigger size facing
down so that positioning is realized) and lay it flat;
LG421505148
LG421505149
3-67

13. Use a copper bar and a tool to knock the steel
sleeve to the bottom; install the shims on the gear
shaft;
LG421505150
LG421505151
14. Apply a circle of seal on the housing, use the

gasket and then apply another circle of seal;
LG421505152
3-68

15. Install two M10 bolts respectively on two
corresponding fabrication holes; use two bolts to
assemble the cover on the housing;
LG421505153
LG421505154
3-69

16. Use a hammer to knock the housing cover
uniformly to press it entirely into the housing;
screw up each bolt to the torque of 52Nm
according to the order of crossing diagonal lines;
LG421505155
LG421505156
3-70

17. Use a hammer and tooling to knock the bearing to
the bottom; sheath the lock washer into the gear
shaft;
LG421505157
LG421505158
3-71

18. Screw in the nuts, and use a hammer and an iron
bar to knock and tighten the nuts till the gap of the
nuts aligns with the jack catch of the lock washers;
use a screwdriver to pry up the lock washer;
LG421505159
LG421505160
3-72

19. Apply a circle of seal on the housing cover, use
the gasket and then apply another circle of seal;
align with the mounting holes and assemble the
cover, and use an inner hexagon spanner to press
the eight screws and the shims to a torque of
26Nm;
LG421505161
LG421505162
20. Pad up the worm box, enable the gearbox to

rotate, and use a tooling and wrench to test
whether the worm box can rotate freely;
LG421505163
3-73
Adjustment of Worm Box Test and oil Filling of Worm Box

Assembly
After the worm box is assembled and there is no
foreign matter in it, fill in 80W-90 heavy-load
wheel gear oil (GL-5) to carry out no-load
operation test, and the worm speed is 200r/min
at this time; operate the worm box for 10min
respectively clockwise and anti-clockwise; the
operation of the worm box should be stable,
WASHER without impact, abnormal noise or leakage; the
temperature rise of the housing is not more than
40°C. After no-load operation, drain the test oil,
rinse off the worm box and fill in SAE 80W-90/LS
lubricant, wherein, the cleanliness of the
lubricant is 20/17 ISO.4406. Fill about 3L of
lubricant, till the lubricant level exceeds the
symbol.
LG421505164
Before installing the worm gear on the worm,

guarantee an axial play of 0.03~0.10 of the worm
by adjusting the thickness of the washers, and
pre-load a pre-tightening torque of 1.5~2.6Nm to
the bearings at both ends of the worm.
WORM
WORM
GEAR
WASHER
SHIM
LG421505165
Adjust the thickness of the adjusting shim to

make the contact area between the shims and
the worm gear teeth surface locate in the middle
of the teeth; the contact patterns between the
shims and the worm are not less than 45% as
per the teeth height and not less than 40% as per
the teeth length.
3-74
4-1
April 17, 2019 Hydraulic System
CLG4215
Hydraulic System
Main Technical Parameters of Hydraulic System.........................................................4-1
Overview of Hydraulic System .......................................................................................4-2
Hydraulic Oil............................................................................................................................................4-3
Overview of Working Hydraulic System........................................................................4-4

Hydraulic Oil tank ...................................................................................................................................4-6
Mounting location and functional structure of hydraulic oil tank .......................................................4-6
Removal and Installation Steps of Hydraulic Oil Tank From the Machine .......................................4-7
Working Pump .....................................................................................................................................4-12
Mounting position and working principle of working pump .............................................................4-12
Internal Structure and Maintenance Instructions of Working Pump ...............................................4-13
Removal and Installation Steps of Working Pump From the Machine ...........................................4-18
Left Multi-way Valve .............................................................................................................................4-22
Right Multi-way Valve ............................................................................................................................4-24
Mounting Position and Functional Structure of Multi-way Valve on the Right Side........................4-24
Removal and Installation Steps of Multi-Way Valve on the Right Side From the Machine ............4-26
Swing Motor .........................................................................................................................................4-30
Mounting Location and Functional Principle of Swing Motor .........................................................4-30
Internal Structure of Swing Motor...................................................................................................4-32
Removal and Installation Steps of Swing Motor From the Machine...............................................4-33
Swivel Joint ..........................................................................................................................................4-34
Mounting Location and Internal Structure of Swivel Joint ..............................................................4-34
Removal and Installation Steps of Swivel Joint From the Machine................................................4-36
Left Blade Angle Changing Oil Cylinder..............................................................................................4-37
Mounting Position and Internal Structure of Left Blade Angle Changing Oil Cylinder....................4-37
Removal and Installation Steps of Left Blade Angle Changing Oil Cylinder From the Machine...4-38
Right Blade Angle Changing Oil Cylinder ............................................................................................4-39
Mounting Position and Internal Structure of Right Blade Angle Changing Oil Cylinder .................4-39
Removal and Installation Steps of Right Blade Angle Changing Oil Cylinder From the Machine 4-40
Blade Lead-out Cylinder .....................................................................................................................4-41
Left Blade Lift Cylinder .........................................................................................................................4-42
Mounting Position and Internal Structure of Left Blade Lift Cylinder ..............................................4-42
Removal and Installation Steps of Left Blade Lift Cylinder From the Machine ..............................4-43
Left Blade Lift Hydraulic Lock ..............................................................................................................4-47
4-2
Hydraulic System April 17, 2019
CLG4215I
Mounting Position and Internal Structure of Left Blade Lift Hydraulic Lock ...................................4-47
Removal and Installation Steps of Left Blade lift Hydraulic Lock From the Machine .....................4-48
Right Blade Lift Cylinder ......................................................................................................................4-48
Right Blade Lift Hydraulic Lock ............................................................................................................4-48
Circle Sideshift Cylinder .......................................................................................................................4-50
Circle Sideshift Hydraulic Lock.............................................................................................................4-51
Front Wheel Tilt Cylinder .....................................................................................................................4-52
Mounting Position and Internal Structure of Front Wheel Tilt Cylinder ..........................................4-52
Removal and Assembly Steps of Front Wheel Tilt Cylinder From the Machine.............................4-53
Front Wheel Tilt Hydraulic Lock ...........................................................................................................4-55
Mounting Position and Internal Structure of Front Wheel Tilt Hydraulic Lock ................................4-55
Removal and Installation Steps of Front Wheel Tilt Hydraulic Lock From the Machine.................4-56
Hitch Steer Cylinder .............................................................................................................................4-58
Mounting Position and Internal Structure of Hitch Steer Cylinder ..................................................4-58
Removal and Installation Steps of Hitch Steer Cylinder From the Machine...................................4-59
Blade Cylinder.....................................................................................................................................4-61
Mounting Position and Internal Structure of Blade Cylinder...........................................................4-61
Removal and Installation Steps of Blade Cylinder From the Machine ...........................................4-62
Blade Hydraulic Lock ...........................................................................................................................4-63
Mounting Position and Internal Structure of Blade Hydraulic Lock ................................................4-63
Removal and Installation Steps of Blade Hydraulic Lock From the Machine .................................4-64
Ripper Cylinder ....................................................................................................................................4-66
Mounting Position and Internal Structure of Ripper Cylinder .........................................................4-66
Removal and Installation Steps of Ripper Cylinder From the Machine ..........................................4-67
Ripper Hydraulic Lock ..........................................................................................................................4-68
Mounting Location of Ripper Hydraulic Lock..................................................................................4-68
Removal and Installation Steps of Ripper Hydraulic Lock From the Machine ...............................4-68
Description of Functional Principles of Working Hydraulic System......................................................4-70
Circle Drive.....................................................................................................................................4-70
Blade Tilt Angle Changing Driving .................................................................................................4-73
Blade Sideshift Driving ...................................................................................................................4-76
Ripper Driving ................................................................................................................................4-79
Blade (Left) Drive ...........................................................................................................................4-82
Blade (Right) Driving ......................................................................................................................4-85
Blade Drive.....................................................................................................................................4-88
Front Heel Tilt Driving ....................................................................................................................4-91
4-3
April 17, 2019 Hydraulic System
CLG4215
Hitch Steer Drive ............................................................................................................................4-94

Circle Sideshift Drive ......................................................................................................................4-97
Test and Detection of Work Hydraulic System Pressure .............................................................4-100
Introduction of Steering Hydraulic System...............................................................4-103

Introduction of Steering Hydraulic System Principle ..........................................................................4-105
Steering Priority Valve .......................................................................................................................4-107
Mounting Position and Functional Structure of Steering Priority Valve ........................................4-107
Removal and Installation Steps of Steering Priority Valve From the Machine .............................4-108
Brief Introduction of Steering Priority Valve Working Principle ....................................................4-109
Steering Gear.....................................................................................................................................4-110
Mounting Position and Functional Structure of Steering Gear .....................................................4-110
Brief Introduction of Steering Gear Working Principle..................................................................4-111
Steering Cylinder ...............................................................................................................................4-113
Mounting Position and Functional Structure of Steering Cylinder ................................................4-113
Removal and Installation Steps of Steering Cylinder From the Machine .....................................4-114
Introduction of Steering Cylinder Working Principle .....................................................................4-116
Test and Detection of Steering Hydraulic System Pressure ..............................................................4-116
Common Faults and Overhaul Method of Steering Hydraulic System...............................................4-118
Introduction of Brake Hydraulic System ...................................................................4-121

Introduction of Brake Hydraulic System Principle ..............................................................................4-123
Prefill Valve ........................................................................................................................................4-127
Mounting Position and Function of Prefill Valve...........................................................................4-127
Overview of Internal Structure of Prefill Valve..............................................................................4-127
Removal and Installation Steps of Prefill Valve From the Machine..............................................4-128
Introduction of Prefill Valve Working Principle .............................................................................4-129
Accumulator .......................................................................................................................................4-133
Mounting Position and Function of Accumulator ..........................................................................4-133
Removal and Installation Steps of Accumulator From the Machine.............................................4-133
Introduction of Accumulator Working Principle ............................................................................4-136
Service Brake Valve...........................................................................................................................4-137
Mounting Position and Functional Structure of Service Brake Valve ...........................................4-137
Removal and Installation steps of Service Brake Valve From the Machine .................................4-138
Introduction of Service Brake Valve Working Principle ................................................................4-139
Parking Brake Valve ..........................................................................................................................4-143
Mounting Position and Functional Structure of Parking Brake Valve ...........................................4-143
4-4
Hydraulic System April 17, 2019
CLG4215I
Removal and Installation Steps of Parking Brake Valve From the Machine ................................4-144
Introduction of Parking Brake Valve Working Principle ................................................................4-150
Parking Brake System .......................................................................................................................4-151
Introduction of Parking Brake Valve .............................................................................................4-151
Pressure Detection for Parking Brake System.............................................................................4-153
Service Brake System........................................................................................................................4-154
Introduction to Service Brake System ..........................................................................................4-154
Service Brake System Pressure Detection ..................................................................................4-156
Common Faults and Overhaul Method of Brake Hydraulic System...................................................4-158
Introduction of Hydraulic Cooling System................................................................4-159

Introduction of Hydraulic Cooling System Principle ...........................................................................4-161
Cooling Pump ....................................................................................................................................4-163
Mounting Position and Working Principle of Cooling Pump .........................................................4-163
Removal and Installation Steps of Cooling Pump From the Machine ..........................................4-163
Safety Valve Assembly ......................................................................................................................4-164
Mounting Position and Internal Structure of Safety Valve Assembly ...........................................4-164
Removal and Installation Steps of Safety Valve Assembly From the Machine ............................4-166
Introduction of Safety Valve Assembly Working Principle............................................................4-167
Fan Motor...........................................................................................................................................4-168
Mounting Position and Internal Structure of Fan Motor................................................................4-168
Removal and Installation Steps of Fan Motor From the Machine ................................................4-169
Introduction of Working Principle of Fan Motor ............................................................................4-171
Return Oil Filter ..................................................................................................................................4-172
Test and Detection of Hydraulic Cooling System Pressure ...............................................................4-173
4-1
April 17, 2019 Main Technical Parameters of Hydraulic System
CLG4215
Main Technical Parameters of Hydraulic System
Main technical parameters of CLG4215 hydraulic system

Hydraulic oil L 186
Working medium
Cleanliness NAS 1638 ?9 grade
Working pump CC/r 30/30
Multi-way valve L/min 70

Work hydraulic system
Max. flow of system L/min 118L/2200r/min
Maximum working pressure of the system MPa 18
Steering gear CC/r 200

Number of steering cylinder--internal radius X
mm 2- φ 35×275
stroke
Steering hydraulic system
Working pressure of the system Mpa 15-17
45°±1°for both left and
Steering angle °
right sides
Maximum pressure of service brake MPa 10.3±0.35
Opening pressure of prefill valve MPa 12.8±0.35
Shut-off pressure of prefill valve MPa 15.9±0.35
Brake system Low pressure alarm pressure of driving braking MPa 10
Low pressure alarm pressure of parking brake MPa 10
Charge flow L/min 10.2±1.9

4-2
Overview of Hydraulic System April 17, 2019
CLG4215
Overview of Hydraulic System
The hydraulic system, the actuator of grader, consists of the functional modules of work implement
hydraulic system, steering hydraulic system, brake hydraulic system and hydraulic cooling system, and
the system is provided with a typical open constant flow pump hydraulic circuit. Of which the system
gives priority to oil supply to the steering circuit through the priority valve to ensure the steering function;
similarly, the system gives priority to oil supply to the brake circuit through the prefill valve to ensure the
braking function; the work hydraulic system controls the coordinated actions of various cylinders and
motors through the multi-way valve to meet the need of grader for adapting to different operating
conditions; the hydraulic cooling system drives the fan through the motor and takes away heat from the
diffuser to cool the hydraulic oil and ensure oil temperature within the reasonable scope of work. The
following is CLG4215 grader hydraulic system schematic:
The following Fig. is only schematic diagram; for details, please refer to auxiliary drawing No.
LG421506001-“CLG4215 Hydraulic System Principle Diagram” on the last page.
LEFT TRAVELLING MOTOR RIGHT TRAVELLING MOTOR

LEFT
BLADE LIFT CYLINDER SIDE
T2
T3 1147/574cc/r 1147/574cc/r
A R
A1 FRONT WHEEL
TILT CYLINDER 1 1
A6
B1
TWO-WAY HYDRAULIC LOCK B6

R A
TWO-WAY HYDRAULIC LOCK
2 2
A2 HINGE STEERING
RIPPER OIL CYLINDER CYLINDER Y Y
A7 CHECK VALVE 1bar
B2 STEERING
CYLINDER B7
G2
AR
TRAVELLING
AV
SWIVEL JOINT
CONTROL VALVE
BLADE DRAWING-OUT
A3
OIL CYLINDER
BLADE SWING OIL CYLINDER A8
B3
B8 2
DIRECTIONAL
TWO-WAY HYDRAULIC LOCK VALVE VALVE
BLADE SHOVELLING ANGLE
TRANSFORMATION 3 1
A9
a
OIL CYLINDER BLADE OIL CYLINDER

PAR
PAV
G
F
B9
TRAVELLING CONTROL VALVE
F
G
BLADE LIFT a
T1 RIGHT
SIDE FILLING
CONTROL CYLINDER
A5 A10
VALVE
SWIVEL HYDRAULIC PAR
WORKING HYDRAULIC MOTOR B5 B10
SYSTEM G2
TWO-WAY PAV
HYDRAULIC LOCK
AR
CONTROL VALVE
AV
18MPa 18MPa
TRAVELLING PUMP
EF P1
45/45/24cc/r
STEERING CYLINDER
TRAVELLING HYDRAULIC
SYSTEM
STEERING GEAR
ACCUMULATOR 9.2MPa 1L
PARKING BRAKE LOW
PRESSURE SWITCH 10MPa
SERVICE BRAKE LOW
R L PRESSURE ALARM SWITCH 10MPa
SW1 C SW4
PARKING BRAKE
ACCUMULATOR 9.2MPa 2X1.6L
SW2
18MPa 18MPa B
BRAKE SERVICE BRAKE

SYSTEM P5 T8 SW3 BRAKE
P5 HYDRAULIC COOLING SYSTEM
SAFETY VALVE
RELIEF VALVE
STEERING HYDRAULIC
SYSTEM HYDRAULIC OIL BULK
T5
P1 P5 A 18MPa
PRIORITY VALVE 0 T7
LS CF EF FAN MOTOR
T6
FILLING VALVE BRAKE
BRAKE PRESSURE
CHARGE VALVEI VALVE 10.3MPa
SERVICE BRAKE
0.5MPa
COOLING PUMP
LIGHT SWITCH
(15.9MPa/12.8MPaε
T4
17.2MPa
WORKING PUMP
P2 P1
OIL RETURN
FILTER
M
3.4Bar
20MPa
HYDRAULIC OIL TANK
LG421506001
4-3
April 17, 2019 Overview of Hydraulic System
CLG4215 Hydraulic Oil
Hydraulic Oil
Hydraulic oil is the working medium for delivering energy in the hydraulic system, and it also has the
functions of lubrication, sealing, cooling, rust protection, etc. In the CLG4215 grader hydraulic system,
due to variation in pressure, speed and temperature within a wide range, the applied hydraulic oil can
adapt to this variation and maintain stable performance as required in order to guarantee the stability of
operating state but not likely to cause great changes or damages due to changes in external conditions,
we have the following requirements for the technical parameters of hydraulic oil:
Main technical parameters of CLG4215 hydraulic oil

Summer: HM46 anti-wear hydraulic oil
Brand ShellTellus
Winter: HV46 anti-wear hydraulic oil
Hydraulic oil Oil quantity L 186
Cleanliness NAS1638 ≤9
Change interval H 2000
Hydraulic oils of the same brand and different specifications cannot be mixed, and hydraulic oils
of the same specification and different brands cannot be mixed, either. If you must use hydraulic
oil of another brand for some reason, please clean up the system first. For details, please refer to
the Maintenance Instructions.
In addition, whether the hydraulic oil is or not clean directly affects the working performance of the
hydraulic system and the service life of hydraulic elements. According to statistics, at least 75% of faults
of the hydraulic system are due to the cleanliness of hydraulic oil not up to standard. Therefore,
precautions for hydraulic oil pollution is necessary. For grader, we shall firstly prevent pollutants from
entering the hydraulic system from the source: We recommend to filter the oil products with the oil filter
vehicle in the process of refueling or renewing of fuel to ensure that the oil products entering the
hydraulic system can meet the standard required by us: ≤ NAS 1638 Class 9 standard.
Oil filter vehicle
LG421506002
4-4
Overview of Working Hydraulic System April 17, 2019
Hydraulic Oil CLG4215
Overview of Working Hydraulic System
The work implement hydraulic system is used to control the movement of various work implements
(blade, ripper, dozer, etc.) of grader, including blade lifting and lowering to the left/right, blade rotation,
blade sideshift relative to or along with the circle, change of blade cutting angle, circle rotation,
contraction & release of ripper and dozer, etc. The system is a dual-pump and double-circuit hydraulic
system (see work hydraulic system Schematic). It consists of a sealed tank, a tandem hydraulic gear
pump, two sets of five-linked multi-way valve, as well as hydraulic cylinder, motor, hydraulic lock, line,
etc. of each working device. Each circuit has its own hydraulic pump, but hydraulic oil is from the same
tank, hydraulic oil for work is absorbed from the fuel tank by two pumps, pumped oil is supplied to two
circuits, respectively, and the coordinated actions of various cylinders and motors are controlled through
the multi-way valve to meet the operational requirements of grader for adapting to different operating
conditions. CLG4215 grader work hydraulic system schematic and layout drawing are as follows:
The following Fig. Is only schematic digram; for details, please refer to drawing No. LG421506003,
LG4215- auxiliary drawing “ Operating Hydraulic System Principle”. .
Principles for work hydraulic system
BLADE LIFT CYLINDER (LEFT SIDE )

T2
T3
A1 FRONT WHEEL
TILT CYLINDER
B1 A6
TWO-WAY HYDRAULIC LOCK B6

TWO-WAY
HYDRAULIC LOCK
A2 HINGE STEERING
RIPPER OIL CYLINDER CYLINDER A7
B2
B7
SWIVEL JOINT
CENTRAL
JOINT
BLADE DRAWING-OUT
OIL CYLINDER A3
CIRCLE SIDE OIL CYLINDER A8
B3
B8
BLADE SHOVELLING ANGLE
TRANSFORMATION
OIL CYLINDER A4 A9
BLADE OIL CYLINDER
B4 B9
BLADE LIFT CYLINDER (RIGHT SIDE )

WORKING HYDRAULIC SYSTEM
A5’ A5 CONTROL A10
VALVE (LEFT )
SWIVEL HYDRAULIC MOTOR
B5’ B5 B10
CONTROL
VALVE (RIGHT )
X2 X3
18MPa 18MPa
P1 P2
FILLING VALVE
PRIORITY VALVE
CF EF
P1(REAR PUMP) P2(FRONT PUMP )
M OIL RETURN FILTER

FILTER HYDRAULIC OIL TANK
WORKING PUMP
20MPa
PUMP
LG421506003
4-5
April 17, 2019 Overview of Working Hydraulic System
CLG4215 Hydraulic Oil
Work hydraulic system layout drawing
4 3 2
4
3
13
6 12
7
8 9
10
11
LG421506004
1. Hydraulic oil tank 8. Swing motor

2. Working pump 9. Swivel joint
3. Multi-way valve 10.Blade drawing-out cylinder
4. Blade lift cylinder 11.Scraping angle transformation oil cylinder
5. Circle sideshift cylinder 12.Blade lift hydraulic lock
6. Tilt hydraulic lock 13.Hinge steering cylinder
7. Front wheel tilt cylinder
1. When the work system has no action, that is, the multi-way valve is in the neutral position, hydraulic
oil is pumped out from the hydraulic oil tank via the working pump, passing through the priority valve,
filling valve, left and right Multi-way valves and return oil filter, respectively, back to the oil tank,
forming a circulation circuit.
2. When one or two control levers are pulled, hydraulic oil opens the check valve in the multi-way valve
and enters corresponding hydraulic cylinder or hydraulic motor to work. The role of the check valve is
to restrict oil in the working device to flow to the oil tank to ensure normal operation of the hydraulic
system.
3. The bidirectional hydraulic lock installed to the blade tilt circuit and two blade lift circuits can prevent
displacement due to the weight and load of equipment itself, and it ensures driving safety and blade
working precision.
4. Since oil is supplied to the left lift cylinder and lift cylinder-rh by two circuits of the same flow, the
lifting of both lift cylinders is fundamentally synchronized at the same speed, so the working
performance of grader is improved.
5. The safety valve integrated on the left & right Multi-way valves are mainly playing a role in overload
protection of the system.
4-6
Hydraulic Oil tank CLG4215
Hydraulic Oil tank
Mounting location and functional structure of hydraulic oil tank
The hydraulic oil tank, positioned on the front frame in the middle of the machine, at the rear side of the
cab, is mainly used to store hydraulic oil for hydraulic system operating cycle. Oil in the tank can
precipitate pollutants, separate air and cool. Below is the main structure diagram of hydraulic oil tank:
Structure diagram of hydraulic oil tank
10
8
1
11
2 7
3 4 5 6
LG421506005
1. Oil tank housing 7. Oil drain plug

2. Oil return pipe clamp 8. Dipstick
3. Direct oil return port 9. Breather plug
4. Baffle 10.Oil filler cap
5. Oil tank cleaning cover 11.Oil return filte
6. Suction tube
Of which the return oil filter mainly filters the oil returned to the hydraulic oil tank to avoid pollution
caused by dirt intruding the system again via the oil tank; hydraulic oil is filled from the filler cap into the
tank after being filtered through the oil filter vehicle; the breather plug is mainly used to avoid too much
oil flowing out of the tank during removal of oil suction line, before this, the plug must be removed first,
and must be reinstalled prior to machine starting; the dipstick is mainly used for observation of the level
of oil in the tank; the drain plug is mainly used to drain oil in the tank through this position; the suction
tube mainly connects the oil tank with the pump suction to supply oil to the pump; the tank cleaning cover
mainly cleans dirt inside the tank through this position; the baffle plate mainly makes oil form isolated
circulation of cold and hot oil in the tank to prevent a large number of bubbles from being generated due
to too much oil sloshing.
4-7
CLG4215 Hydraulic Oil tank
Removal and Installation Steps of Hydraulic Oil Tank From the Machine
Removal steps of hydraulic oil tank as from the machine:

1. Remove 4 fastening bolts (specification M10×20-
8.8-Zn.D, removal wrench or socket specification
15mm) from the refueling breather assembly on
the hydraulic oil tank and take out the refueling
breather assembly ;
LG421506006
LG421506007
2. One person holds on to the ladder on the right

side of the cab to ensure that the ladder will not
fall in the following process of removal; The other
person screws out 4 fastening bolts (specification
M10×40-8.8-Zn.D, removal wrench or socket
specification 16mm) from the ladder; Move the
ladder away;
LG421506008
4-8

3. One person holds on to the right plate on the right
side of the cab to sure that the right plate will not
person screws out 2 fastening bolts ( specification
M10X30-8.8 -Zn.D,removal wrench or socket 16
mm) on the right side;
LG421506009
4. Screw out 1 fastening bolt (specification M8×16-

8.8-Zn.D, removal wrench or socket specification
13 mm) behind the cab; Remove the right plate;
LG421506010
5. Find the position of prefill valve;
LG421506011
4-9

6. Put a waste oil barrel on the right side of the cab
to contain hydraulic oil; Screw off the hose from
the prefill valve, and lead the hose to the waste oil
barrel to collect oil.
LG421506012
7. After hydraulic oil is drained from the hydraulic oil

tank, lift the filler tube of hydraulic oil tank with a
lifting rope;
LG421506013
8. Screw out 4 fastening bolts (specification

specification 18mm) from the split flange;
LG421506014
4-10

9. Screw out 4 fastening bolts (specification
specification 21mm) from the hydraulic oil tank;
×4
LG421506015
10. Screw out 4 return hoses with an open-end

spanner (specification 36mm);
LG421506016
11. Screw out the tee with the open-end spanner;
LG421506017
4-11

12. Lift up the hydraulic oil tank slowly away from the
original position; note that the lifting process must
be smooth, it is not allowed to damage the cab
glass;
LG421506018
13. Put the tank on the storage rack or keep the

complete tank flat; Shield all ports of the return
tube, and shield the outlet tube port.
LG421506019
Installation of hydraulic oil tank assembly:

4-12
Working Pump CLG4215
Working Pump
Schematic diagram of working pump
Mounting position and working
principle of working pump 6 5
The working pump is a tandem gear pump

located in the middle of the machine, below the
cab, driven by the engine to supply oil to the
hydraulic system, so as to realize various
cylinder actions and supply oil sources to
steering and braking circuits.
Gear Pump Working Principle Schematic
1 3 4
2
LG421506021
3 3’ 4’
1. Working pump
2
4
2’ 2. Oil Inlet P1
5’
I 1 II 3. Oil Inlet P2
5
1’
6’ 4. Pump mounting bracket
10 5. Oil outlet
6 w1 w2
10’
7’ 6. Oil outlet P1
9
7 9’ 8’
8
LG421506020
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.
4-13
CLG4215 Working Pump
Internal Structure and Maintenance Instructions of Working Pump
The following is an exploded view of working pump internal structure:

Structure diagram of working pump
3
17
8 18
16
5 6
2
14 13 4 19
9
15
12
1 11
10 7
LG421506022
1. Front cover 8. Connecting shaft 15.E-check ring

2. Pump body 9. Side plate 16.Stud bolt
3. Intermediate part 10.Oil seal 17.Nut
4. Rear cover 11.Slide bearing 18.Washer
5. Drive gear 12.Cylindrical pin 19.Relief valve
6. Driven gear 13.Square seal
7. Secondary pinion gear 14.E-seal ring
Of which serial number 19 (relief valve) only provides overpressure protection for the rear pump, with
pressure value of 20MPa which has been set at delivery, externally nonadjustable.
The following is a simple instruction for maintenance of the working pump cover oil seal:
Simple Instruction for Maintenance of Cover Oil Seal
1. Preparation before the removal and installation:
1. Check to confirm the portion where oil leaks from the gear pump.
2. Clean up the external surface of the gear pump with oil-base cleaning agent (such as kerosene), and
ensure that impurities will not contaminate the inside of gear pump when the seal is replaced.
4-14
2. Removal steps for front cover:

1. Draw two intersecting marker lines (they will have
guiding function in the process of assembly) from
the rear cover, pump body to cover with a marking
pen.
LG421506023
2. Remove the nuts and gaskets.
LG421506024
3. Slightly remove the front cover with a flat

screwdriver (you can keep down the shaft head).
LG421506025
4-15

4. Fix the front cover to the assembly bench, with the
spigot side up, and take out the circlip for hole with
snap ring pliers.
LG421506026
5. Take out the outboard bearing by hand or tools.
LG421506027
6. Remove the sealing skel with a flat screwdriver.
LG421506028
4-16

7. Polish the front cover oil seal hole with
metallographic abrasive paper, clean up and blow-
dry.
LG421506029
8. Apply Loctite retaining compound 680 evenly to

the excircle of oil seal (if the excircle of oil seal is
rubber, the application step is omitted), and press
the oil seal in with special tools.
LG421506030
9. Install the outboard bearing.
LG421506031
4-17

10. Install the circlip for hole into the check ring
recess.
LG421506032
11. Install into the front cover sub-assembly by the

marker lines.
LG421506033
12. Fasten the nut diagonally, tightening torque

271N.m.
LG421506034
The photos used in the instruction are schematics, they may be inconsistent with the real
objects, only reference for maintenance.
4-18
Removal and Installation Steps of Working Pump From the Machine
Removal steps of working pump from the machine:

1. Remove the hood in the "Removal of Hood" steps;
Complete vehicle state after removal of hood;
LG421506035
2. Remove the hydraulic oil tank in the steps of

"Removal of Hydraulic Tank Assembly"; Machine
state after removal of hydraulic oil tank;
LG421506036
3. Shield the suction tube with a plastic bag, etc. to

prevent foreign materials from entering in the
subsequent process of removal;
LG421506037
4-19

4. Remove the hose at the suction tube;
LG421506038
5. Screw off 4 fastening bolts (removal socket

specification 10mm) from the hood, and remove
the hood;
LG421506039

specification 16mm) at the flange;
LG421506040
4-20

specification 24mm) from the pump bracket;
LG421506041
8. Tie the lifting rope to the pump assembly;
LG421506042
9. First, pull out the pump slowly, and then hoist the
pump slowly;
LG421506043
4-21

10. Put the pump assembly on the ground.
LG421506044
Installation steps of pump drive shaft assembly:

4-22
Left Multi-way Valve CLG4215
Left Multi-way Valve
The control valve on the left side is a five-linked mechanical control valve mainly used to control the oil
transformation and on-off of branch circuits in the work hydraulic system, having features as follows:
The first link circuit controls the left blade lift cylinder action, and the valve plate in this link is next to
return opening T2;
The second link circuit controls the ripper cylinder action, this feature is optional, and its valve plate is
next to the first link valve;
The third link circuit controls the blade lead-out cylinder action, and the valve plate in this link is next to
the second link valve;
The fourth link circuit controls the blade angle transformation cylinder action, and the valve plate in this
link is next to the third link valve;
The fifth link circuit controls the swing motor action, and the valve plate in this link is next to the fourth
link valve and inlet P1.
Of which the safety valve integrated in the multi-way valve is for system overpressure protection, with set
value of 18MPa at delivery, and the check valve is used to prevent oil from flowing backward and avoid
affecting the working pump.
Hydraulic Schematic of Multi-way Valve Hydraulic On the Left Side
B5 A5 B4A4 B3A3 B2 A2 B1 A1
T2
18MPa
CONTROL
VALVE
(LEFT)
P1 CONTROL
VALVE
X2
LG421506045
4-23
CLG4215 Left Multi-way Valve
Schematic Diagram of Multi-way Valve Oil Port On the Left Side
P1 B5
B4
B3
B2
X2 B1
A5
A4 T2
A3
A2
A1
LG421506046
4-24
Right Multi-way Valve CLG4215
Right Multi-way Valve
Mounting Position and Functional Structure of Multi-way Valve on the Right Side
The multi-way valve on the right side is a five-linked mechanical multi-way valve mainly used to control
the oil transformation and on-off of branch circuits in the work hydraulic system, having features as
follows:
The first link circuit controls the front wheel tilt cylinder action, and the valve plate in this link is next to
return opening T3;
The second link circuit controls the hitch steer cylinder action, and its valve plate is next to the first link
valve;
The third link circuit controls the blade swing cylinder action, and the valve plate in this link is next to the
second link valve;
The fourth link circuit controls the blade cylinder action, this feature is optional, and its valve plate is next
to the third link valve;
The fifth link circuit controls the right blade lift cylinder action, and the valve plate in this link is next to the
fourth link valve and inlet P2.
Of which the safety valve integrated in the multi-way valve is for system overpressure protection, with set
value of 18MPa at delivery, and the check valve is used to prevent oil from flowing backward and avoid
affecting the working pump.
Hydraulic Schematic of Multi-way Valve Hydraulic On the Right Side
B10 A10 B9A9 B8A8 B7 A7 B6 A6
T3
18MPa
CONTROL
VALVE
(RIGHT ε
P2
X3
LG421506047
4-25
CLG4215 Right Multi-way Valve
Schematic Diagram of Multi-way Valve Oil Port On the Right Side
T3
B6
R7
B8
B9
B10
X3
A6
A7
A8
A9
A10
P2
LG421506048
4-26
Removal and Installation Steps of Multi-Way Valve on the Right Side From the
Machine
Removal steps of left and right multi-way valves from machine:

Removal of left and right ladders and left and right
plates:
1. One person holds on to the ladder on the right

side of the cab to ensure that the ladder will not
fall in the following process of removal;The other
person screws out 4 fastening bolts (removal
wrench or socket specification 16 mm) from the
ladder; Move the ladder away;
LG421506049
2. One person holds on to the right plate on the right

side of the cab to sure that the right plate will not
person screws out 2 fastening bolts (removal
wrench or socket specification 16 mm) on the right
side;
LG421506050
3. Screw out the 1 fastening bolt (removal wrench or

socket specification 13 mm) on the rear side of
cab; Remove the right plate; Remove the left
ladder and left plate refer to above steps;
LG421506051
4-27

Removal of left multi-way valve:
4. Screw off 5 bolts from the linkage by the13mm

open-end spanner;
LG421506052
5. Screw off 4 fastening screws from the dust cover

by a cross screwdriver;
×4
LG421506053
6. Take out the dust cover;
LG421506054
4-28

7. Identify the outside hose with "outside of left multi-
way valve", and be careful to mark firmly ;
Directly identify with letters if parts are
separately removed or modified.
8. After screwing out the hose by 1-2 circles with the
open-end spanner, knock down the joint position
with the spanner to completely relieve pressure of
hydraulic oil, screw out the hose, and fill the oil
into the waste oil barrel;
SCRAP OIL
BUCKET
LG421506055
9. Identify inside hose with "inside of left multi-way

valve", and be careful to mark firmly ;
10. After screwing out the hose by 1-2 circles with the
LG421506056
11. Identify the hose with "A1", "B1" "A2", "B2"…… in

turn from outside to inside, from bottom to top;
12. Removal of 10 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
INSIDE
OUTSIDE
B5 B4 B3 B2 B1 out the hose, and shield the oil port;
A5 A4 A3 A2 A1
LG421506057
4-29

13. 2 persons are needed to lift the multi-way valve
assembly (weight 17Kg) and hold, then the third
person screws off 4 bolts on the left multi-way
valve with a 16mm open-end spanner and
removes the left multi-way valve;
LG421506058
Installation of left and right multi-way valve:
1. Assemble in the reverse sequence of removal, of which the hose assembly part must be connected
with each connector of the multi-way valve as based on the identification of each hose without error.
2. Installation of left and right ladders and left and right plates:
4-30
Swing Motor CLG4215
Swing Motor
Mounting Location and Functional Principle of Swing Motor
The swing motor is located above the circle of work implement, having the main function of driving the
worm gear case and circle to rotate to adapt to different operating conditions for grader. The swing motor
is a gear-within-gear cycloid motor, usually consisting of a pair of meshed gear pairs, spline shaft, output
shaft and flow distribution shaft. There is one more teeth of stationary stator (external gear) than
cycloidal rotor (internal gear), one end of the spline shaft is connected with the ring gear, the other end is
connected with the output shaft to play the role of transmitting actions of both. On one hand, the cycloidal
rotor revolves on its axis O1 during meshing, and on the other hand, it makes reverse orbit action at high
speed around stator axis O. After orbit action for a circle, the working volume sealed between teeth
completes oil feeding and discharge once, at the same time, the cycloidal rotor revolves on its axis by
one tooth.
A B
G
0
01
F ESSENTRIC DISTANCE
ROTOR
C
D
STATOR
E CONJUGATE CYCLOIDAL PROFILE
LG421506060
4-31
CLG4215 Swing Motor
Swing Motor Working Principle Diagram and Oil Port Diagram
A5’ B5’
T1
T1
B5’ A5’
LG421506061
4-32
Swing Motor CLG4215
Internal Structure of Swing Motor
The following is an exploded view of swing motor internal structure:

Structure Diagram of Swing Motor
5.2 13
4.2 11 12.1
2-Z0 10
8
9
8
2-Z1
3
15 21
20
15
19
16
35 15
34 32
30 31
14 18 36
17
33
27
26 37
24
23 28
22
25
29.1
29.2
29.3
LG421506062
1.Dust ring 12.Linkage shaft 21.Flow distribution linkage shaft 30.Bolt

2.Housing 13.Butterfly ring 22.Thrust plate 31.Sign
3.Shaft seal 14.Connecting plate 23.Flow distribution plate 32.Rivet
4.Output shaft 15.O-ring 24.O-ring 33.Oil filler cap
5.Key 16.Stator 25.O-ring 34.Washer
8.Conical roller bearing 17.Gear pin 26.Dowel pin 35.Screw plug
9.Spacer 18.Rotor 27.Wave spring 36.Washer
10.Stop nut 19.Steel ball 28.Limit post 37.O-ring
11.O-ring 20.Flow distribution plate 29.Rear coverRear cover
4-33
CLG4215 Swing Motor
Removal and Installation Steps of Swing Motor From the Machine
Removal steps of swing motor from the machine:
SCREW
T1
B5’
A5’
LG421506063
1. Identify the connecting hoses for 3 oil ports of swing motor as "A5", "B5", "T1", and note to identify
firmly;
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;
3. Disconnect the 2 screws connecting the hydraulic motor with worm gear case with a 16mm inner
hexagon spanner, and remove the hydraulic motor;
Installation steps of swing motor:
Assemble in the reverse sequence of removal, of which the hose assembly part must be connected with
each joint of the swing motor as based on the identification of each hose without error.
4-34
Swivel Joint CLG4215
Swivel Joint
Mounting Location and Internal Structure of Swivel Joint
The swivel joint is located in the center of the circle of work implement, mainly used to connect the
grader work implement fixed part with the hydraulic system line of the rotating part, making the upper
and lower parts of system line have relative rotational action at 360° without interference.
Hydraulic Schematic and Oil Port Diagram of Swivel Joint
J3 J1
J1
J2 J8 J9
J10
J9 J3
J7 J10
J8 J4
J7 J5 J6
J6 J4
J5 J2
LG421506064
4-35
CLG4215 Swivel Joint
Exploded View of Swivel Joint
07
08 10
09
13
08 09
08 01
09
12
08 08 11
09
10
08
07
06
05 08
09
08
14
14 04
14
03
02
LG421506065
1. Grease cup 8. Check ring

2. Screw 9. O-ring
3. Cover plate 10.O-ring
4. O-ring 11.Battle
5. Rotator 12.Washer
6. Cylinder body 13.Bolt
7. Guiding belt 14.Fitting
4-36
Swivel Joint CLG4215
Removal and Installation Steps of 3. Removal of 10 hoses: After screwing out the
Swivel Joint From the Machine hose by 1-2 circles with the open-end
wrench, knock down the joint position with
Removal steps of swivel joint from the the wrench to completely relieve pressure of
machine: hydraulic oil, screw out the hose, and shield
the oil port;
LG421506066
LG421506068
1. Remove 2 mounting plate fastening bolts
below the swivel joint with a 16mm open-end
spanner; 4. Screw out 3 fastening bolts from the swivel
joint with a 18mm open-end spanner, and
remove the swivel joint;
J1 Installation steps of swivel joint:

J10 Install in the reverse sequence of removal, of
which the hose assembly part must be
connected with each joint of the swivel joint as
based on the identification of each hose without
J2 error.
J9 J7 J4
J8 J3
J6 J5
LG421506067
2. Identify the 10 hoses connecting oil ports on

the swivel joint as "J1", "J2", "J3","J4", "J5",
"J6", "J7", "J8", "J9", "J10", and note to
identify firmly;
4-37
CLG4215 Left Blade Angle Changing Oil Cylinder
Left Blade Angle Changing Oil Cylinder
Mounting Position and Internal Structure of Left Blade Angle Changing Oil Cylinder
The blade angle changing cylinder-lh, located on the left side of the blade support in the middle part of
the machine, is an actuator of the blade tilting device, mainly used to adjust the blade tilt angle to adapt
to the requirements of different operating conditions. This cylinder is a typical double-acting cylinder.
Exploded View of left blade angle changing oil cylinder
01
18
10
17
14
13 16
11 12
08 15
05
06
05
07
01 04
03 09
19
19
02
03
LG421506069
1. Grease cup 11.Support ring

2. Knuckle bearing 12.O-ring
3. Check ring 13.Step seal
4. Nylon locknut 14.Lip type seal
5. Guide ring 15.Cylinder cover
6. Combination seal ring 16.O-ring
7. Piston 17.Dust ring
8. O-ring 18.Shaft bushing
9. Cylinder body 19.Fitting
10.Piston rod
4-38
Left Blade Angle Changing Oil Cylinder CLG4215
Removal and Installation Steps of Left Blade Angle Changing Oil Cylinder From the
Machine
The removal and assembly steps of blade angle changing cylinder-lh from the machine are as
follows:
FRONT END REAR END
THE CAVITY THE CAVITY WITH

WITHOUT PISTON ROD
PISTON ROD
NUT , BOLT
PIN SHAFT
COTTER
PIN NUT
LG421506070
1. Identify the 2 hoses connecting oil ports on the blade angle changing cylinder-lh as "head port" and
"rod port", and note to identify firmly;
3. Knock out the cotter pin at the front end of cylinder, and screw out the nut (open-end spanner
4. Screw out 2 nuts at the rear end of cylinder (open-end spanner specification 16mm), and remove the
bolts; knock out the pin;
5. Remove the cylinder;
6. Steps of assembly of left blade angle changing cylinder:
with two connectors of the left blade angle changing cylinder as based on the identification of each
hose without error.
4-39
CLG4215 Right Blade Angle Changing Oil Cylinder
Right Blade Angle Changing Oil Cylinder
Mounting Position and Internal Structure of Right Blade Angle Changing Oil Cylinder
The blade angle changing cylinder-rh, located on the right side of the blade support in the middle part of
the machine, is an actuator of the blade tilting device, mainly used to adjust the blade tilt angle to adapt
to the requirements of different operating conditions. This cylinder is also a typical double-acting cylinder.
Structure diagram of right blade angle changing cylinder
02
18
09
16
14
13 15
11 12
07 17
05
06
05
08
04
03 10
19
19
01
02 03
LG421506071
1. Knuckle bearing 11.Support ring

2. Grease cup 12.O-ring
4. Nylon locknut 14.Lip type seal
5. Guide ring 15.O-ring
6. Combination seal ring 16.Dust ring
7. O-ring 17.Cylinder cover
8. Piston 18.Shaft bushing
9. Piston rod 19.Fitting
10.Cylinder body
4-40
Right Blade Angle Changing Oil Cylinder CLG4215
Removal and Installation Steps of Right Blade Angle Changing Oil Cylinder From
the Machine
Removal steps of right blade angle changing oil cylinder from the machine:
REAR END FRONT END
THE CAVITY WITH

PISTON ROD THE CAVITY
WITHOUT
PISTON ROD
NUT , BOLT
PIN SHAFT COTTER
PIN NUT
LG421506072
1. Identify the 2 hoses connecting oil ports on the right blade angle changing cylinder assembly "head
port" and "rod port", and note to identify firmly;
3. Knock out the cotter pin at the front end of cylinder, and screw out the nut (open-end spanner
4. Screw out 2 nuts at the rear end of cylinder (open-end spanner specification 16mm), and remove the
bolts; knock out the pin;
5. Remove the cylinder;
6. 2.Steps of assembly of right blade angle changing oil cylinder:
with 2 connectors of the blade angle changing cylinder-rh as based on the identification of each hose
without error.
4-41
CLG4215 Blade Lead-out Cylinder
Blade Lead-out Cylinder
The blade lead-out cylinder, located on the blade support in the middle of the machine, is an actuator of
the blade tilting device, mainly used to drive the blade to make lateral movement relative to the circle
along the blade axis to adapt to the requirements of different operating conditions. This cylinder is also a
typical double-acting cylinder. The following is an exploded view of cylinder internal structure:
Structure Diagram of Blade Lead-out Cylinder
13
13
12
11
16
06 10
14
04 15
04
04
02
01
09
08
07
05
03
LG421506073
1. Piston rod 9. O-ring

2. Dust ring 10.Check ring
3. Seal ring 11.Cylinder body
4. Support ring 12.O-ring
5. D-shape seal ring 13.Support ring
6. Guide sleeve 14.Combination seal ring
7. Bolt 15.Piston
8. Washer 16.Nylon locknut
For the removal and assembly steps of blade lead-out cylinder from the machine, please refer to
"Removal and Assembly Steps of Work Implement".
4-42
Left Blade Lift Cylinder CLG4215
Left Blade Lift Cylinder
Mounting Position and Internal Structure of Left Blade Lift Cylinder
The left blade lift cylinder, located on the left side of the swing bearing in the middle of the machine,
connects the swing bearing and rotating support. As an actuator of the blade lift device, it is mainly used
to drive the blade to be lifted and lowered, and adjust the working depth of blade to adapt to the
requirements of different operating conditions of grader. This cylinder is also a typical double-acting
cylinder. The following is an exploded view of cylinder internal structure:
Structure Diagram of left blade left cylinder
13 14
21
19
22
12 18
11
09
07
02
03 06 16 22
20
05 20 13
13 17
04 12
10
10
08
01 15
LG421506074
1. Flange bracket 12.O-ring

2. Nut 13.Grease cup
3. Washer 14.Fitting
4. Bolt 15.Cylinder cover
5. Shim 16.Cylinder body
6. Piston rod 17.Piston
7. Dust ring 18.O-ring
8. Seal ring 19.Combination seal ring
9. O-ring 20.Support ring
10.Support ring 21.Nylon locknut
11.Step seal 22.Jacket
4-43
CLG4215 Left Blade Lift Cylinder
Removal and Installation Steps of Left Blade Lift Cylinder From the Machine
Removal steps of left blade lift cylinder from the machine:

1. Before removal, put the blade on the ground;
Do not make the work implement rise high into
the air; otherwise, the work implement will
instantly fall in the subsequent process of
cylinder removal, causing safety accidents;
LG421506075
Removal of left lift cylinder:
2. Lift the cylinder with a lifting rope and hold, make

the lifting rope slowly rise until it just tightens the
cylinder;
LG421506076
3. Remove 2 bolts (removal socket, open-end

spanner specification mm) from the bearing cap at
the lower end of cylinder;
LG421506077
4-44

4. Make pairing identifications of "I" and "II"
respectively on the assembly surfaces on the left
and right sides of the fork. For subsequent
recovery, be sure to assemble them in pairs by
identifications;
LG421506078
5. Screw out 4 fastening bolts with blower gun

(specification M16×65-10.9-Zn.D, removal wrench
or socket specification 24mm), and remove the
fork cap ;
LG421506079
6. Knock out the cylinder with a plastic hammer or

wood block;
You cannot knock the cylinder with a hammer,
copper bar and other hard tools; otherwise, it will
cause damage to cylinder;
LG421506080
4-45
CLG4215 Left Blade Lift Cylinder

7. Lift down the cylinder;
LG421506081
8. Reinstall the bearing cap, gasket, bolts and nuts

to the lower end of the cylinder;
LG421506082
9. Remove 2 tubes from the hydraulic lock (open-

end spanner specification 30mm);
LG421506083
4-46

10. Reinstall the fork cap by pairing identifications;
LG421506084
11. Hoist the cylinder onto a wooden pallet, and avoid

knocking against the piston rod in the process of
placement;
LG421506085
12. Shield 2 oil ports;
LG421506086
Installation of blade lift cylinder:

4-47
CLG4215 Left Blade Lift Hydraulic Lock
Left Blade Lift Hydraulic Lock
Mounting Position and Internal Structure of Left Blade Lift Hydraulic Lock
The left blade lift hydraulic lock is installed to the left blade left cylinder, this bidirectional hydraulic lock
has the main function of pressure maintenance by locking the left blade lift cylinder to prevent
displacement due to the weight and load of blade itself, and it ensures driving safety and blade working
precision.
Hydraulic Lock Schematic and Oil Port Diagram
C2 V2
C1 V1
LG421506087
Internal Structure Diagram of Hydraulic Lock
02
08
04
01
06
03
01
05 07
LG421506088
1. Check valve 5. Plug

2. Piston 6. Plug
3. Valve body component 7. O ring
4. Check valve 8. O ring
4-48
Right Blade Lift Cylinder CLG4215
Removal and Installation Steps of Left Right Blade Lift Cylinder

Blade lift Hydraulic Lock From the
Machine The right blade lift cylinder, located on the right
side of the swing bearing in the middle of the
Removal steps of left blade lift hydraulic lock machine, connects the swing bearing and
from the machine: rotating support. As an actuator of the blade lift
device, it is mainly used to drive the blade to be
lifted and lowered, and adjust the working depth
C2
of blade to adapt to the requirements of different
operating conditions of grader. This cylinder is
V2 also a typical double-acting cylinder. For
exploded view, please refer to section “Left Blade
Lift Cylinder “.
V1
For the removal and assembly steps of right
blade lift cylinder, please refer to section 6.3.10.
Right Blade Lift Hydraulic Lock

BOLT
LG421506089 The right blade lift hydraulic lock is installed to
the right blade lift cylinder, this bidirectional
hydraulic lock has the main function of pressure
maintenance by locking the right blade lift
the left blade lift hydraulic lock as "V1", "V2",
cylinder to prevent displacement due to the
"C2", and note to identify firmly;
weight and load of blade itself, and it ensures
2. Removal of 3 hoses: After screwing out the driving safety and blade working precision.
hose by 1-2 circles with the open-end
For the hydraulic principle, oil port diagram and
exploded view of this part, please refer to “Left
the wrench to completely relieve pressure of
Blade Lift Hydraulic Lock “.
hydraulic oil, screw out the hose, and shield
the oil port;
3. Screw out 4 bolts with a 13mm open-end
spanner;
4. Remove the hydraulic lock, and shield the
cylinder mounting port;
Installation steps of left blade lift hydraulic

lock:
Install in the reverse sequence of removal, of

connected with three connectors of the left blade
lift hydraulic lock as based on the identification of
each hose without error.
4-49
CLG4215 Right Blade Lift Hydraulic Lock
The removal and assembly steps of right

blade lift hydraulic lock from the machine are
as follows:
C2
V2
V1
BOLT
LG421506090

the right blade lift hydraulic lock as "V1",
"V2", "C2", and note to identify firmly;
2. Removal of 3 hoses: After screwing out the
the wrench to completely relieve pressure of
the oil port;
spanner;
4. Remove the hydraulic lock, and shield the
cylinder mounting port;
5. Steps of assembly of right blade lift hydraulic
lock:
6. Assemble in the reverse sequence of
removal, of which the hose assembly part
must be connected with three connectors of
the right blade lift hydraulic lock as based on
the identification of each hose without error.
4-50
Circle Sideshift Cylinder CLG4215
Circle Sideshift Cylinder
The circle sideshift cylinder, located in the middle of the machine, connects the swing bearing and
rotating support. As an actuator of the circle sideway device, it is mainly used to drive the circle to make
sideway relative to the longitudinal symmetry plane of grader to adapt to the requirements of different
operating conditions of grader. This cylinder is also a double-acting cylinder. The following is an
exploded view of cylinder internal structure:
Structure Diagram of Circle Sideshift
13 14
21
19
22
12 18
11
09
07
02
03 06 16 22
20
05 20 13
13 17
04 12
10
10
08
01 15
LG421506091
1. Flange bracket 12.O-ring

2. Nut 13.Grease cup
3. Washer 14.Fitting
4. Bolt 15.Cylinder cover
5. Shim 16.Cylinder body
6. Piston rod 17.Piston
7. Dust ring 18.O-ring
8. Seal ring 19.Combination seal ring
10.Support ring 21.Nylon locknut
11.Step seal 22.Jacket
4-51
CLG4215 Circle Sideshift Hydraulic Lock
The removal and assembly steps of circle The removal and assembly steps of circle
sideshift cylinder from the machine are as sideshift hydraulic lock from the machine are
follows: as follows:
For the removal and assembly steps of circle

sideshift cylinder, it is important to note that
during removal and assembly of the cylinder,
please install the lifting rope to the position as
V1
shown in figure:
V2
BOLT
C2
LG421506093

the circle sideshift hydraulic lock as "V1",
"V2", "C2", and note to identify firmly;
2. Removal of 3 hoses: After screwing out the
LG421506092

Other removal steps follow "Removal of left lift wrench, knock down the joint position with
cylinder and Lift Cylinder-rh". the wrench to completely relieve pressure of
Circle Sideshift Hydraulic Lock the oil port;
The circle sideshift hydraulic lock is installed to spanner;
the circle sideshift cylinder, this bidirectional 4. Remove the hydraulic lock, and shield the
hydraulic lock has the main function of pressure cylinder mounting port;
maintenance by locking the circle sideshift
cylinder to prevent displacement due to the 5. Steps of assembly of circle sideshift hydraulic
weight and load of blade itself, and it ensures lock:
driving safety and blade working precision. 6. Assemble in the reverse sequence of
For the hydraulic principle, oil port diagram and removal, of which the hose assembly part
exploded view of the hydraulic lock, please refer must be connected with three connectors of
to”Left Blade Lift Hydraulic Lock”. the circle sideshift hydraulic lock as based on
the identification of each hose without error.
4-52
Front Wheel Tilt Cylinder CLG4215
Front Wheel Tilt Cylinder
Mounting Position and Internal Structure of Front Wheel Tilt Cylinder
The front wheel tilt cylinder, installed to the front axle in the front of the machine, connects the front axle
stand and lean-joint. As an actuator of the front wheel tilt device, it is mainly used to drive two front
wheels of grader to tilt toward one side simultaneously to adapt to the requirements of different operating
conditions of grader. This cylinder is also a double-acting cylinder. The following is an exploded view of
cylinder internal structure:
Structure Diagram of Front Wheel Tilt Cylinder
02
01
09
17
15
13
12
13
16
14
11
07 10
06
04
05
02 04
03
08
01
LG421506094
1. Radial spherical plain bearing 10.O-ring

2. Grease cup 11.Check ring
3. Nylon locknut 12.D-shape seal ring
4. Support ring 13.Support ring
5. Combination seal ring 14.O-ring
6. Piston 15.Seal ring
7. O-ring 16.Cylinder cover
8. Cylinder body 17.Dust ring
9. Piston rod
4-53
CLG4215 Front Wheel Tilt Cylinder
Removal and Assembly Steps of Front Wheel Tilt Cylinder From the Machine
Removal steps of front wheel tilt cylinder from the machine:

1. Use M12 bolts in the middle of the axle stand and
tilt rod, and screw on the nuts, wherein, the length
of the M12 bolts is more than 95 and the strength
of the M12 bolts is Grade 10.9;
Proceed with the next steps after the axle
stand and the tilt rod are connected via bolts;
otherwise, potential safety hazard may occur
because of tilt tyres during removal;
LG421506095
2. Identify the hose outside as "outside of tilt

cylinder", identify the hose inside as "inside of tilt
cylinder", and note to identify firmly; After
screwing out the hose by 1-2 circles with the
INSIDE
OUTSIDE
LG421506096
3. Screw off 2 nuts of the screws at the tilt cylinder

piston rod end with two 16mm open-end
spanners, and knock out the pin;
LG421506097
4-54
Front Wheel Tilt Cylinder CLG4215
4. Screw off 2 nuts of the screws on the other side of

tilt cylinder with two 16 mm open-end spanners,
and knock out the pin; Remove oil cylinder.
LG421506098
Installation of tilt cylinder:
Install in the reverse sequence of removal, of which the hose assembly part must be connected with
each connector of the hydraulic lock as based on the identification of each hose without error.
4-55
CLG4215 Front Wheel Tilt Hydraulic Lock
Front Wheel Tilt Hydraulic Lock
Mounting Position and Internal The exploded view of internal structure is as

Structure of Front Wheel Tilt Hydraulic follows::
Lock
The front wheel tilt hydraulic lock is installed at

the inside of the side right plate in the front of
front frame, this bidirectional hydraulic lock has
the main function of pressure maintenance by 01
locking the front wheel tilt cylinder, allowing
04
positions of two front wheels to be locked when
they tilt toward any side to adapt to requirements 02
of various operating conditions of grader.
The hydraulic principle and oil port diagram of 03
hydraulic lock are as follows: 01
LG421506100
1. Check valve
2. Piston
3. Valve body
M22X1.5 M22X1.5 4. O ring
C1 C2
V1 V2
M22X1.5M22X1.5
LG421506099
4-56
Front Wheel Tilt Hydraulic Lock CLG4215
Removal and Installation Steps of Front Wheel Tilt Hydraulic Lock From the Machine
Removal and installation steps of front wheel tilt hydraulic lock from the machine are as
follows:

1. Screw off 6 bolts from the upper cover of front
frame with a 13mm open-end spanner, and
remove the cover;
LG421506101
2. Find the hydraulic lock installed to the front frame,

leaning against the cylinder side of tilt cylinder;
LG421506102
3. Identify 4 hoses as "tilt V1", "tilt V2", "tilt C1", "tilt

C2" as press the oil port identifications of the
TILT V2 TILT V1 hydraulic lock, and note to identify firmly ；
V2 V1 4. Removal of 4 hoses: After screwing out the hose
C2 C1 by 1-2 circles with the open-end wrench, knock
TILT C2 TILT C1 down the joint position with the wrench to
out the hose, and shield the oil port;
LG421506103
4-57
CLG4215 Front Wheel Tilt Hydraulic Lock
5. Screw off 2 bolts from the hydraulic lock with a

13mm open-end spanner, and remove the
hydraulic lock;
C1 C2
V1 V2
LG421506104
Installation of tilt hydraulic lock
4-58
Hitch Steer Cylinder CLG4215
Hitch Steer Cylinder
Mounting Position and Internal Structure of Hitch Steer Cylinder
The hitch steer cylinder, located below the cab in the middle of the machine, connects the front and rear
frames of grader. This cylinder is mainly used to drive the hitch steering of front and rear frames of
grader to form different intersection angles of the front and rear frames of the machine, reduce the
machine turning radius and improve the machine trafficability to adapt to the requirements of different
operating conditions of grader. This cylinder is also a double-acting cylinder. The exploded view of
cylinder internal structure is as follows:
Structure diagram of hitch steer cylinder
02
01
18
17 03
11 02
19
16
14
12
15
13
02 07
03 08
09 06
05
10 04
01 04
02
LG421506105
1. Grease cup 11.Piston rod

3. Radial spherical plain bearing 13.O-ring
4. Fitting 14.Support ring
5. Nylon locknut 15.Cylinder cover
6. Support ring 16.Seal ring
7. Piston 17.Washer
8. Combination seal ring 18.Bolt
9. O-ring 19.Dust ring
10.Cylinder body
4-59
CLG4215 Hitch Steer Cylinder
Removal and Installation Steps of Hitch Steer Cylinder From the Machine
Since the assembly or removal of hitch steer cylinder to the machine is divided into left and right
directions, the removal and assembly steps of left hitch steering cylinder and right hitch steering cylinder
from the machine are respectively as follows:
Removal and installation of left hitch steering cylinder .

1. Identify the 2 hoses connecting oil ports on the left
THE CAVITY
WITH PISTON ROD
hitch steering cylinder as "head port" and "rod
THE CAVITY
WITHOUT
port", and note to identify firmly;
PISTON ROD

by 1~2 circles with the open-end wrench, knock
LG421506106
3. Remove the fastening screws and nuts from

cylinder;
LG421506107
4. Knock out the pin from below with a long iron bar
and hammer;
LG421506108
4-60
Hitch Steer Cylinder CLG4215
5. Pull down the fastening screw from the hitch

cylinder, knock out the pin, and remove the
cylinder;
LG421506109
Installation steps of hitch steer cylinder-lh:
Install in the reverse sequence of removal steps, of which the hose assembly part must be connected
with 2 joints of hitch steer cylinder-lh according to the identification of each hose without error;
Removal and installation of right hitch steering cylinder

1. Identify the 2 hoses connecting oil ports on the
hitch steer cylinder-lh as "head port" and "rod
port", and note to identify firmly;
THE CAVITY
WITH PISTON ROD
THE CAVITY
WITHOUT
PISTON ROD
3. For removal and assembly steps of cylinder, refer
to "Removal and Assembly of Left Hitch Steer
Cylinder".
LG421506110
4-61
CLG4215 Blade Cylinder
Blade Cylinder
Mounting Position and Internal Structure of Blade Cylinder
The blade cylinder, located in the forefront of the machine, is mainly used to drive the blade in front of the
front axle of grader to be lifted or lowered, make the blade contact with the ground and shovel/push mud
or similar materials forward to adapt to the requirements of different operating conditions of grader. This
cylinder is also a double-acting cylinder. The exploded view of cylinder internal structure is as follows:
Structure Diagram of Blade Cylinder
19
01
04
05
18
01
12
0302
0906
06
20
10
08
07
17
15
20 17
14 13
16
01
11
18
19
01
LG421506111
1. Snap ring 11.Cylinder body

2. Dust ring 12.Piston rod
3. Piston rod seal 13.Piston
4. Bolt 14.O-ring
5. Washer 15.Combination seal ring
6. Support ring 16.Locknut
8. Check ring 18.Radial spherical plain bearing
9. Piston rod seal 19.grease cup
10.Cylinder cover 20.Fitting
4-62
Blade Cylinder CLG4215
Removal and Installation Steps of Blade Cylinder From the Machine
Removal steps of blade cylinder from the machine:

1. ut the blade to the lowest level, and make it
contact with the ground;
LG421506112
2. Identify the 2 hoses connecting oil ports on the

blade cylinder as "head port" and "rod port", and
note to identify firmly;
THE CAVITY
WITH PISTON ROD
THE CAVITY
WITHOUT
PISTON ROD
LG421506113
4. Lift the cylinder and link with a lifting rope and

hold, raise the cylinder slowly until the lifting rope
just contacts with the cylinder;
PIN
SHAFT 5. Knock out the pin between cylinder and link;
6. Put down the cylinder and link, and remove the
lifting rope after confirming that they are placed
smoothly ;
LG421506114
4-63
CLG4215 Blade Hydraulic Lock
7. Bind the cylinder body with a lifting rope;

8. Knock out the pin between cylinder and blade
bracket, and lift out the cylinder.
PIN
SHAFT
LG421506115
Installation steps of blade cylinder:
Install in the reverse sequence of removal, of which the hose assembly part must be connected with 2
joints of the blade cylinder as based on the identification of each hose without error.
Blade Hydraulic Lock
Mounting Position and Internal Structure of Blade Hydraulic Lock
The blade hydraulic lock is installed at the inside of the side plate-lh in the front of front frame, this
bidirectional hydraulic lock has the main function of pressure maintenance by locking the blade cylinder,
making the blade device in a position to adapt to the requirements of different operating conditions of
grader.
The hydraulic principle and oil port diagram of hydraulic lock are as follows:
U2 U1
U1
U2
A1
A2
A2 A1
LG421506116
4-64
Blade Hydraulic Lock CLG4215
Removal and Installation Steps of Blade Hydraulic Lock From the Machine
Removal of blade hydraulic lock:

1. Put the blade to the lowest level, and make it
contact with the ground;
LG421506112
2. Screw off 6 bolts from the upper cover of front

frame with a 13mm open-end spanner, and
remove the cover;
LG421506117
3. Find the hydraulic lock installed on the left side of

front frame;
LG421506118
4-65
CLG4215 Blade Hydraulic Lock
4. Identify 4 hoses as "push A1", "push A2", "push

U1", "push U2" as per the oil port identifications of
the hydraulic lock, and note to identify firmly
(Remark: Directly identify with letters if parts are
A1 U1 separately removed or modified);
A2 A1 U1 U2 by 1~2 circles with the open-end wrench, knock
A2 U2 completely relieve pressure of hydraulic oil, screw
BOLT 6. Screw off 2 bolts from the hydraulic lock with a

LG421506119
13mm open-end spanner, and remove the
hydraulic lock;
Installation of blade hydraulic lock:
4-66
Ripper Cylinder CLG4215
Ripper Cylinder
Mounting Position and Internal Structure of Ripper Cylinder
The ripper cylinder, located at the aftermost of the machine, connects the rear frame of grader and a
ripper. This cylinder is mainly used to drive the lifting and lowering of grader ripper, make the ripper
contact with the ground for rippering operation on hard ground through multiple ripper teeth. This
cylinder is also a double-acting cylinder. The exploded view of cylinder internal structure is as follows:
Structure diagram of ripper cylinder
20
19
19
12
20
17
16
08 14
07 18
15
18
06
05
09 11
10
09
01 04
03
13
19 02
01
LG421506120
1. Check ring 11.Cylinder cover

2. Radial spherical plain bearing 12.Cylinder as
3. Dust ring 13.Piston rod
4. Piston rod seal 14.Piston
5. Check ring 15.Combination seal ring
6. O-ring 16.O-ring
7. Bolt 17.Locknut
8. Washer 18.Support ring
9. Support ring 19.Grease cup
10.Piston rod seal 20.Jacket
4-67
CLG4215 Ripper Cylinder
Removal and Installation Steps of Ripper Cylinder From the Machine
Removal steps of ripper cylinder from the machine:
THE CAVITY ROPE POSITION

WITHOUT
PISTON ROD
BOLT ON COVER
THE CAVITY WITH

PISTON ROD
CONNECT
PIN SHAFT
LG421506121
1. Put the ripper to the lowest level, and make it contact with the ground;
2. Identify the 2 hoses connecting oil ports on the ripper cylinder as "head port" and "rod port", and note
to identify firmly;
3. Removal of 2 hoses: After screwing out the hose by 1~2 circles with the open-end wrench, knock
4. Bind the ripper cylinder with a lifting rope, raise the lifting rope slowly until it just tightens the cylinder;
5. Screw out 4 fastening bolts from 2 covers on the cylinder bracket above;
6. After screwing out the pin bolt below, knock out the pin;
Installation of ripper cylinder:
each joint of the ripper cylinder as based on the identification of each hose without error.
4-68
Ripper Hydraulic Lock CLG4215
Ripper Hydraulic Lock
Mounting Location of Ripper Hydraulic Lock
The ripper hydraulic lock is installed to the bottom plate at the rear of rear frame, this bidirectional
hydraulic lock has the main function of pressure maintenance by locking the ripper cylinder, making the
ripper device locked in a position to adapt to the requirements of different operating conditions of grader.
For the hydraulic principle and oil port diagram of hydraulic lock, please refer to section “Blade Hydraulic
Lock”.
Removal and Installation Steps of Ripper Hydraulic Lock From the Machine
Removal steps of ripper hydraulic lock from the machine:

1. The ripper hydraulic lock is located below the rear
frame;
LG421506122
2. Identify the 2 hoses connecting oil ports at the

lower side of the hydraulic lock as "ripper A2" and
"ripper U2", and note to identify firmly;
4. Screw out 2 mounting bolts of the hydraulic lock;
LOOSEN U2 LOOSEN A2
LG421506123
4-69
CLG4215 Ripper Hydraulic Lock
5. Identify the 2 hoses connecting oil ports at the

upper side of the hydraulic lock as "ripper A1" and
LOOSEN A1
"ripper U1", and note to identify firmly;
LOOSEN U1
7. Remove the hydraulic lock.
LG421506124
Installation of ripper hydraulic lock:
4-70
Description of Functional Principles of Working Hydraulic System CLG4215
Description of Functional Principles of Working Hydraulic System
Circle Drive
1. Circle has no action need
When the control lever of the fifth link valve of the left multi-way valve controlling circle actions is in the
neutral position, the leaf valve is in an oil conducting state in the neutral position, namely that hydraulic
oil output by the pump is directly returned to the oil tank via priority valve EF port, multi-way valve P1
and T2 ports, the fluid does not participate in the work, it realizes low pressure unloading of system flow
with the valve in the neutral position, and at this time, the circle has no action response.
PRIORITY VALVE
T1

B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
CONTROL
VALVE
(LEFT)
P
CF
EF P1
X2
LG421506125
4-71
CLG4215 Description of Functional Principles of Working Hydraulic System
2. Circle rotates clockwise
When the control lever of the fifth link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into A5' port of motor
via priority valve EF port, multi-way valve P1 port, check valve and A5 port, so that the motor drives the
worm gear case which drives the circle to rotate clockwise, the fluid from motor B5' is returned to the
multi-way valve via multi-way valve B5 port, and flows back to the hydraulic oil tank via T2 port, thus the
fluid completes a working circuit. Since the swing motor has volumetric efficiency during operation,
leakage is inevitable, and a small amount of leaking oil flows back to the tank via the housing drainage
port T1 of motor.
PRIORITY VALVE
T1

B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa
T2
CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506126
4-72
3. Circle rotates counterclockwise
When the control lever of the fifth link valve is pulled back, the upper position of the leaf valve is opened
and enters the oil conduction state, the oil output by the pump is supplied into B5' port of motor via
priority valve EF port, multi-way valve P1 port, check valve and B5 port, so that the motor drives the
worm gear case which drives the circle to rotate clockwise, the fluid from motor A5' is returned to the
multi-way valve via multi-way valve A5 port, and flows back to the hydraulic oil tank via T2 port, thus the
fluid completes a working circuit. Similarly, since the swing motor has volumetric efficiency during
operation, leakage is inevitable, and a small amount of leaking oil flows back to the tank via the housing
drainage port T1 of motor.
PRIORITY VALVE
T1

B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa
T2
CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506127
4-73
Blade Tilt Angle Changing Driving
1. No need for blade tilt angle

transformation action
When the control lever of the fourth link valve of the left multi-way valve controlling blade tilt angle
transformation action is in the neutral position, the leaf valve is in an oil conducting state in the neutral
position, namely that hydraulic oil output by the pump is directly returned to the oil tank via priority valve
EF port, multi-way valve P1 and T2 ports, the fluid does not participate in the work, it realizes low
pressure unloading of system flow with the valve in the neutral position, and at this time, the blade tilt
angle transformation has no action response..
SWIVEL JOINT
J7 J10
RIGHT BLADE SHOVELLING ANGLE J6
TRANSFORMATION OIL CYLINDER J2
J4 J5
PRIORITY VALVE
LEFT BLADE SHOVELLING ANGLE

TRANSFORMATION OIL CYLINDER
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506128
4-74
2. Decrease in blade tilt angle
When the control lever of the fourth link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into J10 port of the
swivel joint via priority valve EF port, multi-way valve P1 port, check valve and A4 port, then divided into
two circuits of oil by the swivel joint, supplied into the head ports of blade angle transformation cylinder-
lh and blade angle transformation cylinder-rh via J6 and J7 ports respectively, so that the cylinder piston
rod stretches out and drives the link mechanism to finally complete adjustment of decrease in blade tilt
angle; meanwhile, the fluids in the rod ports of blade angle transformation cylinder-lh and blade angle
transformation cylinder-rh flow together via J5 and J4 of swivel joint to J2 port and back to the multi-way
valve via multi-way valve B4, finally flow back to the hydraulic oil tank via T2 port to complete a working
circuit.
SWIVEL JOINT
J7
J10
J6
RIGHT BLADE SHOVELLING ANGLE
J4
J5 J2
PRIORITY VALVE
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
CONTROL
VALVE
P (LEFT）
CF
EF P1
X2
LG421506129
4-75
3. Increase in blade tilt angle
When the control lever of the fourth link valve is pulled back, the upper position of the leaf valve is
swivel joint via priority valve EF port, multi-way valve P1 port, check valve and B4 port, then divided into
two circuits of oil by the swivel joint, supplied into the rod ports of blade angle transformation cylinder-lh
and blade angle transformation cylinder-rh via J5 and J4 ports respectively, so that the cylinder piston
rod retracts and drives the link mechanism to finally complete adjustment of increase in blade tilt angle;
meanwhile, the fluids in the head ports of blade angle transformation cylinder-lh and blade angle
transformation cylinder-rh flow together via J6 and J7 of swivel joint to J10 port and back to the multi-
way valve via multi-way valve A4, finally flow back to the hydraulic oil tank via T2 port to complete a
working circuit.
SWIVEL JOINT
J7
J10
J6
RIGHT BLADE SHOVELLING ANGLE
J4
J5 J2

PRIORITY VALVE TRANSFORMATION OIL CYLINDER
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa
T2CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506130
4-76
Blade Sideshift Driving
1. No need for blade sideshift action
When the control lever of the third link valve of the left multi-way valve controlling blade sideshift action
is in the neutral position, the leaf valve is in an oil conducting state in the neutral position, namely that
hydraulic oil output by the pump is directly returned to the oil tank via priority valve EF port, multi-way
valve P1 and T2 ports, the fluid does not participate in the work, it realizes low pressure unloading of
system flow with the valve in the neutral position, and at this time, the blade sideshift has no action
response..
SWIVEL JOINT
PRIORITY VALVE
BLADE DRAWING-OUT J3 J1
OIL CYLINDER
J8 J9
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa
T2
CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506131
4-77
2. Blade movement to the left
When the control lever of the third link valve is pushed forward, the lower position of the leaf valve is
swivel joint via priority valve EF port, multi-way valve P1 port, check valve and A4 port, then supplied
into the rod port of blade lead-out cylinder via J3 port, so that the cylinder piston rod retracts and drives
the blade sideshift device to move to the left; meanwhile, the fluid in the head port of blade lead-out
cylinder flows back to the multi-way valve via J8 and J9 ports of swivel joint, B3 port of multi-way valve
respectively, finally flows back to the hydraulic oil tank via T2 port to complete a working circuit.
SWIVEL JOINT
PRIORITY VALVE
BLADE DRAWING-OUT J3 J1
OIL CYLINDER
J8 J9
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
T2
18MPa CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506132
4-78
3. Blade movement to the right
When the control lever of the third link valve is pulled back, the upper position of the leaf valve is opened
and enters the oil conduction state, the oil output by the pump is supplied into J9 port of swivel joint via
priority valve EF port, multi-way valve P1 port, check valve and B3 port, then supplied into the head port
of blade lead-out cylinder via J8 port, so that the cylinder piston rod stretches out and drives the blade
sideshift device to move to the right; meanwhile, the fluid in the rod port of blade lead-out cylinder flows
back to the multi-way valve via J3 and J1 ports of swivel joint, A3 port of multi-way valve respectively,
finally flows back to the hydraulic oil tank via T2 port to complete a working circuit.
SWIVEL JOINT
PRIORITY VALVE
BLADE DRAWING-OUT
J3 J1
OIL CYLINDER
J8 J9
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2CONTROL
VALVE
(LEFT）
P
CF
EF P1
X2
LG421506133
4-79
Ripper Driving
1. Ripper has no action need
When the control lever of the second link valve of the left multi-way valve controlling ripper cylinder
action is in the neutral position, the leaf valve is in an oil conducting state in the neutral position, namely
that hydraulic oil output by the pump is directly returned to the oil tank via priority valve EF port, multi-
way valve P1 and T2 ports, the fluid does not participate in the work, it realizes low pressure unloading of
system flow with the valve in the neutral position, and at this time, the ripper has no action response.
RIPPER HYDRAULIC LOCK
PRIORITY VALVE
RIPPER OIL CYLINDER U2 U1
A2 A1
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
CONTROL
VALVE
(LEFT )
P
CF
EF P1
X2
LG421506134
4-80
2. Ripper lowering action
When the control lever of the second link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into U1 port of the
ripper hydraulic lock via priority valve EF port, multi-way valve P1 port, check valve and A2 port, then
supplied into the head port of ripper cylinder via U2 port, so that the cylinder piston rod stretches out and
drives the ripper device to move down; meanwhile, the fluid in the rod port of ripper cylinder flows back to
the multi-way valve via A2 and A1 ports of ripper hydraulic lock, B2 port of multi-way valve respectively,
finally flows back to the hydraulic oil tank via T2 port to complete a working circuit..
PRIORITY VALVE
A2 A1
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa
T2
CONTROL
VALVE
(LEFT)
P
CF
EF
P1
X2
LG421506135
4-81
3. Ripper lifting action
When the control lever of the second link valve is pulled back, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into A1 port of the
ripper hydraulic lock via priority valve EF port, multi-way valve P1 port, check valve and B2 port, then
supplied into the rod port of ripper cylinder via A2 port, so that the cylinder piston rod retracts and drives
the ripper device to move up; meanwhile, the fluid in the head port of ripper cylinder flows back to the
multi-way valve via U2 and U1 ports of ripper hydraulic lock, A2 port of multi-way valve respectively,
finally flows back to the hydraulic oil tank via T2 port to complete a working circuit..
PRIORITY VALVE
A2 A1
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa
T2
CONTROL
VALVE
P (LEFT)
CF
EF P1
X2
LG421506136
4-82
Blade (Left) Drive
1. Blade has no action need on the left side
When the control lever of the first link valve of the left multi-way valve controlling left blade left cylinder
that hydraulic oil output by the pump is directly returned to the oil tank via priority valve EF port, multi-
way valve P1 and T2 ports, the fluid does not participate in the work, it realizes low pressure unloading of
system flow with the valve in the neutral position, and at this time, the blade (left) has no action
response.
BLADE LIFT CYLINDER (LEFT SIDE)
PRIORITY VALVE C2 V2
C1 V1
HYDRAULIC LOCK
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
P CONTROL
CF VALVE
(LEFT)
EF P1
X2
LG421506137
4-83
2. Blade (left) lowering driving
When the control lever of the first link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into V2 port of the
hydraulic lock via priority valve EF port, multi-way valve P1 port, check valve and A1 port, then supplied
into the head port of left blade left cylinder via C2 port, so that the cylinder piston rod stretches out and
drives the blade (lh) to move down; meanwhile, the fluid in the rod port of left blade left cylinder flows
back to the multi-way valve via C1 and V1 ports of hydraulic lock, B1 port of multi-way valve
BLADE LIFT CYLINDER (LEFT SIDE ε
C2 V2
C1 V1
PRIORITY VALVE
HYDRAULIC LOCK
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
P CONTROL
VALVE
CF (LEFT)
EF P1
X2
LG421506138
4-84
3. Blade (left)rising driving
When the control lever of the first link valve is pulled back, the upper position of the leaf valve is opened
and enters the oil conduction state, the oil output by the pump is supplied into V1 port of the hydraulic
lock via priority valve EF port, multi-way valve P1 port, check valve and B1 port, then supplied into the
rod port of left blade left cylinder via C1 port, so that the cylinder piston rod retracts and drives the blade
(lh) to move up; meanwhile, the fluid in the head port of left blade left cylinder flows back to the multi-
way valve via C2 and V2 ports of hydraulic lock, A1 port of multi-way valve respectively, finally flows
back to the hydraulic oil tank via T2 port to complete a working circuit.
BLADE LIFT CYLINDER (LEFT SIDE ε
C2 V2
C1 V1
PRIORITY VALVE
HYDRAULIC LOCK
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
18MPa T2
P CONTROL
VALVE
CF
(LEFT)
EF P1
X2
LG421506139
4-85
Blade (Right) Driving 1. Blade has no action need on the right side
When the control lever of the fifth link valve of the right multi-way valve controlling right blade lift cylinder
that hydraulic oil output by the pump is directly returned to the oil tank via prefill valve O port, multi-way
system flow with the valve in the neutral position, and at this time, the blade (right) has no action
response.
BLADE LIFT CYLINDER (RIGHT SIDE ε
C2 V2
C1 V1
HYDRAULIC LOCK
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
T3
18MPa
CONTROL
VALVE
(RIGHT)
FILLING 0
VALVE P
P2
X3
LG421506140
4-86
2. Blade (right) lowering drive
When the control lever of the fifth link valve is pushed forward, the lower position of the leaf valve is
hydraulic lock via prefill valveO port, multi-way valve P2 port, check valve and A10 port, then supplied
into the head port of right blade lift cylinder via C2 port, so that the cylinder piston rod stretches out and
drives the blade (right) to move down; meanwhile, the fluid in the rod port of right blade lift cylinder flows
back to the multi-way valve via C1 and V1 ports of hydraulic lock, B10 port of multi-way valve
C2 V2
C1 V1
HYDRAULIC LOCK
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
T3
18MPa
CONTROL
VALVE
(RIGHT
FILLING 0
VALVE P
P2
X3
LG421506141
4-87
3. Blade (right) rising drive
When the control lever of the fifth link valve is pulled back, the upper position of the leaf valve is opened
lock via prefill valveO port, multi-way valve P2 port, check valve and B10 port, then supplied into the rod
port of right blade lift cylinder via C1 port, so that the cylinder piston rod retracts and drives the blade (rh)
to move up; meanwhile, the fluid in the head port of right blade lift cylinder flows back to the multi-way
valve via C2 and V2 ports of hydraulic lock, A10 port of multi-way valve respectively, finally flows back to
the hydraulic oil tank via T3 port to complete a working circuit..
C2 V2
C1 V1
HYDRAULIC LOCK
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
T3
18MPa CONTROL
VALVE
(RIGHT)
O
FILLING
VALVE P
P2
X3
LG421506142
4-88
Blade Drive
1. Blade has no action need
When the control lever of the fourth link valve of the right multi-way valve controlling blade cylinder
system flow with the valve in the neutral position, and at this time, the blade has no action response.
BLADE HYDRAULIC LOCK
BLADE OIL CYLINDER
U2 U1
A2 A1
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
T3
18MPa CONTROL
VALVE
(RIGHT
FILLING 0
VALVE
P
P2
X3
LG421506143
4-89
2. Blade lowering action
When the control lever of the fourth link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into U1 port of the
blade hydraulic lock via prefill valve O port, multi-way valve P2 port, check valve and A9 port, then
supplied into the head port of blade cylinder via U2 port, so that the cylinder piston rod stretches out and
drives the dozer as to move down; meanwhile, the fluid in the rod port of blade cylinder flows back to the
multi-way valve via A2 and A1 ports of blade hydraulic lock, B9 port of multi-way valve respectively,
BLADE OIL CYLINDER
U2 U1
A2 A1
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
T3
18MPa
CONTROL
VALVE
(RIGHT)
FILLING 0
VALVE
P
P2
X3
LG421506144
4-90
3. Blade lifting action
When the control lever of the fourth link valve is pulled back, the upper position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into A1 port of the
blade hydraulic lock via prefill valve O port, multi-way valve P2 port, check valve and B9 port, then
supplied into the rod port of blade cylinder via A2 port, so that the cylinder piston rod retracts and drives
the dozer as to move up; meanwhile, the fluid in the head port of blade cylinder flows back to the multi-
way valve via U2 and U1 ports of blade hydraulic lock, A9 port of multi-way valve respectively, finally
flows back to the hydraulic oil tank via T3 port to complete a working circuit.
BLADE OIL CYLINDER
U2 U1
A2 A1
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa
T3
CONTROL
VALVE
(RIGHT）
FILLING 0
VALVE
P
P2
X3
LG421506145
4-91
Front Heel Tilt Driving
1. Front wheel tilt has no action need
When the control lever of the third link valve of the right multi-way valve controlling front wheel tilt
cylinder action is in the neutral position, the leaf valve is in an oil conducting state in the neutral position,
namely that hydraulic oil output by the pump is directly returned to the oil tank via prefill valve O port,
multi-way valve P2 and T3 ports, the fluid does not participate in the work, it realizes low pressure
unloading of system flow with the valve in the neutral position, and at this time, there is no front wheel tilt
action response..
FRONT WHEEL TILT HYDRAULIC LOCK
FRONT WHEEL TILT CYLINDER V2

C2
C1 V1
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa T3
CONTROL
VALVE
(RIGHT)
FILLING 0
VALVE
P
P2
X3
LG421506146
4-92
2. Front wheel tilts to the right
When the control lever of the third link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is supplied into V2 port of the front
wheel tilt hydraulic lock via prefill valve O port, multi-way valve P2 port, check valve and A8 port, then
supplied into the head port of the front wheel tilt cylinder via C2 port, so that the cylinder piston rod
stretches out and drives the front wheel tilt device, so that the front wheel tilts to the right; meanwhile, the
fluid in the rod port of front wheel tilt cylinder flows back to the multi-way valve via C1 and V1 ports of
front wheel tilt hydraulic lock, B8 port of multi-way valve respectively, finally flows back to the hydraulic
oil tank via T3 port to complete a working circuit.
FRONT WHEEL TILT CYLINDER C2 V2
C1 V1
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa
T3
CONTROL
VALVE
(RIGHT)
0
FILLING
VALVE P
P2
X3
LG421506147
4-93
3. Front wheel tilts to the left
When the control lever of the third link valve is pulled back, the upper position of the leaf valve is opened
and enters the oil conduction state, the oil output by the pump is supplied into V1 port of front wheel tilt
hydraulic lock via prefill valve O port, multi-wayl valve P2 port, check valve and B8 port, then supplied
into the rod port of front wheel tilt cylinder via C1 port, so that the cylinder piston rod retracts and drives
the front wheel tilt device, so that the front wheel tilts to the left; meanwhile, the fluid in the head port of
front wheel tilt cylinder flows back to the multi-way valve via C2 and V2 ports of front wheel tilt hydraulic
lock, A8 port of multi-way valve respectively, finally flows back to the hydraulic oil tank via T3 port to
complete a working circuit.
FRONT WHEEL TILT CYLINDER C2 V2
C1 V1
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa
T3
CONTROL
VALVE
(RIGHT)
FILLING 0
VALVE P
P2
X3
LG421506148
4-94
Hitch Steer Drive
1. No need for hitch steer action
When the control lever of the second link valve of the right multi-way valve controlling hitch steer
cylinders-lh & rh actions is in the neutral position, the leaf valve is in an oil conducting state in the neutral
position, namely that hydraulic oil output by the pump is directly returned to the oil tank via prefill valve O
port, multi-way valve P2 and T3 ports, the fluid does not participate in the work, it realizes low pressure
unloading of system flow with the valve in the neutral position, and at this time, there is no hitch steer
action response..
RIGHT HINGE STEERING CYLINDER
CYLINDER
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa T3
CONTROL
VALVE
(RIGHT
FILLING 0
VALVE
P
P2
X3
LG421506149
4-95
2. Left hitch steer driving
When the control lever of the second link valve is pushed forward, the lower position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is respectively supplied into the
head port of hitch steer-rh cylinder and rod port of hitch steer-lh cylinder via prefill valve O port, multi-
way valve P2 port, check valve and A7 port, so that the hitch steer-rh cylinder piston rod stretches out,
the hitch steer-lh cylinder piston rod retracts and drives the machine toward hitch steer-lh; meanwhile,
the fluid in the rod port of hitch steer-rh cylinder and that in the head port of hitch steer-lh cylinder flow
together, then return to the multi-way valve via multi-way valve B7 port, finally flow back to the hydraulic
FRONT WHEEL TILT CYLINDER
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa
T3
CONTROL
VALVE
(RIGHT)
0
FILLING
VALVE P
P2
X3
LG421506150
4-96
3. Hitch steer-rh driving
When the control lever of the second link valve is pulled back, the upper position of the leaf valve is
opened and enters the oil conduction state, the oil output by the pump is respectively supplied into the
rod port of hitch steer-rh cylinder and head port of hitch steer-lh cylinder via prefill valve O port, multi-
way valve P2 port, check valve and B7 port, so that the hitch steer-rh cylinder piston rod retracts, the
hitch steer-lh cylinder piston rod stretches out and drives the machine toward hitch steer-rh; meanwhile,
the fluid in the head port of hitch steer-rh cylinder and that in the rod port of hitch steer-lh cylinder flow
together, then return to the multi-way valve via multi-way valve A7 port, finally flow back to the hydraulic
FRONT WHEEL TILT CYLINDER
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa T3
CONTROL
VALVE
(RIGHT)
0
FILLING
VALVE P
P2
X3
LG421506151
4-97
Circle Sideshift Drive
1. Circle has no sideshift action need
When the control lever of the first link valve of the right multi-way valve controlling circle sideshift cylinder
system flow with the valve in the neutral position, and at this time, the circle has no sideshift action
response.
CIRCLE SIDESHIFT CYLINDER
C2 V2
C1 V1
HYDRAULIC LOCK
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa
T3
CONTROL
VALVE
(RIGHT)
0
FILLING
VALVE P
P2
X3
LG421506152
4-98
2. Circle movement to the left
When the control lever of the first link valve is pushed forward, the lower position of the leaf valve is
hydraulic lock via prefill valve O port, multi-way valve P2 port, check valve and A6 port, then supplied
into the head port of circle sideshift cylinder via C2 port, so that the cylinder piston rod stretches out and
drives the circle to move to the left; meanwhile, the fluid in the rod port of circle sideshift lift cylinder flows
back to the multi-way valve via C1 and V1 ports of hydraulic lock, B6 port of multi-way valve respectively,
C2 V2
C1 V1
HYDRAULIC LOCK
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
T3
18MPa
CONTROL
VALVE
(RIGHT)
0
FILLING
VALVE P
P2
X3
LG421506153
4-99
3. Circle movement to the right
When the control lever of the first link valve is pulled back, the upper position of the leaf valve is opened
lock via prefill valve O port, multi-way valve P2 port, check valve and B6 port, then supplied into the rod
port of circle sideshift cylinder via C1 port, so that the cylinder piston rod retracts and drives the circle to
move to the right; meanwhile, the fluid in the head port of circle sideshift cylinder flows back to the multi-
way valve via C2 and V2 ports of hydraulic lock, A6 port of multi-way valve respectively, finally flows
back to the hydraulic oil tank via T3 port to complete a working circuit.
C2 V2
C1 V1
HYDRAULIC LOCK
B10 A10 B9 A9 B8 A8 B7 A7 B6 A6
18MPa T3
CONTROL
VALVE
(RIGHT)
0
FILLING
VALVE
P
P2
X3
LG421506154
4-100
Test and Detection of Work Hydraulic 3. Make different actions according to the
System Pressure different operating conditions to read values
in the pressure gauge;
CLG4215 grader work hydraulic system is
provided with quick connection pressure test
interfaces at all critical points in the circuit to
facilitate detection of hydraulic system pressure,
making it easy to understand the performance of
the hydraulic system as well as fault detection
and maintenance. The detailed explanation and
instruction for these pressure test points are as
follows.
1. Left multi-way valve pressure test port X2
LG421506156
4. After completion of measurement, remove

the pressure gauge, and reinstall the
pressure test joint screw cap.
The pressure test point has a pressure value

of about 0MPa in the case that no action is
made, namely that the system fluid does not
LG421506155 apply work but directly unloads the oil return
tank at low pressure to realize green energy
saving; when any action of the system is
The red circle in the figure above is the pressure turned to the limiting position and then
test port of left multi-way valve for detecting maintained, the system pressure reaches the
system pressure, it has the main function of maximum 18MPa, at this time, the system
measuring corresponding operating pressure safety valve is opened, the system pressure
values of circle driving, blade tilt angle is limited within 18MPa to protect hydraulic
transformation driving, blade sideshift driving, elements.
ripper device driving and left blade lift driving
under different operating conditions, the method
is as follows:
1. Unscrew the pressure test joint
counterclockwise, and remove the screw
cap;
2. Connect a pressure gauge with range of
0~40MPa or 0~25MPa into the pressure test
port X2;
4-101
2. Pressure test port X3, RH multi-way valve
In the case that the actions are turned to the

limiting position, i.e. keeping down pressure,
the maximum system pressure value is
inconsistent with the above recommended
value, then you need to make adjustments as
shown below and refer to the multi-way valve
Service Manual: Adjust the pressure set
value of safety valve under the operating
condition of keeping down pressure, the
pressure increases with counterclockwise
action and decreases with clockwise action.
LG421506158
The red circle in the figure above is the pressure

test port of multi-way valve-rh for detecting
system pressure, it has the main function of
measuring corresponding operating pressure
values of front wheel tilt driving, hitch steer
driving, circle sideshift driving, dozer driving and
right blade lift driving under different operating
conditions, the method is as follows:
1. Unscrew the pressure test joint
LG421506157
counterclockwise, and remove the screw
cap;
2. Connect a pressure gauge with range of
0~40MPa or 0~25MPa into the pressure test
port X3;
4-102
3. Make different actions according to the

different operating conditions to read values
in the pressure gauge;
In the case that the actions are turned to the
limiting position, i.e. keeping down pressure,
the maximum system pressure value is
inconsistent with the above recommended
value, then you need to make adjustments as
shown below and refer to the multi-way valve
Service Manual: Adjust the pressure set
value of safety valve under the operating
condition of keeping down pressure, the
pressure increases with counterclockwise
action and decreases with clockwise action.
LG421506159
4. After completion of measurement, remove

the pressure gauge, and reinstall the
pressure test joint screw cap.
The pressure test point has a pressure value

of about 0MPa in the case that no action is
made, namely that the system fluid does not LG421506160
apply work but directly unloads the oil return
tank at low pressure to realize green energy
saving; when any action of the system is
turned to the limiting position and then
maintained (maximum accelerator), the
system pressure reaches the maximum
18MPa, at this time, the system safety valve
is opened, the system pressure is limited
within 18MPa to protect hydraulic elements.
4-103
April 17, 2019 Introduction of Steering Hydraulic System
Introduction of Steering Hydraulic System
The system is a quantitative single pump hydraulic system (see steering hydraulic system schematic). It
consists of a quantitative gear pump, priority valve, steering gear, two steering cylinders, line, etc. The
quantitative gear pump used for the system is shared with the work hydraulic system, and the oil
required by the system is sucked out and conveyed from the hydraulic oil tank by the working pump. The
role of the priority valve is to make the oil pumped out of the working pump give priority to the steering
hydraulic system before excess oil enters the work hydraulic system; the built-in safety valve of priority
valve limits the oil pressure of steering system to 17.2MPa, so as to protect the steering system. The
steering gear used in the system is of a cycloidal rotary valve type load sensitive type, internally installed
with two relief valves and two check valves, and it can protect the steering hydraulic system against
damage by external pressure impact; when the external force makes the steering cylinder generate
pressure impact and the steering system is under overpressure, for example, overpressure due to
bumpy road, the relief valves and check valves are opened so that the oil flows from the high pressure
side of the steering system into the low pressure side, so as to protecting the steering cylinder. The
steering cylinder, a common double-acting single piston rod cylinder, is the final actuator of steering. The
return oil filter filters the oil of steering system, it is internally integrated with a filter and a bypass check
valve. During normal operation, return oil in the system flows back to the hydraulic oil tank via the filter;
when the filter is clogged, the check valve is open, and the oil flows back to the tank via the bypass oil
circuit at the check valve. CLG4215 grader steering hydraulic system schematic and layout drawing are
as follows: :
Steering Hydraulic System Schematic
STEERING CYLINDER
STEERING GEAR
R L
18MPa 18MPa
T5
PRIORITY VALVE
TO WORKING HYDRAULIC SYSTEM
LS CF EF
T4
17.2MPa
P1 P2
WORKING PUMP
M
20MPa
OIL RETURN
FILTER
LG421506161
4-104
Introduction of Steering Hydraulic System April 17, 2019
Steering Hydraulic System Layout Drawing
1
3
LG421506162
1. Hydraulic oil tank

2. Tandem pump
3. Priority valve
4. Steering gear
5. Steering cylinder
4-105
CLG4215 Introduction of Steering Hydraulic System Principle
Introduction of Steering Hydraulic System Principle
1. When there is no steering, there is no signal pressure LS, the pressure differential between both
ends of the priority valve spool is the maximum ?P, the spool moves to the left, so that the opening of
EF duct is enlarged, and the opening to CF duct decreases. When CF duct is completely closed, the
oil in the enclosed cavity returns to the tank through LS port, ?P drops to zero, the spool moves to the
right under the action of spring force, open the duct to CF port a little, repeat the above process, and
the spool makes reciprocating motion to maintain dynamic balance. So almost all the fluids are
supplied into EF duct, but there is always only a small amount of oil passing through CF duct.
Flow Direction of System Fluids Without Steering
STEERING CYLINDER
STEERING GEAR
R L
18MPa 18MPa
T5
PRIORITY VALVE
LS CF EF
T4
P
17.2MPa
P1 P2
WORKING PUMP
M
21MPa
OIL RETURN
FILTER
LG421506163
4-106
Introduction of Steering Hydraulic System Principle CLG4215
2. During steering, P1 port is connected with L (or R) port, the ducts of LS and tank are closed, and the
duct to L (or R) is opened. LS oil pressure acts on the left side of spool, ?P decreases instantly, the
spool moves to the right, so that the opening of CF duct is enlarged, the opening of EF duct
decreases until closed.
Flow Direction of System Fluids During Steering (Steering To the Left)
STEERING CYLINDER
STEERING GEAR
R L
18MPa 18MPa
T5
PRIORITY VALVE
LS CF EF
T4
P
17.2MPa
P1 P2
WORKING PUMP
M
21MPa
OIL RETURN
FILTER
LG421506164
3. The case when steering is stopped is the same as that when the steering wheel does not rotate, see
(1).
4. When the steering system pressure exceeds the steering safety valve (i.e. built-in relief valve of
priority valve) set pressure 17.2Mpa, the steering system opens the overflow of steering safety valve.
5. When the pressure at EF port reaches the main safety valve (i.e. built-in relief valve of working
pump) set value 21MPa, the whole hydraulic system overflows.
4-107
CLG4215 Steering Priority Valve
Steering Priority Valve
Mounting Position and Functional Structure of Steering Priority Valve
The steering priority valve, installed to the front frame under the cab in the middle of the machine, has
the main function of giving priority to distribution of fluid pumped out by the working pump to the steering
system to guarantee that the steering system has stable responses under various conditions. Its three-
dimensional exploded view is as follows:
Exploded view of Steering Priority Valve
1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18 19 20
LG421506165
1. Screw plug 11.O ring

2. O ring 12.Valve body
3. Adjusting screw 13.Choke plug
4. Spring seat guide 14.Valve element
5. Spring 15.Choke plug
6. Safety valve element 16.O ring
7. Safety valve seat 17.Screw plug
8. Screw plug 18.Screw plug
9. Strainer 19.O ring
10.Pressing ring 20.Spring
4-108
Steering Priority Valve CLG4215
Removal and Installation Steps of Steering Priority Valve From the Machine
Removal of priority valve:

1. Identify 5 hoses with "priority CF", "priority EF",
"priority LS", "priority T", "priority P" as per the oil
PRIORITY T’
port identifications of the priority valve, and be
PRIORITY LS careful to mark firmly (Remark: Directly identify
with letters if parts are separately removed or
modified);
PRIORITY EF
2. Removal of 5 hoses: after screwing out the hose

PRIORITY P’
PRIORITY CF
LG421506166
3. Screw off 2 bolts from the priority valve with a

13mm open-end spanner, and remove the priority
valve.
LG421506167
Installation of priority valve:
each connector of the priority valve as based on the identification of each hose without error.
4-109
CLG4215 Steering Priority Valve
Brief Introduction of Steering Priority Valve Working Principle
1. When there is no steering and steering is stopped, LS port of priority valve is connected with the
hydraulic oil tank, namely that the left end of spool is connected with the tank, the right end is
connected with working pump outlet P1, the pressure differential between both ends of the priority
valve spool is the maximum ?P, the spool moves to the left, so that the opening of EF duct is
enlarged, and the opening to CF duct decreases. When CF duct is completely closed, the oil in the
enclosed right front of priority valve returns to the tank through LS port, ?P drops to zero, the spool
moves to the right under the action of spring force, open the duct to CF port a little, repeat the above
process, and the spool makes reciprocating motion to maintain dynamic balance. So almost all the
fluids are supplied into EF duct, but there is always only a small amount of oil passing through CF
duct.
2. During steering, the working pump outlet P1 port is connected to L (or R) port, the duct from LS to the
tank is closed, and the duct to L (or R) is opened. LS oil pressure acts on the left side of spool, ?P
decreases instantly, the spool moves to the right, so that the opening of CF duct is enlarged, the
opening of EF duct decreases until closed.
Steering Priority Valve Working Principle
PRIORITY VALVE LS CF PRIORITY VALVE LS CF

EF EF
T4 P T4 P
P1 P1
OIL FLOW DIRECTION WHEN STEERING OIL FLOW DIRECTION OF STEERING

IS NOT DONE OR STEERING STOPS
LG421506168
4-110
Steering Gear CLG4215
Steering Gear
Mounting Position and Functional Structure of Steering Gear
The steering gear, installed at the lower end of steering as, has the main function of controlling the front
wheel steer of the machine, its three-dimensional exploded view is as shown in below figure . The
steering gear is a closed-center rotary valve with reactive hydraulic steering gear, consisting of two parts,
i.e. a control part consisting of No. 10 spool and valve bushing pair, No.13 valve body, etc., and a
steering part consisting of No.19 stator and rotor pair, etc. During steering, fluid flows from the control
part to the steering part, and flows to the steering cylinder via the control part. At the oil inlet, there is a
check valve capable of preventing oil backflow caused by system pressure impact.
Exploded view of steering gear
24
23
11
25
4
9 12 19 21
3 6 16 22
1 2
17
8 10 18
7 13 20
15
5
14
LG421506169
1. Screw 10.Valve element and valve bushing pair 19.Stator/rotor pair

2. Spring washer 11. Leaf spring 20.Spacer
3. Spring washer 12.Pull pin 21.Rear cover
4. O ring 13. Valve body 22.Bolt
5. Dust ring 14. O ring 23.Valve body
6. “X” seal ring 15.Baffle 24.Screw
7. Baffle ring 16. Linkage shaft 25.O ring
8. Needle bearing 17.Steel ball
9. Sliding ring 18.Pin
4-111
CLG4215 Steering Gear
Brief Introduction of Steering Gear Working Principle
1. During left steering, the steering wheel drives the spool in the spool and valve bushing pair (No.10 in
the Exploded view of Steering Gear) in steering gear to rotate, so that the oil port in the spool and
valve bushing pair is opened; fluid in the priority valve CF port is supplied into the head port of
steering cylinder-lh and the rod port of steering cylinder-rh via the steering gear to drive the front
wheel to turn. Inside the steering gear, pressure oil is supplied into the stator and rotor pair (No.19 in
the Exploded view of Steering Gear) via the spool and valve bushing pair to push the rotor to rotate
with the steering wheel and press the oil into the steering cylinder; in this process, pressure oil drives
the stator and rotor pair to rotate, the stator and rotor pair drives the valve bushing in the spool and
valve bushing pair to rotate. Close the oil circuit between spool and bushing pair, and steering is
stopped.
2. During right steering, the case is similar to that during left steering, you can analyze it in combination
with left steering.
3. The steering gear is internally installed with two relief valves and two check valves, and it can
protect the steering hydraulic system against damage by external pressure impact; when the
external force makes the steering cylinder generate pressure impact and the steering system
pressure is above 18MPa, for example, overpressure due to bumpy road, the relief valves and check
valves are opened so that the oil flows from the high pressure side of the steering system into the low
pressure side to balance high and low intensities of pressure and pressure differentials; meanwhile,
the relief valve pressure is set to 18MPa, slight fluctuation in pressure due to roads in driving will not
open the relief valve, thus ensuring the stability of the machine under transport condition. The flow
direction of fluid in left steering due to pressure impact during driving is as shown in figure.
4. The oil inlet end of steering gear is provided with a check valve which can prevent oil backflow
caused by system pressure impact during steering. For example, the front wheel rotates in the
opposite direction due to the action of bumpy road and other external forces during steering.
Steering Gear Working Principle Schematic
STEERING CYLINDER STEERING CYLINDER
STEERING GEAR STEERING GEAR
R L R L
18MPa 18MPa 18MPa 18MPa
T5 T5
LS CF LS CF
OIL FLOW DIRECTION WHEN DRIVING FRONT
OIL FLOW DIRECTION OF LEFT STEERING
WHEELS DUE TO ROAD REASON
LG421506170
4-112
Steering Gear CLG4215
5. Manual steering is allowed after engine flameout or working pump failure. During manual steering,
the stator and rotor pair of steering gear plays the role of oil pump, presses oil in one cavity of the
steering cylinder into the other, and the cylinder piston rod propels the guide pulley to realize
steering.
Working Schematic of Steering Gear Manual Steering
STEERING CYLINDER
STEERING GEAR
R L
18MPa 18MPa
T5
LS CF
OIL FLOW DIRECTION OF LEFT STEERING
LG421506171
4-113
CLG4215 Steering Cylinder
Steering Cylinder
Mounting Position and Functional Structure of Steering Cylinder
The steering cylinder, installed to the front axle, is the final actuator of steering, its structural exploded
view is as follows:
Exploded view of Steering Cylinder
13
16 10
1
2 11
12
14
15
3 15
9
4
8
5 7
6
LG421506172
1. Cylinder body 7. Piston 13. Check ring

2. Grease cup 8. O ring 14. O ring
3. Knuckle bearing 9. Piston rod 15. Dust ring
4. Lock nut 10. Nut 16. Lip type seal
5. Guide ring 11. Cylinder cover 17. Guide ring
6. Seal assy. 12. O ring
4-114
Steering Cylinder CLG4215
Removal and Installation Steps of Steering Cylinder From the Machine
Removal of steering cylinder:

1. Identify 2 hoses connecting oil ports of the
steering cylinder-lh with "A2", "B2", and note to
identify firmly;
A2 out the hose, and shield the oil port;
B2
LG421506173
3. Identify 2 hoses connecting oil ports of the

steering cylinder-rh with "A1", "B1", and note to
identify firmly;
A1
B1
LG421506174
5. Remove the cotter pin at the ball joint of steering

cylinder-lh or steering cylinder-rh;
6. Screw off the nut with a 36mm open-end spanner,
knock the ball joint so as to separate from the
steering knuckle;
LG421506175
4-115
CLG4215 Steering Cylinder

7. Screw out 2 bolts with a 13mm open-end spanner,
and remove the disc above;
8. Pry out the steering cylinder with a crowbar.
×2
LG421506176
Installation of steering cylinder:
each connector of left and right steering cylinders as based on the identification of each hose without
error.
4-116
Test and Detection of Steering Hydraulic System Pressure CLG4215
Introduction of Steering Cylinder Test and Detection of Steering

Working Principle Hydraulic System Pressure
The steering cylinder, steering knuckle and front
axle stand form 2 sets of four-link mechanisms The steering hydraulic system has the maximum
which are the final actuators of steering; the pressure of 17.2MPa, and the pressure test port
steering linkage, front axle stand, steering is located at the priority valve CF port.
knuckle-lh and steering knuckle-rh form another
set of four-link mechanism, this structure
ensures coordinated actions of two sets of four-
link mechanism consisting of steering cylinders,
so as to guarantee coordinate steering of two PRESSURE
JOINT
front wheels.
For left steering, pressure oil is supplied into the
large cavity of steering cylinder-lh and the small
cavity of steering cylinder-rh, and both wheels
swing to the left to realize left steering; for right
steering, pressure oil is supplied into the small PRIORITY VALVE IS
INSTALLED ON LEFT
cavity of steering cylinder-lh and the large cavity OF FRONT FRAME
ON LOWER OF THE
of steering cylinder-rh, and both wheels swing to CAB
LG421506178
the right to realize right steering.
Oil Flow Direction in Steering Cylinder During
The steering system pressure detection
Steering
method is as follows:
1. Park the machine on a flat, open ground, and

lift the blade and other work implements off
the ground.
STEERING CYLINDER STEERING CYLINDER
2. Connect the 20MPa pressure gage

connector with the pressure test connector
on the priority valve.
R L R L
3. Place the gearbox handle in neutral position,

start the engine, turn the steering wheel to
OIL FLOW DIRECTION
OF LEFT STEERING
OIL FLOW DIRECTION
OF RIGHT STEERING the left (or right). During front wheel steering,
observe the pressure gauge reading, and the
pressure value shall be between 15 and
LG421506177
17MPa.
4-117
CLG4215 Test and Detection of Steering Hydraulic System Pressure
4. When you turn the steering wheel to the bottom to the left (or right), continue to turn the steering
wheel in this direction, observe the pressure gauge reading, and the pressure value shall be
17.2±0.5MPa. This pressure value has been set at delivery, and shall not be adjusted by non-
professionals.
LG421506179
If it must be adjusted, the pressure adjustment method is as follows:
1. Remove the screw plug (serial number 1) and O-ring (serial number 2) from the priority valve;
2. When you turn the steering wheel to the bottom to the left (or right), continue to turn the steering
wheel in this direction;
3. At this time, adjust the adjusting screw (serial number 3) while observing the pressure gauge
reading, and adjust the pressure to 17.2MPa; during adjustment, clockwise rotate the screw, the
pressure increases, counterclockwise rotate the screw, then the pressure decreases.
4. Install the O-ring (serial number 2) and screw plug (serial number 1) to the priority valve.
1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18 19 20
LG421506180
4-118
Common Faults and Overhaul Method of Steering Hydraulic System CLG4215
Common Faults and Overhaul Method of Steering Hydraulic System
The steering hydraulic system indicators shall meet the following table under normal operating
conditions:
Main technical parameters of steering hydraulic system
Maximum system pressure 17.2MPa
Working pressure of the system 15~17MPa
Maximum operating back pressure 2.1MPa
Maximum operating temperature 93
Allowable spread with system 28
Power steering torque (0.63MPa back pressure) 2.8~4.0N.m
Maximum allowable manual steering torque 136N.m
In the event of a steering hydraulic system failure during operation, you can refer to the table below for
overhaul:
Common fault and troubleshooting method of steering hydraulic system

Faults Symptom Cause Troubleshooting
Oil leakage in junction surface of Check the junction
Dirt on junction surface
parts; surface and clean up
Oil leakage Oil leakage at the cover; Shaft seal ring is damaged Replace the seal ring
Insufficient bolt (plug)
Oil leakage in bolt (plug) Tighten bolt (plug)
tightening torque
4-119
CLG4215 Common Faults and Overhaul Method of Steering Hydraulic System

Check the oil pump
Oil supply is insufficient
and oil supply line
Steering wheel is heavy when turned
Check whether the
quickly and light when turned slowly Main priority valve spool
main priority valve
binding
spool is flexible
Remove air in the
Cylinder creep,
system;
Air in steering system Check the oil pump
Foam in oil,
inlet for air leakage
Irregular noise
Heavy steering Check for steel ball, ;

Heavy steering, no steering cylinder Manual steering check valve
action failure Check whether it is
cushioned by dirt
Check the cylinder for
FK overload valve leakage
internal leakage;
No cylinder action
Replace the FK
Internal cylinder leakage
combination valve
Leakage cushioned by safety Clean and check the
No-load steering is light, heavy load
valve or safety valve spring safety valve in priority
steering is heavy
failure valve
Heavy steering High hydraulic oil viscosity
No steering back to neutral position Leaf spring failure Replace leaf spring
Pull pin bend or broken

Pressure oscillation is significantly Replace the pin or
increased, even no steering Rupture at linkage shaft linkage shaft
cotterway
When you turn the steering wheel, it
Incorrect mutual alignment of
immediately rotates in the opposite Reassembly
linkage shaft and rotor
Steering failure direction or swings from side to side
Two-way overload valve
Vehicle off tracking during moving
cushioned by dirt Check the overload
No steering when steering wheel is valve
Spring failure
turned
Priority valve binding, no oil at
No turning CF port
LS port clogging
Exocentric installation of
steering column and spool
Pressure drop in the neutral position
No automatic Steering column axially abuts
increases, when the steering wheel Troubleshooting in
return to the the spool to the bottom
stops rotating, the steering gear is accordance with
neutral position of Great steering column steering
not unloaded (vehicle off tracking specific conditions
steering wheel resistance
occurs)
Leaf spring break
4-120

No steering of steering cylinder to Increase the pressure
No steering to the
the extreme position, steering is Low pressure of safety valve of safety valve
extreme position
heavy as reflected properly
When you turn the steering wheel
forcibly after the steering cylinder
Increase overload
rotates to the extreme position, the
No end point Low overload valve pressure valve pressure
steering wheel can slightly rotate
appropriately
(without feeling that it is the end
point)
During power steering, the cylinder
piston moves to the extreme
No feel of end
position, the driver does not have Large radial or axial clearance Replace the stator and
point during
obvious feel of end point; during of stator and rotor pair rotor pair
steering
manual steering, the steering wheel
rotates but the cylinder is still
4-121
April 17, 2019 Introduction of Brake Hydraulic System
CLG4215 Common Faults and Overhaul Method of Steering Hydraulic System
Introduction of Brake Hydraulic System
The system is a single-circuit split-body valve brake system, divided into service brake and parking
brake (see the brake hydraulic system schematic). The system mainly consists of prefill valve, service
brake valve, service brake, parking brake valve, parking brake, etc. The hydraulic pump of this system is
a tandem pump shared with the work hydraulic system. After the machine is started, the tandem pump of
the work hydraulic system sucks oil from the tank, the pressure oil output by the pump charges two
service brake accumulators and a parking brake through the prefill valve first; oil charge of accumulator
only takes a very short period of time, then the prefill valve is cut off, and oil is supplied to the work
hydraulic system.
Of which the service brake is of a shoe type, acting on four rear wheels of grader. Depress the service
brake valve, oil flows from the service brake accumulator to the service brake via the service brake
valve, the brake shoe stretches for braking of the complete machine. The parking brake is of a caliper
disc type, acting on the gearbox & torque converter as. Press the button on the parking brake valve, the
parking brake valve is energized, oil flows from the parking brake accumulator to the parking brake via
the parking brake valve, the brake caliper disc is released, and brake is removed; when the brake
system pressure is less than 10MPa, the brake caliper disc cannot be released completely, the parking
brake low pressure alert switch on the parking brake valve is on, and the indicator on the dashboard is
lightened up. CLG4215 grader brake hydraulic system schematic and layout drawing are as follows:
Brake Hydraulic System Schematic
ACCUMULATOR (9.2MPa)(1L) PARKING BRAKE LOW

PRESSURE ALARM SWITCH
(10MPa)
SERVICE BRAKE LOW PRESSURE SW1 C SW4

ALARM SWITCH (10MPa) PARKING BRAKE
ACCUMULATOR (9.2MPa)
ACCUMULATOR
SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING P2 P5 A
HYDRAULIC SYSTEM
O T7
FILLING VALVE
BRAKE VALVE
(15.9MPa/12.8MPa) (MAXIMUM BRAKE
T6 PRESSURE 10.3MPa)
SERVICE BRAKE LIGHT
SWITCH (0.5MPa)
P1 P2
WORKING PUMP
M
21MPa
HYDRAULIC OIL TANK
LG421506181
4-122
Introduction of Brake Hydraulic System April 17, 2019
Brake Hydraulic System Layout Drawing
3
1
4
2
5
9 7
LG421506182
1. Hydraulic oil tank 4. Parking brake valve 7. Service brake accumulator

2. Tandem pump 5. Service brake valve 8. Service brake
3. Parking brake accumulator 6. Prefill valve 9. Parking brake
4-123
CLG4215 Introduction of Brake Hydraulic System Principle
Introduction of Brake Hydraulic System Principle
1. When the accumulator pressure is less than 12.8MPa, the prefill valve is opened to charge the
accumulator, the oil flow direction is as shown in figure: the oil output by the pump is supplied to two
service brake accumulators and a parking brake accumulator through the prefill valve.
Oil Flow Direction in Charge Mode of Prefill Valve
ACCUMULATOR (9.2MPa)(1L) PARKING BRAKE

LOW PRESSURE
ALARM SWITCH (10MPa)

SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING P2
HYDRAULIC SYSTEM P5 A
O T7
FILLING VALVE BRAKE VALVE

T6 PRESSURE 10.3MPa) SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
21MPa
HYDRAULIC OIL TANK
LG421506183
4-124
Introduction of Brake Hydraulic System Principle CLG4215
2. When the accumulator pressure is up to 15.9MPa, the prefill valve cuts off oil supply to the
accumulator, and oil flows to the work hydraulic system.
Oil Flow Direction in Cut-off Mode of Prefill Valve

PRESSURE ALARM
SWITCH (10MPa)

SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING
P2 P5 A
HYDRAULIC SYSTEM
O T7
FILLING VALVE
BRAKE VALVE
PRESSURE 0.3MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
21MPa
HYDRAULIC OIL TANK
LG421506184
4-125
CLG4215 Introduction of Brake Hydraulic System Principle
3. During service braking, the brake fluid flow direction is as shown below. When the accumulator
pressure is less than 12.8MPa after braking, oil in the prefill valve charges the accumulator as per
(1);when the accumulator pressure is above 15.9MPa, oil in the prefill valveis supplied to the work
hydraulic system as per (2).
Oil Flow Direction During Service Braking

PRESSURE ALARM SWITCH
(10MPa)
SERVICE BRAKE LOW PRESSURE
ALARM SWITCH (10MPa) SW1 C SW4
PARKING BRAKE
SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING
P2 P5 A
HYDRAULIC SYSTEM
O T7
FILLING VALVE
(15.9MPa/12.8MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
PRESSURE SWITCH
P1 P2
WORKING PUMP
BRAKE VALVE (MAXIMUM BRAKE PRESSURE 10.3MPa)
M
21MPa
HYDRAULIC OIL TANK
LG421506185
Oil Flow Direction With Service Brake Removed

PRESSURE ALARM
SWITCH (10MPa)
SERVICE BRAKE LOW
PRESSURE ALARM SW1 C SW4
SWITCH (10MPa) PARKING BRAKE
SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING P2 P5 A
HYDRAULIC SYSTEM
O T7

(MAXIMUM BRAKE
(15.9MPa/12.8MPa) PRESSURE 10.3MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
21MPa
HYDRAULIC OIL TANK
LG421506186
4-126
Introduction of Brake Hydraulic System Principle CLG4215
4. When the parking brake valve is energized, C port is connected to B port, brake fluid flows to the
parking brake via the parking brake valve, the parking brake caliper disc is released, and brake is
removed. When the parking brake valve is de-energized, B port is connected to T4 port, oil in the
parking brake flows back to the hydraulic oil tank via the parking brake valve, the brake caliper disc is
clamped for braking of complete machine.
Oil Flow Direction With Parking Brake Removed

PRESSURE ALARM
SWITCH (10MPa)
SERVICE BRAKE LOW
SW2
B
SERVICE BRAKE
P5 P5 T8 SW3
BRAKE SYSTEM
TO WORKING P2
O T7
FILLING VALVE
BRAKE VALVE
PRESSURE 10.3MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
HYDRAULIC OIL TANK
21MPa
LG421506187
Oil Flow Direction During Parking Braking

PRESSURE ALARM
SWITCH (10MPa)
SERVICE BRAKE LOW
SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING P2
O T7

(MAXIMUM BRAKE
(15.9MPa/12.8MPa) PRESSURE 11.3MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
HYDRAULIC OIL TANK
21MPa
LG421506188
4-127
CLG4215 Prefill Valve
Prefill Valve
Mounting Position and Function of Prefill Valve
The prefill valve is located on the right side of front frame under the cab, when the oil pumped out from
the working pump flows through the prefill valve, it first charges the accumulator, when the accumulator
pressure is up to 15.9MPa, oil is supplied to the work hydraulic system; when the accumulator pressure
drops to below 12.8MPa due to frequent braking, etc., charge the accumulator again, and always
guarantee that the accumulator pressure is above 12.8MPa.
Overview of Internal Structure of Prefill Valve
The internal structure of prefill valveis as follows:

Exploded view of Prefill Valve
35
PRESSURE
PORT
9
34 8 7
33
FLOW
32 THRU PORT
31
30
29
6
5
DRAIN PORT 4
19
3
28 18
ACCUMULATOR
17 2
PORT 27 16 1
26
25 15
24 14
23
22 13
21 12
20 11
10
LG421506189
1. Plug 13.Spring 25.Valve element

2. O ring 14.Valve element 26.Valve bushing
3. Bar 15.Vavle seat 27. O ring
4. Spring 16. O ring 28. O ring
5. Oil seal 17.Washer 29.Steel ball
6. Valve element 18.Filter 30.??
7. Valve body 19.Washer 31.Spring
8. O ring 20.Plug 32.??
9. Plug 21. O ring 33. O ring
10.Nut 22.Spring 34.Plug
11.Bolt assy. 23.Bracket 35.Plug
12. O ring 24.Steel ball
4-128
Prefill Valve CLG4215
Removal and Installation Steps of Prefill Valve From the Machine
Removal of prefill valve:

1. The prefill valve is located on the right side of the
A2
front frame; identify the 5 connecting hoses for oil
ports of prefill valve as "A2", "P3", "T2", "O", "P",
P3 and note to identify firmly;
T2 2. Removal of 5 hoses: after screwing out the hose
P O
LG421506190
3. Unscrew off two bolts from prefill valve with a

open-end wrench (16 mm), and take out the prefill
valve;
×2
LG421506191
Installation of prefill valve:
each connector of the prefill valve as based on the identification of each hose without error.
4-129
Introduction of Prefill Valve Working Principle
1. Charging mode of prefill valve:

The prefill valve charges the accumulator by controlling the oil flow direction depending on the
movement of internal spool.
When the working pump starts operating, the pressures of both upper and lower cavities of spool (4) are
low, the spring (2) makes the spool (4) in the lower position, the duct between port P and port O is closed
at a small angle, resulting in an obvious throttling effect and high pump outlet pressure.
High pressure oil filtered by the filter (6) pushes the check valve spool (12) open to charge the
accumulator via oil port A. The control valve spring (7) makes the low pressure relief ball valve (10) open
and high pressure relief ball valve (8) closed, and the control valve spool can only make one of the
pressure relief ball valves open. The opened low pressure relief ball valve (10) enters the oil chamber (1)
while oil flows through the accumulator; meanwhile, oil is supplied into the oil chamber (5) via an internal
passage of the spool (4) and pushes the spool (4) to move up, so that a part of oil flows to oil port O,
when a balance between pressure in upper and lower chambers of the spool (4) and spring force is
reached, the spool stops moving. The spring (2) ensures that the pump outlet oil pressure is always
higher than the accumulator oil pressure, so as to ensure the priority of charging function.
Inside of prefill valve in Charging Mode
12
Standby Mode
1
11
Accumulator Port
10
2
A
9
PRESSU
8
RE Port 3 T
P Tank Port
O
Flow Thru
7
Port
4
5
LG421506192
4-130
System Oil Flow Direction in Charging Mode
P5
P2
O
FILLING VALVE
CHARGE VALVE
(15.9MPa/12.8MPa) T6
P1 P2
WORKING PUMP
M
HYDRAULIC OIL TANK
21MPa
LG421506193
4-131
2. Prefill valve cut-off mode:

When the accumulator pressure is up to 15.9MPa, the control valve spool (9) moves down, so that the
high pressure relief ball valve (8) is opened and the low pressure relief ball valve (10) is closed. Oil in the
oil chamber (1) is connected to T port via the high pressure relief ball valve (8), then flows into the
hydraulic oil tank, and oil chamber (1) pressure is relieved. The spool (4) overcomes the pressure of
spring (2) under the action of pressure oil in the oil chamber (5) and moves up, the duct between P port
and O port is enlarged, and oil is supplied into the work hydraulic system via O port. The fluid pressure at
P port drops, the check valve (12) is closed, obstructing the oil circuit between P port and accumulator.
When the prefill valve operates in the cut-off mode, if the pressure required by all the positions of work
hydraulic system to which oil is supplied by O port is lower than the pressure of spring (2), the oil
pressure at working pump outlet is equal to the pressure of spring (2); when the pressure required for a
position of the work hydraulic system to which oil is supplied by O port is higher than the pressure of
spring (2), the oil pressure at working pump outlet is equal to the pressure in this position.
When the accumulator pressure is below 12.8MPa, the spring (7) opens the low pressure relief ball valve
(10), and the prefill valve operates after switching to the charging mode.
Inside of prefill valve in Cut-off Mode
12
Standby Mode
1
11
Accumulator Port
10
2
A
9
PRESSU
8
RE Port 3 T
P
O Tank Port
Flow Thru
7
Port
4
5
LG421506194
4-132
System Oil Flow Direction in Cut-off Mode
P5
P2
O
FILLING VALVE
(15.9MPa/12.8MPa)
T6
P1 P2
WORKING PUMP
M
21MPa HYDRAULIC OIL TANK
LG421506195
4-133
CLG4215 Accumulator
Accumulator
Mounting Position and Function of Accumulator
The brake system has a total of three accumulators, two of them are 1.6L service brake accumulators,
located on the right side of front frame under the cab; the other is a 1L parking brake accumulator,
located on the left side of front frame under the cab. The accumulator shall be prefilled with nitrogen
before use, prefill pressure 9.2MPa. It has the main function of supplying brake pressure oil source for
braking of complete machine.
Removal and Installation Steps of Accumulator From the Machine
Removal of parking brake accumulator:

1. Refer to "Pressure Relief" steps in "Removal of
Parking Brake Valve" for pressure relief, and you
must not conduct subsequent steps until ensuring
that the accumulator pressure is completely
released;
2. Hose removal: After screwing out the hose by 1-2
circles with a 24mm open-end spanner, knock
down the joint position with the spanner to
LG421506196
3. State of hose after removal;
LG421506197
4-134
Accumulator CLG4215

4. Screw off 3 fastening bolts from the accumulator
baffle with a 13mm socket or open-end spanner,
and remove the accumulator baffle;
LG421506198
5. Screw off 2 fastening nuts (on the inside of the

bracket) from U-bolts with a 13m open-end
spanner, and remove the U-bolts;
LG421506199
6. Remove the accumulator;
LG421506200
Installation of parking brake accumulator:
Asseble according to reverse steps of removal;

The Removal and assembly steps of service brake accumulator are as follows:
4-135
CLG4215 Accumulator
Removal of service brake accumulator (also known as rear axle brake accumulator):

1. Refer to "Pressure Relief" steps in "Removal of
Service Brake Valve" for pressure relief, and you
must not conduct subsequent steps until ensuring
that the accumulator pressure is completely
released;
2. Identify 3 hoses connecting oil ports at 2
P1 accumulators with "A2", "P1", "A4", and note to
A2 mark firmly;
A4 by 1-2 circles with the open-end wrench, knock
LG421506201
4. Screw off 3 fastening bolts from the accumulator
baffle with a 13mm socket or open-end spanner,
×3 and remove the accumulator baffle;
LG421506202
5. Screw off 4 fastening nuts (on the inside of the

bracket) from 2 U-bolts with a 13m open-end
spanner, and remove 2 U-bolts; Remove 2
accumulators.
LG421506203
Installation of service brake accumulator:

4-136
Accumulator CLG4215
Introduction of Accumulator Working Principle
Both parking brake accumulator and service brake accumulator are bladder accumulators, the bladder is
filled with high-pressure nitrogen to store and release pressure energy depending on the compression
and expansion of high-pressure nitrogen. The prefill valve guarantees that pressure in the accumulator is
above 12.8MPa, when braking is required, the accumulator can supply a large amount of pressure oil
within a short period of time to guarantee the braking speed.
Accumulator Structure Diagram
SERVICE BRAKE
ACCUMULATOR AIR CHARGING
VALVE
HOUSING
AIRBAG
OIL INLET
VALVE
LG421506204
PARKING BRAKE
ACCUMULATOR AIR CHARGING
VALVE
HOUSING
AIRBAG
OIL INLET
VALVE
LG421506205
4-137
CLG4215 Service Brake Valve
Service Brake Valve
Mounting Position and Functional Structure of Service Brake Valve
The service brake valve, installed on the right side of platform in the cab, is the final actuator of service
brake, its structure drawing is as follows:
External View of Service Brake Valve As
BRAKE PEDAL
SERVICE
BRAKE VALVE
MOUNTING
PLATE
SERVICE BRAKE
VALVE
LG421506206
Exploded view of Service Brake Valve
6
14
15
13
5
12
11
4
10
3
9
2 8
1
LG421506207
1. Plug 6. Oil seal 11.Spring

2. O ring 7. Cover 12.Spring
3. Spring 8. Valve seat assy. 13.Valve bushing
4. Valve element 9. Washer 14.Jacket
5. Valve body 10.Spring 15.Bolt
4-138
Service Brake Valve CLG4215
Removal and Installation steps of Service Brake Valve From the Machine
Removal of service brake valve:

Pressure relief:
1. Shut down the complete machine, depress the

service brake pedal for 15 to 20 times for full
pressure relief of hydraulic line;
LG421506208
The service brake valve is located on the right

side of the platform plate at the bottom of the cab;
2. Mark 3 hoses connecting oil ports of the service

brake valve with "A1", "P1", "T1", and note to mark
T1
firmly;
A1 completely relieve pressure of hydraulic oil, screw
P out the hose, and shield the oil port;
LG421506209
4. Screw out 4 fastening bolts from the service brake

valve with a 13mm open-end spanner, and
remove the service brake valve;
SERVICE BRAKE
VALVE
LG421506210
Installation of service brake valve:
each connector of the service brake valve as based on the identification of each hose without error.
4-139
Introduction of Service Brake Valve Working Principle
When brake is removed, the service brake valve spool is in the uppermost side position, and A port is
connected to T7 port. Oil in the brake at four rear wheels flows back to the tank via the brake valve, and
brake force is removed.
Service Brake Valve With Brake Removed
Single Modulating Power Brake Valve

(spool design-neutral position)
Callout Key
(1)Bias Spring
(2)Spool
(3)Return Spring
(10)Input Piston
Color Key
Return Line PRESSURE 3 10

HYDRAULIC SYSTEM
PRESSURE
2 Tank
Port T7
A Brake
Port
PRESSURE
Port P5
1
LG421506211
Oil Circuit Condition of Service Brake With Brake Removed
SERVICE BRAKE
P5 A
T7
BRAKE VALVE
(MAXIMUM BRAKE SERVICE BRAKE LIGHT SWITCH (0.5MPa)
PRESSURE 10.3MPa)
HYDRAULIC OIL TANK
LG421506212
4-140
In the braking transition stage of service brake, the service brake valve spool is in the neutral position, A,
T7 and P5 ports are not connected with each other. Oil in the brake at the four rear wheels and oil in the
accumulator are sealed in the oil circuit to guarantee a smooth transition from brake removal to brake.
Service Brake Valve in Braking Transition Stage of Service Brake

(spool design-initial pedal apply)
Callout Key
(1)Bias Spring
(2)Spool
(4)Compensating Spring
(5)Land
(6)Land
Color Key
Return Line PRESSURE 4

HYDRAULIC SYSTEM
PRESSURE
2 Tank
Port T7
A Brake 6
Port
PRESSURE
Port P5
1
5
LG421506213
Oil Circuit Condition of Service Brake in Braking Transition Stage of Service Brake
SERVICE BRAKE
P5
A
T7
BRAKE VALVE (MAXIMUM SERVICE BRAKE LIGHT SWITCH (0.5MPa)

BRAKE PRESSURE 10.3MPa)
HYDRAULIC OIL TANK
LG421506214
4-141
In the braking stage of service brake, the service brake valve spool is in the downside position, A and P5
ports are connected. Oil in the accumulator flows to the brake at the four rear wheels via the service
brake which makes the brake shoe stretch for machine braking. When the service brake valve spool
passes across the neutral position, braking is initiated; the lower the service brake valve spool position
is, namely that the lower the brake pedal position is, the greater the braking force is; the faster the
service brake valve spool moves down, namely that the faster the brake pedal is depressed, the faster
braking is accordingly.
Service Brake Valve in Braking of Service Brake

(spool design-pedal applied)
Callout Key
(2)Spool
(5)Land
(7)Pilot Orifice
(8)Cavity
Color Key
Return Line PRESSURE 4

HYDRAULIC SYSTEM
PRESSURE
BRAKE SYSTEM 2 Tank
PRESSURE Port T7
A Brake
Port
PRESSURE
Port P5
7
8 5
LG421506215
il Circuit Condition of Service Brake in Braking of Service Brake
SERVICE BRAKE
P5
A
T7
BRAKE VALVE
(MAXIMUM BRAKE SERVICE BRAKE LIGHT SWITCH (0.5MPa)
PRESSURE 10.3MPa)
HYDRAULIC OIL TANK
LG421506216
4-142
In the brake maintenance stage of service brake, the service brake valve spool is maintained in the
downside position, A and P5 ports are connected. The oil pressure in the oil chamber at the downside of
service brake valve spool, the spring force and foot brake force are balanced, and the machine is
maintained in a braking state; if you need to brake for a long time, you need to use the parking brake
after putting into neutral position. When you release the parking brake pedal, the spring force of the oil
chamber at the downside of service brake valve spool resets the spool, and braking is removed.
Service Brake Valve in Brake Maintenance Stage of Service Brake

(spool design-pedal applied, balanced spool)
Callout Key
(2)Spool
(5)Land
(6)Land
(8)Cavity
(9)Shirns
(10)Piston
(11)CHECK Ball
10 9
Color Key
4 11
Tank
Return Line PRESSURE Port
2 Brake 6
HYDRAULIC SYSTEM
PRESSURE Port
PRESSURE
Intermediate Modulated Port
PRESSURE
8 5
LG421506217
4-143
CLG4215 Parking Brake Valve
Parking Brake Valve
Mounting Position and Functional Structure of Parking Brake Valve
The parking brake valve, installed on the left side of front frame under the cab, is the final actuator of
parking brake, its internal structure is as follows:
Exploded view of Parking Brake Valve
7 4
4 6
LG421506218
1. Screw 5. Valve body

2. Cover 6. Pressure joint
3. Check valve 7. Solenoid valve
4. Plug
4-144
Parking Brake Valve CLG4215
Removal and Installation Steps of Parking Brake Valve From the Machine
Removal of parking brake valve:

Pressure relief:
1. Park the complete machine on the level ground,

open the hinged cylinder, adjust the left side of the
complete machine to the maximum angle to
ensure a greater space for maintenance;
LG421506219
2. Turn on the key to the 1st gear;
LG421506220
3. Press and pull the hand brake repeatedly;
LG421506221
4-145

4. Until the accumulator hose is completely soft;
LG421506222
5. Unscrew the accumulator collar nut with a 24mm

open-end spanner to slowly drain out hydraulic oil;
LG421506223
4-146
Removal of parking brake valve group:

1. Removal of 2 pressure switch wires;
LG421506224
2. First remove the boot, and remove 2 connecting

plugs;
LG421506225
3. Cut off the tie that ties up wires with scissors;

4. Tear the harness connector apart;
LG421506226
4-147

5. Mark 4 hoses connecting oil ports of the parking
brake valve with "B3", "T3", "A3", "P3", and note to
REMOVAL SEQUENCE
mark firmly;
P3
6. Removal of 4 hoses in turn from bottom to top:
A3 After screwing out the hose by 1-2 circles with the
T3
hydraulic oil, screw out the hose, and shield the oil
B3
port
LG421506227
7. Remove 2 bolts from the mounting plate with a

18mm open-end spanner or double offset ring
spanner, and remove the parking brake valve;
LG421506228
Installation of parking brake valve:
Install the parking brake valve in the reverse sequence of "Removal of Parking Brake Valve Gp", of
which the hose assembly part must be connected with each connector of the parking brake valve based
on the identification of each hose without error;

1. Screw down the hose at the accumulator;
LG421506229
4-148

2. Assembly of upside pressure switch wire: Insert 2
connecting plugs (wire sizes 413#, 129#) into the
pressure clamp, ensure secure connection after
assembly, and install the boot into the pressure
switch;
3. Assembly of downside pressure switch wire:
Insert 2 connecting plugs (wire sizes 410#, 129#)
into the pressure clamp, ensure secure
connection after assembly, and install the boot
into the pressure switch;
LG421506230
4. Connect separated harness connectors;
LG421506231
5. Tie down the wires with a tie to avoid wire

looseness;
LG421506232
4-149

6. Condition after oil pipe and wires are well
connected;
LG421506233
7. Start the machine, pull up the hand brake, and

check all connectors for oil leakage; if there is any
oil leakage in connectors, shut down the machine,
and continue to tighten the collar nut where there
is oil leakage;
LG421506234
8. If there is no oil leakage, adjust the lift cylinder, lift

the blade to a reasonable position, align the hinge
plate, and straighten the grader.
LG421506235
4-150
Introduction of Parking Brake Valve Working Principle
For parking braking, B and T8 ports of the parking brake valve are connected, oil in the parking brake
flows back to the hydraulic oil tank via the parking brake valve, the disc parking brake is clamped for
braking of the complete machine.
Condition of Oil Circuit In Parking Braking

PRESSURE ALARM
SWITCH (10MPa)
SERVICE BRAKE LOW

PRESSURE ALARM SW1C SW4
SW2
B
T8 SW3 HYDRAULIC OIL TANK
LG421506236
When parking brake is removed, B and C ports of the parking brake valve are connected, oil in the
parking brake accumulator flows to the parking brake via the parking brake valve, the disc parking brake
is released, and machine braking is removed. If the system pressure is below 10Mpa for some reason
when parking braking is removed, the disc parking brake cannot be completely released at this time, the
parking brake low pressure alarm switch is on, sending an alarm signal.
Condition of Oil Circuit When Parking Braking is Removed

PRESSURE ALARM
(10MPa)
SERVICE BRAKE LOW

SW2
B
T8 SW3 HYDRAULIC OIL TANK
LG421506237
4-151
CLG4215 Parking Brake System
Parking Brake System
Introduction of Parking Brake Valve
The parking brake system mainly consists of accumulator, parking brake valve, parking brake, etc. The
accumulator supplies pressure oil for braking removal; the parking brake valve is used to control the
parking braking and its removal of the complete machine; the parking brake, a caliper disc brake coming
with the gearbox & torque converter as, is a brake actuator. For parking braking, pressure oil in the
parking brake flows back to the hydraulic oil tank through the parking brake valve, and the brake clamp is
clamped; when parking braking is removed, the two-position three-way reversing valve in the parking
brake valve is reversed, pressure oil flows from the accumulator to the parking brake via the parking
brake valve, and the brake clamp is released. Namely that when pressure oil in the parking brake
accumulator flows to the parking brake, parking braking is removed, at this time, a pressure between
12.8 and 15.9MPa shall be possibly detected at the parking brake pressure test port SW3.
Oil Flow Diagram in Braking of Parking Brake System

PRESSURE ALARM
SWITCH (10MPa)
SERVICE BRAKE LOW
SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING P2 P5 A
HYDRAULIC SYSTEM
O T7
FILLING VALVE
BRAKE VALVE
PRESSURE10.3MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
LG421506238
4-152
Parking Brake System CLG4215
il Flow Diagram With Braking of Parking Brake System Removed

PRESSURE ALARM
SWITCH (10MPa)
SERVICE BRAKE LOW
SW2
B
SERVICE BRAKE
SW3
P5 P5 T8
BRAKE SYSTEM
P5 A
TO WORKING P2
HYDRAULIC SYSTEM T7
O
BRAKE VALVE
FILLING VALVE (MAXIMUM BRAKE
PRESSURE10.3MPa)
T6
(15.9MPa/12.8MPa) SERVICE BRAKE LIGHT
SWITCH(0.5MPa)
P1 P2
WORKING PUMP
M
LG421506239
4-153
CLG4215 Parking Brake System
Pressure Detection for Parking Brake System
Steps of parking brake system pressure

detection:
1. Park the machine on a flat, open ground, and lay the blade and other work implements on the ground
flatwise.
2. Connect 20MPa pressure gauge connector with pressure test connector SW3 on the brake valve as.
3. With the gearbox handle placed in neutral position, start the engine, when you press the parking
brake button, there shall be a reading on the pressure gauge, and its value shall be between 12.8-
15.9 MPa.
PARKING BRAKE
VALVE IS
INSTALLED ON LEFT
LOWER OF CAB
PLATFORM
PRE
20
SSU
RE
GAU
10 GE
30
0 PARKING BRAKE
SYSTEM
40 PRESSURE SHALL
BE WITHIN 12.8-15.9
LG421506240
PARKING BRAKE
PRESSURE
JOINT SW3
PLEASE IDENTIFY
SW2/SW3
ACCORDING TO
STAMP
CHARACTERS
LG421506241
4-154
Service Brake System CLG4215
Service Brake System
Introduction to Service Brake System
The service brake system mainly consists of accumulator, charge valve, service brake valve, service
brake, etc. The accumulator supplies brake pressure oil; the prefill valve maintains sufficient oil pressure
for the accumulator, and the service brake valve controls the service braking and removal of complete
machine; the service brake, a shoe brake acting on four rear wheels of grader, is an actuator of braking.
When service braking is removed, pressure oil in the service brake flows back to the hydraulic oil tank
through the service brake valve, as shown in Fig. 6.5.28; for service braking, the three-position three-
way reversing valve in the service brake valve is reversed, pressure oil flows from the accumulator to the
service brake via the service brake valve for braking of complete machine, as shown in below figure“Oil
Flow Diagram in Braking of Service Brake System”.
Oil Flow Diagram With Braking of Service Brake System Removed

PRESSURE ALARM
SWITCH (10MPa)
ALARM SWITCH (10MPa) SW1C SW4
PARKING BRAKE
SW2
B
SERVICE BRAKE
P5 T8 SW3
P5
BRAKE SYSTEM
TO WORKING P2 P5 A
HYDRAULIC SYSTEM
O T7
FILLING VALVE
BRAKE VALVE
PRESSURE 10.3MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
M
21MPa
HYDRAULIC OIL TANK
LG421506242
4-155
CLG4215 Service Brake System
Oil Flow Diagram in Braking of Service Brake System
ACCUMULATOR (9.2MPa)(1L) PARKING BRAKE LOW PRESSURE


SW1C SW4 PARKING BRAKE
SW2
B
SERVICE BRAKE
P5 SW3
T8
P5
BRAKE SYSTEM
TO WORKING P2 P5 A
HYDRAULIC SYSTEM
O T7
FILLING VALVE
(15.9MPa/12.8MPa)
T6 SERVICE BRAKE
LIGHT SWITCH
(0.5MPa)
P1 P2
WORKING PUMP
BRAKE VALVE (MAXIMUM
M BRAKE PRESSURE 10.3MPa)
LG421506243
4-156
Service Brake System CLG4215
Service Brake System Pressure Detection
Steps of service brake system accumulator pressure detection:
1. Park the machine on a flat, open ground, and lay the blade and other work implements on the ground
flatwise.
2. Connect 20MPa pressure gauge connector with pressure test connector SW2 on the brake valve as
3. With the gearbox handle placed in neutral position, start the engine, when you press the service
brake pedal, there shall be a reading on the pressure gauge, and its value shall be between 12.8-
15.9 MPa.
PARKING BRAKE
VALVE IS
INSTALLED ON LEFT
LOWER OF THE CAB
PLATFORM
PRE
20
SSU
RE G
AUG
10 E
30
0 SERVICE BRAKE
ACCUMULATOR
PRESSURE SHALL
40 BE WITHIN
12.9-15.9 MPa
LG421506244
SERVICE BRAKE
PRESSURE
JOINT SW2
LG421506245
4-157
CLG4215 Service Brake System
Drive axle brake pressure.
1. Connect 20MPa pressure gauge connector with pressure test connector on the tandem
2. With the gearbox handle placed in neutral position, start the engine, when you depress the service
brake pedal, there shall be a reading on the pressure gauge, its value shall be 10.3±0.3MPa, and at
the same time, the stop lights on the battery box-lh and battery box-rh at the rear of the machine shall
come on
PRESSURE POINT
OF DRIVE AXLE IS IN
THE MIDDLE OF
RIGHT SIDE TANDEM
20
PRESSURE
GAUGE
10
30
0
40
LG421506246
SERVICE
BRAKE
PEDAL
LG421506247
BRAKE LIGHT IS
LOCATED BEHIND
LEFT/RIGHT BATTERY
BOX
LG421506248
4-158
Common Faults and Overhaul Method of Brake Hydraulic System CLG4215
Common Faults and Overhaul Method of Brake Hydraulic System
For common faults of brake hydraulic system, you can refer to the table below for overhaul:
Fault phenomenon Possible causes Trouble mode

1. Pump fault 1. Check the pump
2.Brake valve fault 2. Check the brake valve
3.Air in brake line 3. Deflate

Service brake
underpowered 4.Leakage in brake line 4. Check the brake lines
5.Large clearance between brake drum and 5. Readjust according to the
brake shoe requirements of use
6.Oil on brake shoe 6. Clean up brake shoe
1. Check air valve, supplement
1.Air valve leakage
nitrogen
Accumulator doesn't work
2.Bladder is broken, nitrogen leakage in 2. Remove and check the bladder or
capsule replace it
1.Insufficient system oil pressure in a short 1. Solvable after machine running for a
Service brake low pressure period of time for machine starting period of time
warning lights 2.The machine has system failure and oil
2. Inspection after stopping machine
pressure drop during operation
Check the brake valve, check the
No normal release of Parking brake valve failure
pressure at pressure test port SW3
parking brake
Parking brake cylinder leakage Replace cylinder oil seal parts
4-159
April 17, 2019 Introduction of Hydraulic Cooling System
CLG4215 Common Faults and Overhaul Method of Brake Hydraulic System
Introduction of Hydraulic Cooling System
The system is a single-pump single-motor quantitative hydraulic system (see the hydraulic cooling
system schematic). It consists of a cooling pump, a fan motor, a safety valve as, an oil cooler, etc. The
hydraulic cooling system starts operating immediately after the machine is started, the cooling pump
absorbs oil from the hydraulic oil tank and supplies high pressure oil to the fan motor which drives the fan
to cool all the coolers. Low pressure oil flow out of the motor is cooled by the oil cooler, then filtered by
the return oil filter and flows back to the hydraulic oil tank. A safety valve and a check valve are
integrated in the safety valve as, the safety valve mainly performs overload protection on the fan motor,
namely that when the cooling pump outlet pressure is above 18MPa, the safety valve is opened, the
pressure of high pressure oil is relieved by the safety valve to guarantee that the motor operating
pressure is lower than 18MPa; the check valve is mainly used to avoid vacuum at the oil inlet end of the
motor, namely that when the engine is suddenly shut down so that the cooling pump suddenly stops
rotating but the cooler motor is still running, the oil pressure at the motor outlet is higher than the oil
pressure at the inlet, at this time, the check valve is opened, and oil flows from the motor outlet to motor
inlet to avoid vacuum at the motor inlet. In the hydraulic system of grader, only oil in this system is
connected to the oil cooler for cooling, while oil in the work hydraulic system, steering system and brake
system does not pass through the oil cooler. CLG4215 grader hydraulic cooling system schematic and
layout drawing are as follows:
Hydraulic Cooling System Schematic
SAFETY VALVE ASSY.
CHECK
SAFETY VALVE VALVE
FAN MOTOR
18MPa
PRESSURE POINT
HYDRAULIC OIL BULK
OIL RETURN FILTER

COOLING PUMP
HYDRAULIC
OIL TANK
LG421506249
4-160
Introduction of Hydraulic Cooling System April 17, 2019
Common Faults and Overhaul Method of Brake Hydraulic System CLG4215
Hydraulic Cooling System Layout Drawing
6 5
4
2 3
LG421506250
1. Oil suction line 5. Fan motor

2. Cooling pump 6. Hydraulic oil bulk
3. Safety valve assy. 7. Oil return pipe
4. Fan
4-161
CLG4215 Introduction of Hydraulic Cooling System Principle
Introduction of Hydraulic Cooling System Principle
1. After the machine is started, the engine drives the cooling pump which absorbs oil from the hydraulic
oil tank and supplies high pressure oil to the fan motor which drives the fan to cool all the coolers.
Low pressure oil flow out of the motor is cooled by the oil cooler, then filtered by the return oil filter
and flows back to the hydraulic oil tank.
Oil Flow Direction In Normal Cooling
SAFETY VALVE ASSY.
CHECK
SAFETY VALVE VALVE
FAN MOTOR
18MPa
PRESSURE POINT
HYDRAULIC OIL BULK
OIL RETURN
FILTER
COOLING PUMP
HYDRAULIC
OIL TANK
LG421506251
4-162
Introduction of Hydraulic Cooling System Principle CLG4215
2. When the cooling pump outlet pressure is higher than 18MPa, the safety valve is opened, the
pressure of high pressure oil is relieved by the safety valve to ensure that the motor operating
pressure is lower than 18MPa.
Oil Flow Direction at Pump Outlet Pressure of More Than 18MPa
SAFETY VALVE ASSY.
CHECK
SAFETY VALVE VALVE
FAN MOTOR
18MPa
PRESSURE POINT
HYDRAULIC OIL BULK
OIL RETURN
COOLING PUMP FILTER
HYDRAULIC
OIL TANK
LG421506252
3. When the engine is suddenly shut down so that the cooling pump suddenly stops rotating but the
cooler motor is still running, the oil pressure at the motor outlet is higher than the oil pressure at the
inlet, at this time, the check valve in the safety valve is opened, and oil flows from the motor outlet to
motor inlet to avoid vacuum at the motor inlet.
4-163
CLG4215 Cooling Pump
Cooling Pump Removal and Installation Steps of

Cooling Pump From the Machine
Mounting Position and Working Removal and assembly of cooling pump
Principle of Cooling Pump
The cooling pump, installed at the power take-off

port of the transfer case on the left of engine, has BOLT
the main function of supplying pressure oil
source to the cooler motor to cool all the coolers A
of the machine.
The cooling pump is a one-way quantitative gear
pump, and its working principle sketch is as
shown in below figure “Diagram of Cooling Pump
Working Principle”. During operation, when the P
gear rotates in the illustrated direction, the
volume of the sealed working chamber of suction
chamber downside is gradually increased to form LG421506254
partial vacuum, oil in the tank is sucked in, filling
up the slot in tooth space, and oil is brought into
the pressure oil chamber upside with gear 1. Identify 2 hoses connecting oil ports on the
rotation. On the side of pressure oil area, the cooling pump with "P", "A", and note to
volume of sealed working chamber constantly identify firmly;
decreases, oil is squeezed out, so as to supply 2. Removal of 2 hoses: after screwing out the
high pressure oil to the fan motor and drive the hose by 1-2 circles with the open-end
fan to cool all the coolers. wrench, knock down the joint position with
Diagram of Cooling Pump Working Principle the wrench to completely relieve pressure of
the oil port;
3. Unscrew off two bolts from cooling pump with
a open-end wrench (16 mm), and take out
3
2 3’ 4’ the cooling pump;
4
2’
5’
I 1 II
5
1’ Installation of cooling pump:
6’
10
6 w1 10’
w2
9
7’ Install in the reverse sequence of removal, of
7 9’
8 8’
connected with two connectors of the cooling
pump as based on the identification of each hose
without error.
LG421506253
4-164
Safety Valve Assembly CLG4215
Safety Valve Assembly
Mounting Position and Internal Structure of Safety Valve Assembly
The safety valve as, installed in the middle of the left side of rear frame, has the main function of
overload protection of hydraulic cooling system. Its internal structure is as shown in below figures.
Exploded view of Safety Valve As
8 7 6 5 4 3 2 1
10
17
16
11
12 13 14 15
LG421506255
1. Valve body assy. 7. One-way valve 13.O ring

2. Connector 8. Spring 14.O ring
3. Pressure joint 9. O ring 15. Bracket
4. Joint 10. Location plug 16.Safety valve
5. O ring 11. Bolt 17.Bolt
6. Connector 12.Washer
4-165
CLG4215 Safety Valve Assembly
Of which the internal structure of No.16 safety valve is as follows:

安全阀爆炸图
12 11
10 9 8 7
6
3 4 5
1 2
LG421506256
1. O ring 5. Gasket 9. Copper gasket

2. O ring 6. Spring 10.Cover
3. Valve body 7. Blind nut 11. Screw
4. Valve element 8. Nut 12.Gasket
4-166
Safety Valve Assembly CLG4215
Removal and Installation Steps of Safety Valve Assembly From the Machine
Removal of safety valve assembly:

1. Location of safety valve assembly;
SAFETY VAL
VE ASSY.
LG421506257
1. Mark 4 hoses connecting oil ports of the safety

B1 valve assembly with "A1", "A2", "B2", "B2", and
note to mark firmly;
A1
B2 completely relieve pressure of hydraulic oil, screw
A2
LG421506258
3. Screw out 2 fastening bolts from the safety valve

assembly with a 16mm open-end spanner, and
remove the safety valve assembly
LG421506259
Installation of safety valve as:
each connector of the safety valve assembly based on the identification of each hose without error.
4-167
CLG4215 Safety Valve Assembly
Introduction of Safety Valve Assembly Working Principle
A safety valve and a check valve are integrated inside the safety valve assembly. The safety valve
mainly performs overload protection on the fan motor, namely that when the cooling pump outlet
pressure is above 18MPa, the safety valve is opened, the pressure of high pressure oil is relieved by the
safety valve to guarantee that the motor operating pressure is lower than 18MPa. The check valve is
mainly used to avoid vacuum at the oil inlet end of the motor, namely that when the engine is suddenly
shut down so that the cooling pump suddenly stops rotating but the cooler motor is still running, the oil
pressure at the motor outlet is higher than the oil pressure at the inlet, at this time, the check valve in the
safety valve assembly is opened, and oil flows from the motor outlet to motor inlet to avoid vacuum at the
motor inlet. Specific working condition is as below:
Working Condition of Safety Valve Assembly
SAFETY VALVE ASSY. SAFETY VALVE ASSY. SAFETY VALVE ASSY.
CHECK CHECK CHECK

SAFETY VALVE VALVE SAFETY VALVE VALVE SAFETY VALVE VALVE
18MPa 18MPa 18MPa
PRESSURE POINT PRESSURE POINT PRESSURE POINT
OIL FLOW DIRECTION WHEN OIL FLOW DIRECTION WHEN OIL OIL FLOW DIRECTION WHEN
OIL PRESSURE AT PUMP PRESSURE AT PUMP MOTOR PUMP STOPS
OUTLET IS LESS THAN 18MPa OUTLET IS MORE THAN 18MPa LG421506260
4-168
Fan Motor CLG4215
Fan Motor
Mounting Position and Internal Structure of Fan Motor
The fan motor, installed at the tail of the machine, has the main function of cooling all coolers of the
machine. Its internal structure is as shown below:
Exploded view of Fan Motor
7
18
17
16
15
1 24 14
20
13 19
11
10
12 3
9
6
23
14
21
8
22
5
2
LG421506261
1. Front cover 9. Outer ball bearing 17. Cylinderical pin

2. Pump body 10.Bearing retainer 18.Square seal ring
3. Rear cover 11.Circlip for shaft 19.Washer
4. Main gear I 12.Motor washer 20.Hex bolt
5. Driven gear 13.Motor oil seal 21.Cotter pin
6. External shaft 14.Seal ring II 22.Nut
7. Side plate 15. Needle bearing 23.Woodruff key
8. Circlip for hole 16.Oil plug screw 24.Oil drain plug
4-169
CLG4215 Fan Motor
Removal and Installation Steps of Fan Motor From the Machine
Removal of fan motor

1. Open the left and right door of engine hood;
2. Hang the 2 handrails by lifting rope;
3. Remove the 2 bolts P1 under the rear hood
firstly(parts number 00B0075, specification
M8×20-8.8-Zn.D, socket specification 13 mm),
P2 than remove the 2 bolts P2 above the hood;
P2
P1 P1
LG421506262
4. Take down the rear hood; unplug the harness

connector of plate license light during this
process.
please use lifting rope to lift rear hood and
avoid potential hazard due to manual materials
handling(such as bruised, injured by a crashing
object).
5. State without rear cover;
LG421506263
6. Screw out 6 bolts from the motor mounting plate

with a 13mm open-end spanner or socket;
7. State without fan;
LG421506264
4-170
Fan Motor CLG4215

8. Mark 3 hoses connecting oil ports of the cooler
motor with "A", "B", "T", and note to mark firmly;
A by 1-2 circles with the open-end wrench, knock
B
LG421506265
10. Remove 3 connectors from the cooler motor, and

shield 3 oil ports to avoid foreign materials
entering the motor;
LG421506266
1. Screw out 4 bolts from the motor mounting plate

with a 16mm open-end spanner or socket;
2. Take out the cooler motor.
LG421506267
Installation of cooler motor:
each joint of the cooling motor as based on the identification of each hose without error.
4-171
CLG4215 Fan Motor
Introduction of Working Principle of Fan Motor
The fan motor is a one-way quantitative gear motor. During operation, pressure oil output by the cooling
pump flows in from the motor oil inlet P port, drives the gear in the motor to rotate, the gear drives the fan
through the power output shaft, so as to cool all the cooling systems. Low pressure oil after applying
work flows to the cooler via the motor return port T port for cooling; oil leaked into the motor housing
directly flows back to the hydraulic oil tank via return port O, the specific working condition is as shown in
figure on the right:
Oil Flow Direction in Fan Motor Operation
T FAN MOTOR
HYDRAULIC OIL BULK
P O
OIL RETURN
COOLING
PUMP FILTER
HYDRAULIC
OIL TANK
LG421506268
4-172
Return Oil Filter CLG4215
Return Oil Filter
The return oil filter, installed to the return port of hydraulic oil tank, has the main function of filtering the oil
flowing back from the hydraulic system back to the hydraulic oil tank.
A filter and a bypass check valve are integrated in the return oil filter. During normal operation, system
return oil in the hydraulic system flows back to the hydraulic oil tank via the filter; when the filter is
clogged, the check valve is opened, and oil flows back to the tank via the bypass oil circuit at the check
valve; the specific working condition is as shown below:
Working Condition of Return Oil Filter
OIL RETURN OIL RETURN

FILTER FILTER
OIL FLOW DIRECTION OIL FLOW DIRECTION WHEN

AT NORMAL WORK THE FILTER IS CLOGGED
LG421506269
4-173
CLG4215 Test and Detection of Hydraulic Cooling System Pressure
Test and Detection of Hydraulic Cooling System Pressure
The hydraulic cooling system has the maximum operating pressure of 18Mpa, with a pressure test port
on the safety valve. The pressure value shall be around 12MPa when the machine operates normally.
The safety valve overflow pressure test method is as follows: To test the pressure, remove the oil pipe
from safety valve to fan motor, and block the oil port in corresponding position on the safety valve with a
plug; start the complete machine for idle running, and the pressure value shall be 18Mpa. This pressure
value has been set at delivery, generally not to be adjusted.
Three-dimensional Diagram of Safety Valve As
CONNECT
RADIATOR
OIL INLET
SAFETY
VALVE
PRESSURE
PORT CONNECT
FAN OIL
RETURN
OPENING
OIL INLET
CONNECT MOTOR OIL

INLET , WHEN PRESSURE
MEASURING, REMOVE THIS
OIL PIPE AND SEAL IT BY
PLUG
LG421506270
If the difference between the pressure measured by the above method and 18Mpa is great, you can
adjust the safety valve set pressure on the safety valve as, refer to the figure below, and the adjustment
method is as follows: Remove the screw cap (serial number 1) and copper packing (serial number 2)
from the safety valve; unscrew the locknut (serial number 3); rotate the screw (serial number 6) with a
slot type screwdriver, the clockwise rotating pressure is increased, and the counterclockwise pressure
decreases; adjust the overflow pressure to 18MPa, screw down the locknut, and install the copper
packing and screw cap.
Safety Valve
2 3 6
LG421506271
4-174
Test and Detection of Hydraulic Cooling System Pressure CLG4215
5-1
April 17, 2019 Electrical System
CLG4215
Electrical System
Electrical System Parameters ........................................................................................5-1
Electrical System Overview............................................................................................5-1
Precautions for Maintenance .................................................................................................................5-1
Operation Instruction of Digital Multimeter .............................................................................................5-2
Introduction of Electrical System............................................................................................................5-2
Battery ..............................................................................................................................5-3
Battery Parameter ..................................................................................................................................5-3
Battery Overview....................................................................................................................................5-3
Disconnect Switch ................................................................................................................................5-4
Removal and Installation of Battery .......................................................................................................5-4
Battery Maintenance ..............................................................................................................................5-6
Alternator .........................................................................................................................5-8
Alternator Parameter..............................................................................................................................5-8
Alternator Description ............................................................................................................................5-8
Alternator Terminal Wiring ..................................................................................................................5-9
Starter Motor ..................................................................................................................5-10

Start Motor Parameter .........................................................................................................................5-10
Starter Motor Overview ........................................................................................................................5-10
Starter Motor Terminal Wiring ..............................................................................................................5-10
Starter Switch (Electric Lock).......................................................................................5-11

Central Control Box ......................................................................................................5-11
Parking Brake System...................................................................................................5-15
Overview of Parking Brake System......................................................................................................5-15
Parking Brake Button ...........................................................................................................................5-15
Shift Control System .....................................................................................................5-16

Overview of Shift Control System ........................................................................................................5-16
SG-6S Gear Selector ..........................................................................................................................5-17
Shift control solenoid valve ..................................................................................................................5-23
Output Speed Sensor ..........................................................................................................................5-25
Lamp ...............................................................................................................................5-26
5-2
Electrical System April 17, 2019
CLG4215
Headlight ..............................................................................................................................................5-26
Work light .............................................................................................................................................5-28
Rear combination light .........................................................................................................................5-28
Dome Light and Licence Plate Light ....................................................................................................5-30
Rocker Switch................................................................................................................5-31
Sensor ............................................................................................................................5-38
Pressure Switch ...................................................................................................................................5-43
Fuel Level Sensor ................................................................................................................................5-45
Intake Air Filter Alert Switch .................................................................................................................5-46
Instrument ......................................................................................................................5-47
Water Temperature Gauge and Oil Temperature Gauge ....................................................................5-47
Fuel Gauge ..........................................................................................................................................5-49
Voltmeter..............................................................................................................................................5-50
Hourmeter .........................................................................................................................................5-51
Alarm Light ...........................................................................................................................................5-53
Wiper System.................................................................................................................5-55
Sound System................................................................................................................5-58
Preheating system.........................................................................................................5-63
Main Circuit Fuse...........................................................................................................5-66
Main Power Circuit ........................................................................................................5-67
Starter Circuit.................................................................................................................5-70
Shutdown Circuit...........................................................................................................5-73
Schematic Diagram of Electrical Units ......................................................................5-76
Schematic Diagram of Electrical Connector Positions ............................................5-77
5-1
April 17, 2019 Electrical System Parameters
CLG4215 Precautions for Maintenance
Electrical System Parameters 3. Properly connected connectors: the letter

identification of connectors and wire colors
are correspond when connecting. Otherwise,
Electrical system it may damage the connectors and even
burnt the harness.
System voltage 24V
4. Please grasp the connector body when
plugging the connectors. Do not pull out the
Electrical System Overview wire with too much force. Make sure the
fitting and good contact of lock buckles when
connecting the connectors.
This part is composed on the basis of relevant
electrical system principle diagram and electrical 5. Make sure the connectors are dry and
working principle during production. Please be protective measure should be taken to meet
subject to the delivery attached documentation the requirements of damp proof and water
from Liugong dealers when purchasing machine proof.
if modifications of product are various according 6. Read and understand the circuit diagram,
to different types of machine. which indicates the relationship and functions
Maintenance personnel must master general of the electrical system’s components and
knowledge of maintenance electrician and be devices, which contributes quickly make the
familiar with electrical system and working right judgments to the failure phenomenon,
principle of Liugong grader before fault diagnosis and then save maintenance time. Don't
and maintenance. remove and dismantle the machine to a large
extent blindly.
Precautions for Maintenance 7. Understand the meaning of "ground"
correctly: the negative pole of the battery is
the "ground". Negative grounding is used in
Before maintenance, please do understand and in the construction machinery, that is,
keep safety and warning information & negative pole of the battery is connected to
precautions in mind in case of personal injuries the complete vehicle (including metal
or damages to electrical elements and its conductors linking together such as frame,
relevant equipments. Please obey the following cab, etc.); therefore, the complete vehicle
precautions strictly during the maintenance of body is also the ground when negative pole
electrical system. of the battery is connected to the complete
Read and understand the Manual for Testing vehicle tightly. (Caution: surface of the
Equipments to use the testing equipments measuring ground position can be coated
correctly. with butter, it should be appropriate to avoid
the bad ground; paint, oil, dust etc are not
1. Complete vehicle power should be cut off allowed.) .
before maintenance; and then disconnect
wires and connectors. If not, harness will be 8. Bind harnesses and wires correctly: a. avoid
damaged and the fuse will be blown; even folding and bending harnesses with
fire will be caused because of short circuit of excessive force; b. keep away from the
wires. movable parts and avoid breaking and wear;
c. avoid friction with sharp metal edges and
2. Correctly identify the wire colors and corners; d. keep away from oil and water to
functions: wire colors and wire gauge are the greatest extent; e. keep away from the
corresponding to three-digit line mark in the parts of high temperature(such as the engine
schematic. Please distinguish colors and wire body).
gauges correctly for easy maintenance.
5-2
Electrical System Overview April 17, 2019
Operation Instruction of Digital Multimeter CLG4215
9. If wire or harness are found to be worn, they ● Black probe connects to jack "COM" and red
should be replaced and wrapped to jack "V Ω".
immediately, and fix the harness in place not
● Put the range switch to the position of
be worn.
required voltage range.
10. Correctly replace the safety device: when
● Bridge the meter probe over both sides of the
replace the safe device (also known as fuse),
measured resistance and the display value is
you must use one in the same specification, it
the value of measured resistance.
does not allow use of copper wire for
emergency treatment . Chip type fuse and 3. Measuring method of diode
flat plate type fuse used in this product
● Put the measuring range switch to
should meet relevant regulations of QC/T
420 Fuses for Auto. Therefore, if fuses need the" " position.
to be replaced during the maintenance,
please use the authentic accessories ● Black probe connects to jack "COM" and red
provided by Liugong. to jack "V Ω".
● Red probe connects to the positive terminal
Operation Instruction of Digital of diode, black to the negative terminal and
Multimeter then reading will displayed or it will display for
reverse connection.
Notice: appropriate measured range should

be selected when measuring voltage and
current to avoid damages to instruments. It is
prohibited to measure voltage on the current
and resistance position. (For detailed
operation instructions, safety requirements
and precautions, please refer to the operation
instructions of digital meter.)
LG421507001
Introduction of Electrical System
The electrical system consists of cab wiring, rear

1. Measuring method of DC voltage
frame wiring, front frame wiring, battery wiring,
● Put the range switch to the position of light group system, wiper system, sound system,
required voltage range (DC 200V position is etc. This manual mainly introduces the
usually used for the system voltage of installation position of electrical system
machine is DC 24V). elements, control principle of circuit, working
mode of the elements anf fault diagnosis &
● Black probe connects to jack "COM" and red
overhauling of the circuit, etc.
to jack "V Ω".
● Red probe connects to the measured point,
black to the grounding and the display value
is the voltage value of this point.
2. Measuring method of resistance
5-3
April 17, 2019 Battery
CLG4215 Battery Parameter
The rated voltage of the electrical system is 24V. Battery

Wires with a sectional area of below 5mm² are
Japanese standard wires, i.e. AVSS, AVS wires,
wires with a sectional area of above 5mm² are Battery Parameter
QVR wires, and all wires are provided with wire
sizes.
Model 6-QW-120T
Wire identification:
Quantity 2 series
For example: 602WH1.25
Ground Cable (-)
602: wire No.
Rated voltage 12V
WH: color
20 hourly rate
120Ah
1.25: wire gauge(mm²) capacity
Reserve capacity 230min
Abbr. code for colors
Low-temperature
850A(-10°C)
WH:WHITE GY:GRAY OR:ORANGE starting current
Blue Grey Orange Battery Disconnect switch
disconnection (Disconnect negative electrode
mode and frame)
Length 406mm
Width 172mm
Height 211mm
Overall height 231mm
Reference weight 29.2±0.5Kg
Battery Overview
The electrical system of complete vehicle is

provided with 24V voltage by two 12V batteries
connected in series. The batteries supply power
to the complete vehicle before the engine starts,
and supply start current to the start motor. The
batteries are installed in the left and right battery
boxes at the tail of complete vehicle. The battery
cable (-) is connected to the disconnect switch
connected to the frame ground, and the
disconnect switch controls the connection and
disconnection of battery.
5-4
Battery April 17, 2019
Disconnect Switch CLG4215
Installation position diagram is as below: Disconnect Switch
LEFT
BATTERY BOX
RIGHT
BATTERY BOX
LG421507002
LG421507004
Rated voltage 24V

Current continuously
≤200A
passing main contact
NEGATIVE
TERMINAL
ELECTRIC
EYE
POSITIVE
TERMINAL Transient current (5s) 1200A
PILE HEAD
PILE HEAD
Working ambient
-40°C~+120°C
temperature
The disconnect switch is installed in the left

battery box. When the switch lever points to the
"I" position on the switch panel, the disconnect
switch is in the ON state.
LG421507003
Removal and Installation of

Battery
1 4
LG421507005
5-5
CLG4215 Removal and Installation of Battery
5
4
LG421507006
When the battery is to be removed, the

following steps shall be observed:
1. Disconnect the disconnect switch, No.2;

2. Remove the connecting cable between the
battery cable(-) and disconnect switch, No. 1;
3. Remove the cable between the battery cable
(+) and starter motor, No. 5;
4. Remove the connecting cable between two
batteries, No.4;
5. Remove steel angles (No.3) and battery
hooks (No.6) for fixing batteries.
The installation sequence is opposite to the

removal steps, and you shall confirm that the
disconnect switch is in the OFF position prior
to installation.
When install the battery : The battery shall

not be tilted at more than 40°; Do not place
the battery upside down or laterally; Prior to
installation, check the hydrometer, and
confirm that it is green;
5-6
Battery April 17, 2019
Battery Maintenance CLG4215
Battery Maintenance
Visual inspection of battery hydrometer state
Color Green Black Bright color

Charging
Charge larger than 65% Charge smaller than 65% Electrolyte level is too low
state
Countermeas Charge the battery, then do the load
Load test Need to replace the battery
ure test
Battery open-circuit voltage inspection
Inspection items Reasons Treatment

Above 12.5V, hydrometer is green Normal
Between 12.4 and 11V, hydrometer is
Undercharge Charging
black
Voltag 1. Over discharging (Hydrometer is
Charging
e green)
2. Short circuit (Hydrometer is
About 10.5 V or less Replacement
green)
3. Open circuit (Hydrometer is
Replacement
green)
Recharge the battery

Battery maintenance requirements
1. Causes for battery undercharge: With the
1. For a vehicle parked for more than 15 days, vehicle not started, long turn-on time of
the disconnect switch shall be disconnected; electric appliances on the vehicle and other
abnormal uses, electric leakage and vehicle
2. The battery shall be installed without
lay-off for a long time, or alternator charging
looseness, and there shall be no spilled acid,
fault lead to failed charging of battery,
cracks, damage resulted from bump or dirt at
causing undercharged battery and black
the surface of battery case or the junction
battery hydrometer, even vehicle starting
with positive and negative terminals;
failure, and the battery needs to be charged.
3. Check the charge state of battery every 3
2. Check the battery appearance before
months, and the battery with a voltage of
charging:
more than 12.50V is a normally charged
battery. The battery with a voltage of less a. For no charging of a battery with broken
than 12.50V is an undercharged battery. case or acid leakage, find out the cause,
and replace the battery.
4. For a vehicle stored for more than 1 year
(battery never charged), the battery must be b. For no charging of a battery with broken
replaced and scrapped. terminal post, find out the cause, and
replace the battery.
c. Do not charge a battery with white
hydrometer, replace the battery.
d. Before charging, clean the terminal posts,
and remove scale on the surface.
5-7
CLG4215 Battery Maintenance
3. Precautions during charging:Wear safety d. The correspondence between charging

glasses. time and battery voltage before charging is
shown in the table below (for reference,
a. Maintain a ventilated environment during
the smaller the charging current is, the
charging, and charge at a normal
longer the charging time is).
temperature.
b. Do not smoke during charging, and avoid Battery voltage Charging time
introduction of fire. 12.55~12.45V 2 hours
12.45~12.35V 3 hours
c. Connect the positive cable first during
12.35~12.20V 4 hours
wiring for charging; disconnect the
12.20~12.05V 5 hours
negative cable first during disconnection
prior to charging. 12.05~11.95V 6 hours
11.95~11.80V 7 hours
4. Recharge the battery operation 11.80~11.65V 8 hours
a. Confirm that the battery terminal posts are 11.65~11.50V 9 hours
clean, and the charging circuit is in good 11.50~11.30V 10 hours
connection. Connect the charger positive 11.30~11.00V 12 hours
to the battery positive, and connect the Below 11.00V 14 hours
charger negative to the battery cable(-). Do
not charge the batteries in series (24V). b) When charging is completed, check the
b. It is recommended to charge the battery at color of battery hydrometer. The green
constant voltage of 16.0V (no more than hydrometer indicates that the battery has
16.2V at most, current limited to 25A a lot been fully charged. If the hydrometer is
of water will be electrolyzed when this limit black, check whether the charging cable
is exceeded, causing liquid level drop, is in solid connection, the connection
white charge indicator, battery scrap) until points are clean and the voltage at the
the hydrometer shows green. The green end of charging reaches 16V, place it for
battery hydrometer indicates that the 24h, measure the voltage, compare the
battery has been fully charged. relationship between voltage and
charging time and continue to charge.
c. If there is no condition for charging at
constant voltage, constant current
charging is allowed per the following spec:
a) Select 1/10 amp charging current (12A
for 37B0108 battery) of rated capacity
(C20), the voltage at the end of charging
should be reached but cannot exceed
16V (voltage less than 16V at the end of
charging is easy to cause the hydrometer
to show black even after charging is
completed). When the charger cannot
guarantee that the charging voltage is
limited to below 16V, the charged battery
terminal voltage must be manually
monitored every hour; otherwise, it can
cause water loss in battery due to
overvoltage charging and affect the life of
battery and even failure.
5-8
Alternator April 17, 2019
Alternator Parameter CLG4215
c) At the end of charging, if you find that the Alternator

hydrometer shows white, it may be due to
bubbles in the hydrometer, and you can
expel them by gently shaking the battery. Alternator Parameter
If it still shows white after shaking, it
indicates that the electrolyte has been
lost, and the battery has been scrapped Alternator
and shall be replaced. Type Alternator
Rated voltage 28V
Rated current 70A

For a battery with a voltage of less than 11.0 B+ terminal and
M6,4.5~6.5N.M
V, the battery may not be charged at the tightening torque
beginning of charging. As the proportion of Equipped with DJ7011-6.3-
D+ terminal
20
sulfuric acid in a seriously under charged
battery is close to that of pure water, the E terminal and
M5,2.3~4.5N.M
tightening torque
internal resistance of the battery is very high.
As battery charging proceeds, the proportion
of sulfuric acid in the battery rises, and the Alternator Description
charging current of battery can return to
normal gradually.
The alternator is an equipment supply power to
If acid is sprayed from the battery vent during the electrical appliances of the complete vehicle.
charging, the charging shall be stopped Before the engine starts, the battery supplies
immediately. power to the electrical appliances of the
If the battery temperature exceeds 45° during complete vehicle. After the engine starts, the
charging, stop charging; reduce the charging alternator supplies power to the electrical
current by half and continue to charge after appliances of the complete vehicle and charges
the battery temperature drops to room the battery. It is forbidden that only the alternator
temperature. supplies power to the complete vehicle when the
connecting cable between the battery and
Check the hydrometer state once every hour alternator is disconnected.
during battery charging. The green battery
hydrometer indicates that the battery has
been fully charged, and stop charging.
5-9
April 17, 2019 Alternator
CLG4215 Alternator Terminal Wiring
Alternator Terminal Wiring a. Check the tension of alternator pulley, and

apply a force of 100N between two pulleys;
the deflection of new belt shall be about
5~10mm, and that of old belt is about
7~14mm. Too loose belt will cause "lost
rotation" of alternator, resulting in
insufficient generating capacity,
D+ undercharged battery and other faults.
B+
E b. Check whether the terminals of alternator
are tightened, and the terminals of
alternator connected with the battery are
tightened.
If the above detected items are normal, please
LG421507007 contact Lg dealers and Commins service
providers.
Terminal Wiring
B+ Red
E Grey
D+ White
Judgment method for Alternator faults:
1. Adjust the digital multimeter to DC 200V

range;
2. Turn on the disconnect switch without turning
on the electric lock and starting the engine,
connect the red pen to the alternator "B+"
terminal and the black pen to the alternator
earthing point, and after the reading of the
multimeter is stable, read the voltage value
which shall be between 24V and 26V;
3. Start the engine. Ensure that all the electrical
appliances on the vehicle are disconnected,
and repeat the measurement in Step 2; the
measured value shall be higher than that in
Step 2, which shall be about 28V. It proves
that the alternator works normally;
If the measured result in Step 3 has no change
compared with that in Step 2, turn off the engine
and check the following:
5-10
Starter Motor April 17, 2019
Start Motor Parameter CLG4215
Starter Motor Starter Motor Terminal Wiring
Start Motor Parameter
Rated output 24V,6KW

30
Rated work time 30S 50
Terminal 30# and
M10,13.5~15.8N.M
tightening torque
Terminal 50# and
M5,2~2.5N.M
tightening torque
Starter Motor Overview

LG421507008
The starter motor, installed on the engine, is a

device that converts the electric energy of battery Judgment method for starter motor faults:
into mechanical energy, which drives the engine
to rotate, thereby starting the engine. If the starter circuit is on, the starter motor has no
action, and judge whether the starter motor is
damaged according to the following steps.
1. Check the connecting wiring from the battery
"+" terminal to starter motor for loose or
oxidized terminals;
2. Confirm that the voltage of terminal 30 is
above 24 V.
3. Confirm that the voltage of terminal 50 is
about 24 V.
4. If all above conditions are normal. It shows
that the start motor has fault, please contact
Commins service providers for solution.
5-11
April 17, 2019 Starter Switch (Electric Lock)
CLG4215 Starter Motor Terminal Wiring
Starter Switch (Electric Lock) Central Control Box
START
SWITCH
Ė ė Ę
ę
START
CONTACTOR
LG421507009
LG421507010
The starter switch (also called electric lock) is on Fuse setting table
the right control box panel of cab seat, including
four positions clockwise: I, II, III and IV. Rated Wire
No. Function
I position: Auxiliary, used for engine preheating current No.
system; when the key is turned to this position
counterclockwise, the engine air intake 30A 120 Shut-down
preheating system works to heat intake air for 50A 121 Start
45s, and the key automatically returns to "OFF"
position when released. F1 10A 108 Electric lock
II position: OFF, the position which the start F2 10A 107 Standby
switch key stays in normally; when the key is in
this position, the circuit of complete vehicle is cut F3 10A 148 Pin switch
off (except some electrical appliances directly Centralized
connected to the battery). F4 10A 124
lubrication system
III position: ON, the first position which the start F5 7.5A 141 Radio
switch key is turned to clockwise after being
inserted; when the key is in this position, the F6 10A 129 Brake pressure switch
electrical appliances of complete vehicle is F7 10A 147 Standby
switched on.
F8 7.5A 139 Shift control
IV position: Start, the second position which the
start switch key is turned to clockwise after being F9 10A 109 Flashing relay
inserted; the engine start circuit is on, the start
motor rotates to start the engine, and the key F10 10A 137 Instrument
returns to ON position when released. F11 10A 142 Cigarette lighter
Gear table is as below: F12 10A 128 alarm light
Position light and
Gears Connected Contact F13 10A 144
dome light
I B1-B2-G1 F14 15A 140 Wiper and washer
II B1-B2 F15 7.5A 145 Heater
III B1-B2-M F16 10A 130 Electric horn
IV B1-B2-M-S-G2 F17 7.5A 132 Emergency brake

5-12
Central Control Box April 17, 2019
Starter Motor Terminal Wiring CLG4215
Fuse setting table Relay parameter details

F18 7.5A 160 Standby 31B0005 flashing relay overall dimension
F19 10A 161 Blade work light
drawing
F20 15A 162 Standby ROTATE IN DIRECTION A
F21 10A 131 Brake light Ø6.5
B
18
F22 15A 135 Headlight
17
11
3
L
F23 10A 136 Work light
1.5
F24 10A 151 Rotating beacon
34.5
1.5 8.5
0.7
F25 10A 150 Front dome light
2.5
1
3
F26 10A 134 Rear dome light
16.5
2
11
4
0.8 THREE
3
PLACES
Ø26.92MAX 14
Relay position diagram LG421507012
The B terminal is connected to the power supply

1 2 3 positive 24V, the E terminal is connected to the
power supply negative, and the L terminal is
4 connected to the turn signal light load. Flash
rate: 60~12 times/min.
5
9 6
31B0094 main power relay overall dimension
7
drawing
34.7±0.5
8
LG421507011
17±0.15
Relay function
S/N Part No.
8.4±0.15
description 87
17.9±0.15
86 85
32.7±0.5
1 flashing relay 31B0005

6.5±0.15
2 Main power relay 31B0094 30
3 Shutdown relay 31B0095

LG421507013
4 Neutral interlock relay
5 Start protection relay
6 brake light relay

31B0173
7 Headlight relay
8 Dome light relay
9 Backup relay
5-13
April 17, 2019 Central Control Box
CLG4215 Starter Motor Terminal Wiring
31B0094 main power relay schematic diagram

31B0095 shutdown relay schematic diagram
S1
86 87a 87
85 30
87
86 87a 85
30 85 86 87
(3) (2) (1) (5) 30
LG421507014
Recommended polarity Term.86+
Term.30+
LG421507015
31B0094 Main power relay parameter table 31B0095 shutdown relay parameter table
Rated voltage 24V
Rated voltage 24V
Allowable current of normally
Coil resistance 310 Ω ±10% 20A
open contact
Terminal specification(85 Allowable of normally closed
6.3*0.8mm 10A
and 86) contact
Terminal specification(30
9.5*1.2mm Coil resistance 255±15 Ω
and 87)
Fault judgment:
Fault judgment:
Adjust the digital multimeter to ohm range, and
Adjust the digital multimeter to ohm range, and
measure the resistance of relay terminals 85 and
measure the resistance of relay terminals 85 and
86, which shall be 255±15 Ω ; in normal state, the
86, which shall be 310 Ω ±10%; connect the
terminals 30 and 87a are connected, and the
circuit of terminals 85 and 86, and the terminals
terminals 30 and 87 are disconnected; connect
30 and 87 shall be connected.
the circuit of terminals 85 and 86, and the
terminals 30 and 87 shall be connected.
5-14
Central Control Box April 17, 2019
Starter Motor Terminal Wiring CLG4215
31B0173 shutdown relay schematic diagram
DIRECTION A
23MAX
8
15.5MAX
3
9
25.4MAX
4
24.1
2
6
11
0.8
6.3 2
4.8 3
4
A
3 5
3
3
1 2
LG421507016
31B0173 Relay parameter table

Coil rated voltage 24V
Contact circuit load (resistivity) 10A/20A
Fault judgment:
In normal state (not energized), the contact

terminals 3 and 4 are connected, and the
resistance between the coil terminals 1 and 2 is
about 300?. After the coil terminals 1 and 2 are
connected, the contact terminals 3 and 5 are
connected. If not connected, cut off power and
measure whether the resistance between the coil
terminals 1 and 2 is normal. Replace the relay if
abnormal.
5-15
April 17, 2019 Parking Brake System
CLG4215 Overview of Parking Brake System
Parking Brake System
Overview of Parking Brake System
The parking brake system consists of a parking brake switch, parking brake solenoid and gearbox. When
the parking brake switch is pressed, the parking brake is actuated to cut off the power output from the
gearbox, and the caliper disc brake of gearbox works at the same time. It can prevent the complete
vehicle from moving backward after parking.
Parking Brake Button
The parking brake switch is a switch preventing the complete vehicle from moving during parking. The
parking brake is actuated when the switch is pressed, and the vehicle can move after the switch is pulled
up.
Installation position diagram
PARKING BRAKE
SWITCH
LG421507017
Wiring schematic
1 2
3 4
LG421507018
When the switch is pressed, the contacts 1 and 2 are disconnected, and the contacts 3 and 4 are
disconnected; when the switch is pulled up, the contacts 1 and 2 are connected, and the contacts 3 and
4 are connected.
Meanwhile, signals are sent to the gear and parking brake solenoid.
5-16
Shift Control System April 17, 2019
Overview of Shift Control System CLG4215
Shift Control System
Overview of Shift Control System
For the shift control system, the electrical control part of ZF6WG200 gearbox produced from ZF
Friedrichshafen AG is mainly introduced. The gear selector output circuit of shift control system drives
the combined motions of shift control solenoid located on the gearbox, so as to gain the gear selected by
the operator. The gear selector has downshift protection function. If downshift operation is needed when
the gearbox is above 3rd gear, the E module controls the opening and closing of gear selector return
lock according to the feedback signal of speed sensor, and the downshift operation can be done only
after the speed drops below the downshift point of each gear.
3 4
1 5
LG421507019
1. Shift control solenoid

2. SG-6S gear selector
3. E module
4. Connecting harness
5. Output speed sensor
5-17
April 17, 2019 Shift Control System
CLG4215 SG-6S Gear Selector
SG-6S Gear Selector
Overall dimension drawing
SICHERUNG 5A
FUSE 5A
EXTENDED LENGTH GESTRECKTE LAENGE 1000mm

ANSICAHT X2
272
VIEW X22 4 6
FLACHSTECKERCEHAUSE
99
FLATPIN HOUSING
12 12
1 3 5 7
20°
M8
12°
(F)
8
V
17.5 23
ANSICHT X1
Ø12
VIEW X1
N
STECKHUELSENCEHAEUSE
13.5
SOCKET HOUSING
7 5 3 1
8 6 4 2
R
GESTR.LAENGE 100mm 164
LG421507020
installation position diagram
R6
R6
105
5
6
3
2
4
55
N
1
3
2
114
118.6
LG421507021 LG421507022
5-18
SG-6S Gear Selector CLG4215
Gear diagram
X2:1
VP1 X1:5
AD1
(+)
X2:4 X1:7
ED1 AD2
X1:8
X2:5
ED3
SG-6S AD3
X1:6
6 AD4
5
X1:4
4 AD5
X2:2
AD10 3 3
AD7
X2:7
2 2
1 1
X2:8
AD6
N
AD9
X2:6
(-) (-)
VM1 VM2
X2:3 X1:3
LG421507023
The gear selector has 6 forward gears and 3

reverse gears. N represents neutral gear.
Symbols of schematic
Interface definition
AD1: Solenoid valve 1 (output)
AD6: Neutral start interlock (output)
AD7: E module W signal (output)
AD9: Backup signal (output)
ED1: Downshift interlock protection (input)
ED3: Clutch disengagement (power cutoff)
(input)
5-19
Working principle
The output signal of gear selector is determined by the internal circuit, the output signal of different gear
controls different solenoid group, and the clutch is controlled through the solenoid so as to control
gearbox shift. The gear selector has downshift protection function. When the gearbox is in 3rd gear and
above, the E module starts working, and judges the engine speed through the output speed sensor
signal of torque converter turbine; when needed, downshift operation can be done only after the speed is
below the downshift speed point of selected gear. Otherwise, the return solenoid of gear selector works,
and downshift operation is unavailable. For example, if the speed is above the 3rd and 4th gear shift
point when the gearbox is downshifted to 3rd gear from 4th gear, the gear selector cannot be pulled back
to forward 3rd gear.
AUSGABE OUTPUT SIGNAL
GANG VORWAERTS RUECKW. NEUTRAL

GEAR FORW. REV.
1 2 3 4 5 6 1 2 3 N N1 N2
AD1 M1
AD2 M2
AD2 M3
AD4 M4
AD5 M5
AD6 AS
AD7 W
0.4 SEC. AUS BEI GANGWECHSEL
0.4 SEC. OFF AT GEARCHANGE
AD9 RF
LG4215070
The above figure is the shift output signal figure of gear selector. According to the above figure, the
digital multimeter can be used for fault judgment on gear selector.
5-20
Fault detection of SG-6S gear selector

Pin diagram of gear selector X1 and X2 Wiring table of gear selector connector X2
connectors Terminal
Signal Guide wire color
No.
1 Power Black 6 (with 5A fuse)
POLBILD POLBILD 2 Vacant None
X1 X2
3 VM1 Black 8, brown
8 6 4 2 2 4 6 8
4 ED1 Black 9
5 ED3 Black 5
7 5 3 1 1 3 5 7
AMP AMP
6 AD9 Black 7
8-POL. 8-POL. 7 AD7 Black 10
BUCHSE STIFT
8 AD6 Green yellow
LG421507025
Use the multimeter for detection, and the
detection steps are as follows:
1. Turn off the electric lock, remove the

Wiring table of gear selector connector X1 mounting bolt of SG-6S gear selector, detect
for good earthing, adjust the digital
Terminal No. Signal Guide wire color
multimeter to ohm 200? range, and connect
1 Vacant None the pens to the No.3 hole earthing wire
2 Vacant None
(brown wire) of X2 connector and to any
earthing bolt in cab respectively. In theory,
Brown (ground the resistance to earth shall be0, the actual
3 VM2
cable)
measured resistance value shall be milliohm
4 AD5 Black 13 level, and the multimeter displays 0.00X or
5 AD1 Black 1 0.0X?; if the resistance value is bigger
obviously, check whether the harness is
6 AD4 Black 4
connected reliably and the earthing point is
7 AD2 Black 2 secure.
8 AD3 Black 3 2. After confirming good earthing, turn on the
electric lock without starting the engine,
adjust the digital multimeter to DCV 200V
range, measure whether the lever power is
connected normally, respectively connect the
digital multimeter pens to the No.1 hole
(black 6 wire) and No.3 hole (brown wire) of
X2 connector, and the multimeter shall
display between "24" and "31"V.
5-21
3. c. Disconnect the gear selector connector 6. Place the gear selector to N2 position, and
X1, and adjust the digital multimeter to DCV find out AD2 and AD6 output +24V voltage
200V range. The following combinations shall signal at N2 position according to the shift
be detected when each gear of gear selector output signal figure of gear selector. Adjust
is placed (the following abbreviations indicate the digital multimeter to DCV 200V range,
wire color and wire size): black 1, black 2, respectively connect the red pen to the #7
black 3, black 4, black 5, black 6, black 7, hole (black 2 wire) of X1 connector and and
black 8, black 9,black 10, black 13,brown #8 hole (greenyellow wire) of X2 connector,
and green yellow. (Caution: the emergency and the black pen to the #3 hole (brown wire)
brake switch must be pulled up! As the of X1 connector according to the wiring table
complete vehicle is beyond emergency of gear selector connector, and the digital
braking state at the moment, the complete multimeter shall display between "24" and
vehicle must be parked in a flat road, and "31"V.
chocks shall be placed below wheels to
7. Place the gear selector to forward 1st gear,
ensure that the complete vehicle will not
and find out AD2, AD3 and AD4 output +24V
move.)
voltage signal at forward 1st gear according
4. Place the gear selector to N position, and find to the shift output signal figure of gear
out AD6 output +24V voltage signal at N selector. Adjust the digital multimeter to DCV
position according to the shift output signal 200V range, respectively connect the red pen
figure of gear selector. Adjust the digital to the #6 hole (black 4 wire), #7 hole (black 2
multimeter to DCV 200V range, respectively wire), and #8 hole (black 3 wire) of X1
connect the red pen to the No.8 hole connector, and the black pen to the #3 hole
(greenyellow wire) of X2 connector, and the (brown wire) of X1 connector according to the
black pen to the No.3 hole (brown wire) of X1 wiring table of gear selector connector, and
connector according to the wiring table of the digital multimeter shall display between
gear selector connector, and the digital "24" and "31"V.
multimeter shall display between "24" and
8. Place the gear selector to forward 2nd gear,
"31"V.
and find out AD2, AD4 and AD5 output +24V
5. Place the gear selector to N1 position, and voltage signal at forward 2nd gear according
find out AD6 output +24V voltage signal at to the shift output signal figure of gear
N1 position according to the shift output selector. Adjust the digital multimeter to DCV
signal figure of gear selector. Adjust the 200V range, respectively connect the red pen
digital multimeter to DCV 200V range, to the #4 hole (black 13 wire), #6 hole (black
respectively connect the red pen to the No.8 4 wire), and #7 hole (black 2 wire) of X1
hole (green yellow wire) of X2 connector, and connector, and the black pen to the #3 hole
the black pen to the #3 hole (brown wire) of (brown wire) of X1 connector according to the
X1 connector according to the wiring table of wiring table of gear selector connector, and
gear selector connector, and the digital the digital multimeter shall display between
multimeter shall display between "24" and "24" and "31"V.
"31"V.
5-22
9. Place the gear selector to forward 3rd gear, 12. Place the gear selector to forward 6th gear of
and find out AD3, AD4 and AD7 output +24V forward gear, and find out AD5 and AD7
voltage signal at forward 3rd gear according output +24V voltage signal at forward 6th
to the shift output signal figure of gear gear according to the shift output signal
selector. Adjust the digital multimeter to DCV figure of gear selector. Adjust the digital
200V range, respectively connect the red pen multimeter to DCV 200V range, respectively
to the #6 hole (black 4 wire), #8 hole (black 3 connect the red pen to the #4 hole (black 13
wire) of X1 connector and the #7 hole (black wire) of X1 connector and the #7 hole (black
10 wire) of X2 connector, and the black pen 10 wire) of X2 connector, and the black pen
to the #3 hole (brown wire) of X1 connector to the #3 hole (brown wire) of X1 connector
according to the wiring table of gear selector according to the wiring table of gear selector
connector, and the digital multimeter shall connector, and the digital multimeter shall
display between "24" and "31"V. display between "24" and "31"V.
10. Place the gear selector to forward 4th gear, 13. n. Place the gear selector to reverse 1st gear,
and find out AD4, AD5 and AD7 output +24V and find out AD1, AD2, AD4 and AD9 output
voltage signal at forward 4th gear according +24V voltage signals at reverse 1st gear
to the shift output signal figure of gear according to the shift output signal figure of
selector. Adjust the digital multimeter to DCV gear selector. Adjust the digital multimeter to
200V range, respectively connect the red pen DCV 200V range, respectively connect the
to the #4 hole (black 13 wire) and #6 hole red pen to the #5 hole (black 1 wire), #6 hole
(black 4 wire) of X1 connector and the #7 (black 4 wire), #7 hole (black 2 wire) of X1
hole (black 10 wire) of X2 connector, and the connector and the #6 hole (black 7 wire) of
black pen to the #3 hole (brown wire) of X1 X2 connector, and the black pen to the #3
connector according to the wiring table of hole (brown wire) of X1 connector according
gear selector connector, and the digital to the wiring table of gear selector connector,
multimeter shall display between "24" and and the digital multimeter shall display
"31"V. between "24" and "31"V.
11. Place the gear selector to forward 5th gear, 14. Place the gear selector to reverse 2nd gear,
and find out AD3 and AD7 output +24V and find out AD1, AD4 and AD9 output +24V
voltage signal at forward 5th gear according voltage signals at reverse 2nd gear
to the shift output signal figure of gear according to the shift output signal figure of
selector. Adjust the digital multimeter to DCV gear selector. Adjust the digital multimeter to
200V range, respectively connect the red pen DCV 200V range, respectively connect the
to the #8 hole (black 3 wire) of X1 connector red pen to the #5 hole (black 1 wire) and #6
and the #7 hole (black 10 wire) of X2 hole (black 4 wire) of X1 connector and the
connector, and the black pen to the #3 hole #6 hole (black 7 wire) of X2 connector, and
(brown wire) of X1 connector according to the the black pen to the #3 hole (brown wire) of
wiring table of gear selector connector, and X1 connector according to the wiring table of
the digital multimeter shall display between gear selector connector, and the digital
"24" and "31"V. multimeter shall display between "24" and
"31"V.
5-23
CLG4215 Shift control solenoid valve
15. Place the gear selector to reverse 3rd gear,

and find out AD1 and AD9 output +24V
voltage signals at reverse 3rd gear according
to the shift output signal figure of gear
selector. Adjust the digital multimeter to DCV
200V range, respectively connect the red pen M4
to the #5 hole (black 1 wire) of X1 connector M3

and the #6 hole (black 7 wire) of X2
connector, and the black pen to the #3 hole M5
(brown wire) of X1 connector according to the M2
wiring table of gear selector connector, and

M1
the digital multimeter shall display between
"24" and "31"V.
LG421507027
Shift control solenoid valve The symbols of shift control valve schematic
are shown as follows:
There are five solenoids (M1~M5) in the shift
control solenoid valve, which are arranged as
shown in the following figure. When the operator
selects a gear, the signal from the gear selector
is sent to the solenoid group, ECU gives the 400 A Y5
corresponding gear engagement signal 401 B Y1
according to software computation, and it is 408 C Y2
realized by outputting the driving voltage to the 412 D Y3
solenoid. The solenoid is mainly used to control 416 E Y4
the opening/closing of clutch oil flow in the 420 F (-)
gearbox, so as to realize the gear engagement
or reversing of gearbox.
W1-X2
LG421507028
The corresponding relationship between the

solenoid and gear selector signal is as
follows:
Handle signal Solenoid valve

AD1 Y1/M1
AD2 Y2/M2
AD3 Y3/M3
LG421507026
AD4 Y4/M4
AD5 Y5/M5
VM2 (-)
5-24
Shift control solenoid valve CLG4215
The working diagram of solenoid and clutch is as shown in the following figure, and " ● "
indicates that the corresponding solenoid works.
INDUKTIVGEBER 65
ANTRIEBSDREHZAHL 63 KV K1
INDUCTIVE SENSOR 22
INPUT SPEED
1.NEBENABTRIEB
MOTOEABHAENGIG
ANTRIEB INPUT
1.POWER TAKE OFF
PVMPE 74 ENGINEDEPENDENT
52 KR K2 21
63
INDUKTIVGEBER
ABTRIEBSDREHZAHL
INDUCTIVE SENSOR
OUTPUT SPEED
65 52 51
36
27
K4 K3
52
37
ABTRIEB ABTRIEB
OUTRYT OUTRUT
45
MAGNET UNDER VOLTAGE

FORWARD REVERSE NEUTRAL
SPEED 1 2 3 4 5 6 1 2 3
M1
M2
M3
M4
M5
CLUTCH KV K4 KV K4 KV K4 KR KR KR K3
K1 K1 K2 K2 K3 K3 K1 K2 K3
LG421507029
The above figure gives the working condition of solenoid for each gear, and the working condition of the
corresponding meshed clutch. For instance, the machine is in forward 1st gear, the solenoids M2, M3
and M4 in the shift control valve work, and the clutches K1 and KV in the gearbox are meshed at the
same time. The above figure shows the control relationship between solenoids and clutches. They are
basically such that the solenoid M5 controls the clutch K4, M3 controls KV, M1 controls KR, the
solenoids are energized, and the clutches work. The solenoids M2 and M4 jointly control the clutches
K1, K2 and K3. When M4 is energized and M2 is not energized, the clutch K2 works. When both M2 and
M4 are energized, the clutch K1 works. When neither M2 nor M4 is not energized, the clutch K3 works.
Solenoid Valve Test
The resistances of solenoid valves are about 90?, and X9 is the solenoid valve group connector, located
on the shift control solenoid valve. After unscrewing X9 connector, you can see six ferrules, A, B, C, D, E
and F from the connector socket, where F is common for five solenoid valves. Detect at X9 connector
(the end of shift control solenoid valve) by the ohm 200? range of digital multimeter. The resistance
values of A-F, B-F, C-F, D-F and E-F shall be between 85? and 100?. Or, it can be judged that the
solenoid valveis damaged.
5-25
CLG4215 Output Speed Sensor
Output Speed Sensor
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. The
signal is sent to ECU for processing through harness connection.
Working principle of output speed sensor is as below:
TRANSMISSION
HOUSING SURFACE
LG421507030
The installation of speed sensor is very important, and the L value is generally kept at about 0.5+0.3mm.
As shown in the above figure, if L size is big, due to limited action of magnetic field, generally that the
action of magnetic field decreases as the distance increases, The coil fails to induce signals. If it is small,
the speed sensor may be cut by high-speed rotating gear due to mechanical error. If the sensor is
replaced from the Complete vehicle, remove the old speed sensor from the machine, clean the mounting
washer, install it on the new speed sensor, and screw up the new speed sensor into the sensor mounting
hole.
5-26
Lamp April 17, 2019
Headlight CLG4215
Lamp
The lighting system of grader consists of two Headlights, two work lights, two rear combination lights,
license plate light and dome light in the cab.
Headlight
LG421507031
The headlights fall into a left one and a tight one, installed at both sides of front frame. The headlight is a
combination light, including high/low beam, turn signal light and position light, which are respectively
controlled by the high/low beam switch, turn signal switch and position light switch.
Headlight parameter
Name of internal combination light Power

High beam light 75W
Headlight Low beam light 70W
Turn signal light 21W
Position light (lamplet) 10W
Connector model DJ7061-6.3-11

5-27
April 17, 2019 Lamp
CLG4215 Headlight
Schematic wiring diagram of Headlight
X51
EARTH WIRE 227GY1.25 3

408WH 4 RIGHT FRONT POSITION LIGHT
RIGHT TURN SIGNAL
416WH 5 RIGHT TURN SIGNAL LIGHT
LIGHT SWITCH
404WH1.25 1
405WH1.25 2 HIGH BEAM
LOW BEAM
6
6
LOW BEAM SWITCH 405WH1.25 LOW BEAM
2
HIGH BEAM
HIGH BEAM SWITCH 404WH1.25 1
LEFT TURN SIGNAL LIGHT SWITCH 415WH 5 LEFT TURN SIGNAL LIGHT
POSITION LIGHT SWITCH 408WH 4 LEFT FRONT POSITION LIGHT
X52
LG421507032
5-28
Lamp April 17, 2019
Work light CLG4215
Work light Rear combination light
BLADE WORK LIGHT
REAR COMBINATION
LIGHT
WORK
LIGHT
LG421507033 LG421507035
The rear combination light consists of rear

lamplet(position light), brake light, turn signal
REAR ROOF light and backup light, respectively controlled by
REAR ROOF
the lamplet switch, brake light relay, turn signal
LIGHT
LIGHT
switch and backup alert relay.
when the ripper is not provided, rear

combination light is installed on both sides of
engine hood.
LG421507034
Headlight parameter
The complete vehicle is provided with 8 work Name of internal

lights, including 2 front dome lights, 2 rear dome Power
combination light
lights, 2 work lights and 2 blade lighting lights.
Among then, the front work light switch controls 2 Rear Turn signal light 21W
front work light, the rear work light switch combination Brake light 21W
controls 2 rear work lights, the work light switch light
controls 2 work lights and 2 blade lighting lights. Backup light 21W
Rear lamplet (position
5W
Work light parameter light)
Connector DJ7021-1.5-11 (two cores)

24V, 70W, the lighting angle is adjustable.
model DJ7041-1.5-11 (four cores)
Wiring terminal: two M4*12 bolts.
5-29
April 17, 2019 Lamp
CLG4215 Rear combination light
Schematic wiring diagram of rear combination light
X56
REVERSING ALARM 422WH1.25 1
REVERSING ALARM
232GY1.25 2
RR COMBINATION LIGHT
226GY1.25 3
TURN SWITCH 416WH 4 RIGHT TURN SIGNAL LIGHT
421WH 2 BRAKE LIGHT
408WH 1 REAR POSITION LIGHT
X58
RL COMBINATION LIGHT

TURN SWITCH 415WH 4 LEFT TURN SIGNAL LIGHT
BRAKE RELAY 421WH 2 BRAKE LIGHT
POSITION LIGHT SWITCH 408WH 1 REAR POSITION LIGHT
X60
408WH 2 2
LICENCE PLATE LIGHT
226GY1.25 1 1
X87 X69
LG421507036
5-30
Lamp April 17, 2019
Dome Light and Licence Plate Light CLG4215
Dome Light and Licence Plate

License plate light parameter
Light
24V,10W
Connector model: AMP282104-1
Schematic wiring diagram of license plate

light
LICENCE PLATE
LIGHT
POSITION
LIGHT
SWITCH
408WH 1 1
EARTH
LG421507037
WIRE
226GY1.25
2 2
X87 X69
The dome light is in the cab, used for the internal

lighting of cab, controlled by its self-provided
switch. The license plate light is at the tail, used LG421507039
for lighting the license plate, controlled by the

position light switch.
Dome light parameter
24V,10W
Mounting screw: M5*18
Connector model: DJ7022-6.3-11
Schematic wiring diagram of dome light
DOME LIGHT
EARTH
2 233GY1.25 WIRE
POWER
1 144OR SUPPLY
0 1
X31
LG421507038
5-31
April 17, 2019 Rocker Switch
CLG4215 Dome Light and Licence Plate Light
Rocker Switch The switches control the connection and

disconnection of electrical appliances of lights,
wipers and washers. The switches are installed
on the instrument panel and control box panel in
the cab. The outline and interface drawings of all
FRONT
the switches are as follows:
WORK ROOF LIGHT
LIGHT
10
HEADLAMP
43.5
46
9
REAR ROOF WORK
LIGHT LIGHT
7 5 3 1
LG421507040
26
18.5
MUFFLER
SWITCH 50
LG421507042
REAR WIPER QUARTZ
SWITCH 1/2
1/1 20
24 28
32
HOURS
1
10
VOO
VOO
BEACON SWITCH
Rocker switch 34B0309
WASHING
SWITCH
FORCED
LUBRICATION
SWITCH
FRONT WIPER
SWITCH
HAZARD
FLASHER
SWITCH
LG421507041
LG421507043
5-32
Rocker Switch April 17, 2019
34B0309 Rocker combination switch

Gear Lock Special
Symbol Symbo
S/N Name Model descriptio buckl Reset descriptio
pattern l color
n e n
Mandatory 0 Lock
1 lubricating JK932-162 Green
switch I ① -- ⑤ With
0
Rotating
2 beacon JK939-002 I ① -- ⑤ Amber
switch
0
Silence
3 JK939-002 Amber
switch
I ① -- ⑤
4 Cover
Schematic wiring diagram is as blow:
1 5
418WH BUZZER
9 10
223GY
MUFFLER SWITCH
408WH
417WH ALARM SIGNAL
1 5 ROTATION
426WH1.25
BEACON
9 10
223GY
ROTATION
BEACONSWITCH 408WH
151OR1.25 POWER SUPPLY
1 5 FORCED
427WH1.25
LUBRICATION
9 10
223GY EARTH WIRE
FORCED
LUBRICATION POSITION LIGHT
SWITCH 408WH
SWITCH
(OPTIONALε
124OR1.25 POWER SUPPLY
LG421507047
5-33
LG421507048

Gear Lock
Res Symbol Symbo Special
S/N Name Model descripti buck
et pattern l color description
on le
0
Hazard flasher JK932-
1 I ① -- ⑤ Red
switch 157
② -- ⑥
0 ⑤ -- ⑦
Front wiper JK939-
2 I ③ -- ⑤ Green
switch 047
II ① -- ③
Switch of 0
JK939-
3 windshield Green
009
cleaner I ① -- ⑤ With
0 ⑤ -- ⑦
Rear wiper JK939-
4 I ③ -- ⑤ Green
switch 047
II ① -- ③
5-34
2
1
REAR WIPER MOTOR, 0
1
HIGH GEAR 429WH1.25 REAR WIPER SWITCH
REAR WIPER MOTOR, 5 3
430WH1.25
LOW GEAR
7
10 9
223GY
POSITION LIGHT SWITCH 408WH

POWER SUPPLY 309WH1.25
EARTHING 243GY1.25
5 1
WASHING MOTOR 428WH1.25
10 9
223GY
WASHING SWITCH
408WH
FUSE 140OR1.25
2
1
0
FRONT WIPER MOTOR, HIGH GEAR 431WH1.25 1
FRONT WIPER MOTOR, LOW GEAR 432WH1.25 5 3
7
FRONT WIPER SWITCH
10 9
223GY
408WH
POWER SUPPLY 308WH1.25
EARTHING 240GY1.25
5 1
HAZARD FLASHER 415WH
HAZARD FLASHER
6 2
416WH
10 9 HAZARD FLASHERSWITCH
EARTHING 223GY
408WH
FLASHER RELAY 414WH
LG421507049
5-35
Rocker combination switch 34B1263
LG421507050

Gear Lock Special
Symbol Symbo
pattern l color
n e n
0 Control work
Work light lights and
1 JK939-157 I ① -- ⑤ Green
switch blade work
② -- ⑥ light
Rear 0
2 dome light JK939-002 Green
switch I ① -- ⑤
1 5 136OR1.25 POWER
SUPPLY
2 6 161OR1.25 POWER
SUPPLY
WORK 9 10
LIGHT 210GY
SWITCH 408WH
BLADE WORK
402WH1.25 LIGHT
407WH1.25 WORK LIGHT
1 5 POWER
150OR1.25
SUPPLY
ROOF 9 10
210GY EARTH WIRE
LIGHT POSITION
SWITCH 408WH LIGHT
409WH1.25 FRONT ROOF
LIGHT
LG421507053
5-36
Rocker combination switch 34B0231
LG421507054

Gear Lock Symbol Symbol Special
S/N Name Model Reset
description buckle pattern color description
0
Control work
Headlight
1 JK939-028 I ③ -- ⑤ Green light and blade
switch
work light
II ① -- ③
0
Position light
2 JK939-002 Green
switch
I ① -- ⑤
3 5 LOW
405WH1.25
BEAM
1 HIGH
404WH1.25
HEADLAMP 9 10 BEAM
210GY
SWITCH
408WH
135OR1.25
POWER
SUPPLY
1 5 POWER
144OR
SUPPLY
POSITION 9 10 210GY EARTH
LIGHT WIRE
SWITCH
408WH POSITION
LIGHT
LG421507057
5-37
LG421507058
34B0233 Rocker switch

Gear Lock Special
Symbol Symbo
pattern l color
n e n
Front 0
1 dome light JK939-002 Green
switch I ① -- ⑤
1 5
134OR1.25 134OR1.25
9 10 210GY 210GY
REAR ROOF
LIGHT SWITCH
408WH 408WH
406WH1.25 406WH1.25
LG421507059
5-38
Sensor April 17, 2019
Sensor Overall dimension drawing
Sensors are signal acquisition components in the

complete vehicle, used for the display and alarm
of instruments. The CLG4215 grader is provided
with the water temperature sensor, oil
temperature sensor, engine oil pressure switch,
transmission oil pressure switch, fuel lever Gewinde
Thread
L
sensor, intake air filter alert switch, service brake
pressure switch and parking brake pressure
switch.
Water Temperature Sensor and

Oil Temperature Sensor LG421507061
The water temperature sensor and oil Installation position diagram

temperature sensor take charge of monitoring
the changes in engine water temperature and
torque converter oil temperature when the
complete vehicle is operating, and display the
changes in water temperature and oil WATER TEMPERATURE
SENSOR
temperature on the instruments, for the driver to

judge the operating conditions of complete
vehicle.
A1polig uber Masse1-pole

LG421507062
common GND 6.3x0.8mm
LG421507060 TORQUE CONVERTER OIL

TEMPERATURE SENSOR
LG421507063
5-39
April 17, 2019 Sensor
Technical parameter table is as below
Engine water temperature Torque converter oil

sensor 30B0183 temperature sensor 30B0207
Material Thermistor Thermistor
Rated voltage 6V~24V 6V~24V
Thread size 1/2-14NPTF M14X1.5
Wiring terminal 6.3*0.8 6.3*0.8
L(mm) 29 29
?(mm) 9 9
Resistance in work temperature (?) 90°C=51.2±4.3 120°C=36.5±2.7
Maximum temperature (°C) 120 150
Output property list Property list I Property list II
Sensor output property list
Property list I
°C R(Ohm) ±Tol (%) ±Tol (Ohm)

-40.0 36563.56 14.26 5212.38
-35.0 26284.63 13.87 3645.02
-30.0 19149.20 13.48 2581.56
-25.0 14127.68 13.11 1851.71
-20.0 10540.68 12.77 1346.27
-15.0 7721.35 12.60 972.85
-10.0 5720.88 12.45 712.14
-5.0 4284.03 12.32 527.68
0 3240.18 12.21 395.75
5.0 2473.60 12.13 300.01
10.0 1905.87 12.05 229.70
15.0 1486.65 12.10 179.88
20.0 1168.64 12.17 142.19
25.0 926.71 12.25 113.52
30.0 739.98 12.34 91.32
35.0 594.90 12.43 73.97
40.0 481.53 12.51 60.26
45.0 392.57 12.36 48.51
50.0 322.17 12.17 39.20
5-40
Property list I
°C R(Ohm) ±Tol (%) ±Tol (Ohm)

55.0 266.19 11.97 31.87
60.0 221.17 11.77 26.02
65.0 184.72 11.60 21.42
70.0 155.29 11.36 17.64
75.0 131.38 11.00 14.45
80.0 112.08 10.48 11.75
85.0 96.40 10.00 9.64
90.0 82.96 9.68 8.03
95.0 71.44 9.32 6.66
100.0 61.92 8.87 5.49
105.0 54.01 8.45 4.56
110.0 47.24 8.07 3.81
115.0 41.42 7.73 3.20
120.0 36.51 7.32 2.67
125.0 32.38 7.36 2.38
130.0 28.81 7.41 2.14
135.0 25.70 7.76 1.99
140.0 23.00 8.09 1.86
145.0 20.66 8.36 1.73
150.0 18.59 8.66 1.61
155.0 16.74 8.85 1.48
160.0 15.11 9.04 1.37
165.0 13.66 9.24 1.26
170.0 12.38 9.46 1.17
175.0 11.25 9.67 1.09
180.0 10.24 9.90 1.01
5-41
Property list II
°C R (Ohm) ±Tol (%) ±Tol (Ohm)

-40.0 17162.35 16.93 2906.00
-35.0 12439.50 16.32 2029.83
-30.0 9134.53 15.72 1435.77
-25.0 6764.48 15.13 1023.58
-20.0 5067.60 14.56 737.59
-15.0 3833.89 14.14 542.02
-10.0 2929.90 13.75 40.82
-5.0 2249.44 13.37 300.80
0 1743.15 13.00 226.69
5.0 1364.07 12.65 172.56
10.0 1075.63 12.34 132.75
15.0 850.09 12.18 103.51
20.0 676.95 12.02 81.36
25.0 543.54 11.74 63.83
30.0 439.29 11.50 50.52
35.0 356.64 11.38 40.59
40.0 291.46 11.25 32.79
45.0 239.56 11.11 26.62
50.0 197.29 11.20 22.10
55.0 161.46 10.86 17.54
60.0 134.03 10.04 13.46
65.0 113.96 9.86 11.23
70.0 97.05 9.87 9.58
75.0 82.36 9.49 7.82
80.0 70.12 9.21 6.46
85.0 59.73 8.91 5.32
90.0 51.21 8.48 4.34
95.0 44.32 8.07 3.58
100.0 38.47 7.74 2.98
105.0 33.40 8.18 2.73
110.0 29.12 8.59 2.50
115.0 25.53 9.22 2.35
120.0 22.44 9.89 2.22
5-42
Property list II
°C R (Ohm) ±Tol (%) ±Tol (Ohm)

125.0 19.75 10.53 2.08
130.0 17.44 11.16 1.95
135.0 15.46 11.82 1.83
140.0 13.75 12.49 1.72
145.0 12.26 13.17 1.61
150.0 10.96 13.86 1.52
Fault detection
Adjust the digital multimeter to " Ω " 200 Ω range, connect one pen to the sensor wiring terminal and
other pen to the nearest frame ground, measure resistance, and find out the temperature value
according to the property list. Measure the temperature of cylinder body near the sensor by a
thermometer. Compare the difference between two temperature values. If the difference is within 5°C, it
indicates that the sensor is ok.
5-43
CLG4215 Pressure Switch
Pressure Switch Installation position diagram
The pressure switches are used to detect

pressure signals, and output alert signals for the
alarm display of instruments. The complete
vehicle is provided with engine oil pressure
switch, transmission oil pressure switch, service
brake pressure switch and parking brake
TRANSMISSION
pressure switch. PRESSURE SWITCH
EXTERNAL THREAD
CONNECTION
LG421507066
AMP 6.3x0.8
TINPLATING
46
hex 24
9 SERVICE BRAKE
PRESSURE SWITCH
LG421507064
PARKING BRAKE
PRESSURE SWITCH

LG421507067
ENGINE OIL
PRESSURE SWITCH
LG421507065
5-44
Pressure Switch CLG4215
Transmission oil Service brake pressure

Engine oil pressure
pressure switch switch and parking brake
switch 30B0131
30B0132 pressure switch 13C0078
Material Galvanized steel Galvanized steel Galvanized steel
Maximum voltage 42V 42V 42V
Switch power 100VA 100VA 100VA
Rated current 4A 4A 4A
Thread size NPT1/8 M10*1 NPT1/8
Wiring terminal AMP6.3*0.8 AMP6.3*0.8 AMP6.3*0.8
Switch contact Normally closed contact Normally closed contact Normally closed contact
Operating value (MPa) 0.059 1.45 10
Pressure adjusting state Action during lifting Action during lifting Action during lowering
Adjusting range, allowable
[0.01,0.1]±0.02 [1,2]±0.1 [5,15]±0.5
tolerance
Working principle
3
5
2
1
LG421507068
As shown in the above figure, the left is a diaphragm pressure switch with a group of normally open
contacts, the right is a piston pressure switch with a group of normally closed contacts, and the following
will explain the working principle of pressure switch by taking the left one in the above figure as an
example. The measured medium acts on the diaphragm (2) after passing the pressure switch junction
(2); if the pressure of the measured medium is higher than the pretightening force of compression spring
(3), the plunger (4) will drive the contact disc (5) to move, so as to close the circuit between contacts (6).
When the drop of the measured medium pressure is greater than hysteresis, the switch will be opened
again. For the pressure switch with normally closed contacts, its contacts act reversely. The actuation
pressure of pressure switch can be adjusted by turning the adjusting stud (7). The actuation pressure of
pressure switch has been adjusted when leaving factory, and marked with colored paint. The adjusting
screw can not be adjusted at will, or the actuation value will change to cause safety accidents.
5-45
CLG4215 Fuel Level Sensor
Fuel Level Sensor

The dry reed fuel level sensor consists of shaft
made of polished aluminum-alloy pipe, annular
magnetic float capable of moving up and down
along the shaft, and internal printed circuit board.
Two permanent magnets are embedded in the
floating ball.
25
62.5±4
L9
142.5±4
212.5±4
L8 LG421507070
297.5±4
372.5±4
L7
442.5±4
482.5±4

542.5±4
592.5±4
L6
Fuel level sensor
675±4
L5
30B0672
Material Galvanized steel
L4
L3
Rated voltage 24V
Continuous work
L2 15-40V
voltage
L1 Electrical connection
DJ7021-1.5-11
mode
#1 pin description Signal cable (blue)

#2 pin description Earthing cable (black)
LG421507069 Working medium Diesel fuel
5-46
Intake Air Filter Alert Switch CLG4215
Output property list
Upper plane position

Below L1 L1-L2 L2-L3 L3-L4 L4-L5
of float
Output resistance
78±2 70±1 64±2 56±2 48±2
value (?)
Upper plane position
L5-L6 L6-L7 L7-L8 L8-L9 Above L9
of float
Output resistance
40.5±2 33±2 25±2 17±2 9±2
value (?)
Intake Air Filter Alert Switch
The intake air filter alert switch is provided together with the air filter. When the air filter is clogged, it
outputs alert signal to the alarm light in the cab.
AIR FILTER CLOGGING

ALARM SWITCH
LG421507071
QUARTZ
HOURS
1/2 24 28 1
20 10
1/1 32
VOO VOO
AIR FILTER
CLOGGING ALARM
LG421507072
5-47
April 17, 2019 Instrument
CLG4215 Water Temperature Gauge and Oil Temperature Gauge
Instrument
The instrument system of complete vehicle is used to display the complete vehicle state messages and
various alarm messages of water temperature, oil temperature, voltage, fuel level, etc. The instruments
include: water temperature gauge, oil temperature gauge, fuel level gauge, voltmeter, service hour meter
and alarm light.
Water Temperature Gauge and Oil Temperature Gauge
The water temperature gauge and oil temperature gauge are used together with the engine water
temperature sensor and torque converter oil temperature sensor. They are used to display the water
temperature of engine and the oil temperature of torque converter.
72.5mm max
61.1mm
64mm
55.6mm 38.5mm
39mm 10.5mm
44.3mm
5mm
4mm
11mm 14mm
15mm
dia. 52mm
19.7mm
18mm dia 1.5mm 12.8mm
49mm
0.5 ... 8mm

Clamping width
LG421507073
C C
80 100 100
60 120 60 160
TORQUE
ENGINE WATER
CONVERTER OIL
TEMPERATURE
TEMPERATURE
GAUGE
GAUGE
LG421507074
5-48
Instrument April 17, 2019
Water Temperature Gauge and Oil Temperature Gauge CLG4215
Engine water temperature Torque converter oil

gauge 35B0096 temperature gauge 35B0097
Rated voltage 21.5V~30V 21.5V~30V
Temperature display range 40~120°C 50~150°C
"+" Terminal wiring Power Power
"-" Terminal wiring Ground Ground
"S" Terminal wiring Sensor Sensor
Instrument display property list Property list I Property list II
Property list I
Dial scale (°C) 40 50 60 70 80 90 100 110 120
Resistance (?) 287.4 193.3 134 95.2 69.1 51.3 38.6 29.4 22.7
Pointer deflection
0 3.3 8.3 15.5 25.8 40 58 75.2 88.2
angle (°)
Angle tolerance (°) ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6
Property list II
Dial scale (°C) 50 80 90 100 110 120 130 140 150
Resistance (?) 322.8 112.5 83 62.2 47.5 36.5 28.9 23.1 18.6
Pointer deflection
0 12.4 19.8 29.6 42 56.8 69.7 80.2 88.1
angle (°)
Angle tolerance (°) ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6
5-49
CLG4215 Fuel Gauge
Fuel Gauge
The fuel gauge is used to display the residual diesel amount in the fuel tank, and used together with the
fuel level sensor.
$"%&

64mm
#

!!
5mm
4mm
11mm 14mm
15mm
"
$
# '% "#
49mm
#

*<%=>'?
@[!"$$
QUARTZ
HOURS
1/2 24 28 1
20 10
1/1 32
VOO
VOO
1/2
1/1
VOO
LG421507076
5-50
Voltmeter CLG4215
Fuel level gauge 35B0098

Rated voltage 21.5V~30V
"+" Terminal wiring Power
"-" Terminal wiring Ground
"S" Terminal wiring Sensor
Instrument display property list Property list
Property list
Dial scale 0 1/4 1/2 3/4 1/1
Resistance ( Ω ) 60~90 0.5
Pointer deflection angle (°) 0 22 44 66 87.4

+0 +5.4
Angle tolerance (°)
-5.4 -0
Voltmeter
The voltmeter is used to display the voltage of electrical system.

72.5mm max
61.1mm
64mm
55.6mm 38.5mm
39mm 10.5mm
44.3mm
5mm
4mm
11mm 14mm
15mm
dia. 52mm
19.7mm
18mm dia 1.5mm 12.8mm
49mm
0.5 ... 8mm

Clamping width
LG421507077
5-51
CLG4215 Hourmeter
QUARTZ
HOURS
1/2 24 28 1
20 10
1/1 32
VOO
VOO
24 28
20
32
VOO
LG421507078
Voltmeter 35B0099
Rated voltage 18V~32V
“+” Terminal wiring Power
“-” Terminal wiring Ground
Hourmeter
38max 37
0.8-0.6mm
QUARTZ
2-M4
HOURS
38±0.25
24±0.25
1
64
10
!!\
12.8±0.5 11
47.3±0.5
#
LG421507079
5-52
Hourmeter CLG4215
QUARTZ
HOURS
24 1
1/2
1/1
20 28
32
10
QUARTZ
VOO
VOO
HOURS
1
10
LG421507080
Hourmeter 35B0038
Working voltage 8V~60V
Measuring range 0~99999.9h
Precision ±0.1%
Adapter terminal 4.8*0.6
5-53
CLG4215 Alarm Light
Alarm Light Installation position diagram
The alarm lights are used for the indication and

alarm of complete vehicle messages, including
left and right turn indicators, high beam indicator,
charging indicator, service brake low-pressure
alarm light, parking brake low-pressure alarm
light, engine oil pressure alarm light,
transmission oil pressure alarm light, engine ALARM
water temperature alarm light (not enabled) and INDICATOR
main alarm light (not enabled). When any of the

service brake low-pressure alarm light, parking
brake low-pressure alarm light, engine oil
pressure alarm light and transmission oil LG421507083
pressure alarm light is on, the buzzer in the

instrument desk will sound to remind the driver to
stop the vehicle and check. The silence switch
can control the buzzer volume.
50 20 10
E L
D I
3
100
C H
B J
A F
54
LG421507081
46
K
98
LG421507082
5-54
Alarm Light CLG4215
Rated voltage
Descriptio Rated power for
Icon for position Color Pin
n position light
light
Left turn 24V 2W Green, flashing J1/J2
Service brake
low voltage 24V 2W Red J5/J6
alarm
Engine water
temperature 24V 2W Red K1/K2
alarm
Parking brake
low voltage 24V 2W Red K5/K6
alarm
Right turn 24V 2W Green, flashing K9/K10
Headlight
24V 2W Blue J3/J4
high beam
Charging
24V 2W Red J7/J8
indication
Chief alarm
24V 2W Red K3/K4
light
Engine oil
pressure 24V 2W Red K7/K8
alarm
Transmission
oil pressure 24V 2W Red K11/K12
alarm
5-55
April 17, 2019 Wiper System
CLG4215 Alarm Light
Wiper System
The wiper system of CLG4215 grader consists of washer reservoir, wiper, nozzle and rocker switch. The
wiper is installed on the front glass of cab, and the washer reservoir is installed below the cab,
respectively controlled by the wiper switch and washer reservoir switch. The wiper has a high-speed
position and a low-speed position, capable of resetting automatically. The motor has five externally
connected wires, where the red is power wire (common brush lead of high-speed armature and low-
speed armature, connected with #140 wire), the black is negative wire (connected with earth through
motor housing, connected with #240 earthing wire), the blue is the other brush lead of high-speed
armature (connected with #431 wire), the green is the other brush lead of low-speed armature
(connected with #432 wire), and the white is reset wire (connected with #308 wire).
Schematic diagram
WASHING SWITCH FRONT WIPER SWITCH
9
9
1
1 0
2
1
10
10
5
X32
428WH1.25
140OR1.25
431WH1.25
432WH1.25
308WH1.25
240GY1.25
8
7
FRONT WIPER MOTOR
6
5 308WH1.25
R
2 240GY1.25
E
M 3 431WH1.25
H
4 432WH1.25
L
1 140OR1.25
B
15A
+24V
WASHING MOTOR
1 428WH1.25
M 2 231GY1.25
X55
LG421507084
April 17, 2019
CLG4215
@[!"$#
100±2
110±2
ROTATE IN
DIRECTION A
`j$"^^"
LG421507085
Slice×rod=450×550
HOLE 19
TAPPING
NEGATIVE 172±2
TERMINAL POSITIVE
WIRE WIRE
(BLACK ε (REDε
150±2
43±2
74
94±3°
220
MOUNTING PLATE
^"_
20
_"
241±2
251±2
!
_"
WIRE HARNESS
LENGTH 380±10
`j$"^^"
_
A
Wiper System
Alarm Light
AIR DUCT WATER PIPE LENGTH 380±10
5-56
5-57
April 17, 2019 Wiper System
CLG4215 Alarm Light

Installation position diagram Wiper 46C7200
Working voltage 24V
Power 50W
Motor connector KET32510008
Washer reservoir
46C0708
Working voltage 24V
Power 30W
Motor connector DJ7021-1.5-21

LG421507087
LG421507088
LG421507089
5-58
Sound System April 17, 2019
Alarm Light CLG4215
Sound System
The sound system consists of radio, speaker and antenna. You can use the radio and tape player after
turning on the electric lock. A standard USB interface is reserved for the radio, available for connecting
USB devices, only supporting MP3 audio files.
Schematic diagram
X36
LEFT
2 436WH
LOUDSPEAKER 1 435WH
2 434WH
RIGHT
LOUDSPEAKER 1 433WH
X35
X34
LEFT
LOUDSPEAKER 7 435WH
LEFT
LOUDSPEAKER 8 436WH
RIGHT
LOUDSPEAKER 2 433WH
RIGHT
RADIO LOUDSPEAKER
1 434WH
1
GROUND 8 236GY
POWER SUPPLY + 4 141OR 7.5A

POWER SUPPLY + 7 141OR +24V
X33
LG421507090
5-59
April 17, 2019 Sound System
CLG4215 Alarm Light
79ERF
8 6 4 2
A
7 5 3 1
5
8 6 4 2
B
7 5 3 1
BLOCK ASSY XALE24 178.6
8.5ERF
50
152.5
10 B
86.1
LIUGONG
46.1
60±0.4
52.1
ORIGINRL
190±0.4
LG421507091
1110±20
593±3
{
z"@
@{|*@}"z @
PP B
C3604B Cr/B BASE COVER 16*49.5*26
ABS B
SHIM
ANTENNA MAST 19.2*52.5*7
14.5±0.2
ANTENNA MAST SUPPORT ABS B
"z$#@ 23*26*14.6
(33)
SUS304 Cr/B ABS B(PAINTING ε

4.8
(52.5)
SUPPORT SHIM17.6*25.5*14.6
EPDM B *~!z@ *~!z@
SUS304 N SUS304 N
25.5
R9 *|@*@@|
3C2V
R6.3
(18ε
3.175±0.078
13±0.5
R7.5
19.4
R9.7
@[!"$"
5-60
Alarm Light CLG4215
132
4-
2.
5
BUSHING BF7021-1.5-21
4 -5
BLUE/WHITE
33.2
38
116
WHITE
50
SCREEN DJ6211-1.5-21 55
93
12 102
6
LG421507093
LG421507094 LG421507095
5-61
April 17, 2019 Sound System
CLG4215 Alarm Light
Technical parameter table
Radio 37B0769 Speaker 38B0047 Antenna 37B0243

Rated voltage 24V
Maximum working
5A
current
Resistance 4Ω
Power 10W
DJ7082A-3.5-10
Connector DJ7021-1.5-21
DJ7082-3.5-10
5-62
Alarm Light CLG4215
Fault detection
Function illustration diagram
Fault mode: The player panel displays normally,
but there is no sound or the sound volume is too
1 2 4 5 13 14 small.
7 15
Ensure that the player is in radio or play state,
and detect whether there is voltage at the
LIUGONG speaker positive and negative terminals by
digital multimeter; if any, check the speaker.
ORIGINRL Whether the speaker is good or not can be
judged by detecting the resistance of speaker
positive and negative terminals, which shall be
11 equal to or close to the rated resistance of
3 6 8 9 10 12 speaker; if the resistance is 0 or the speaker is
LG421507096 open, the speaker is damaged. If there is no
voltage at the speaker positive and negative
terminals, check whether the wiring and
1. Power connector are loose or open.
2. Sound mode/switching source
3. Volume adjusting
4. Radio reset key 1/track position
5. Radio preset key 2 Radio reset key 3/pause and play
6. Radio preset key 4 / PREV
7. Radio preset key 5 / NEXT
8. Radio reset key 6/track scan
9. Forward search / Prev song / adjusting hour
10.Automatic station storage/enter and exit setting
screen
11.Backward scan/next track/adjusting minute
12.Standard audio input interface
13.USB interface
14.Radio band selection
5-63
April 17, 2019 Preheating system
CLG4215 Alarm Light
Preheating system
The engine of CLG4215 grader is provided with an air intake preheating unit, which is applicable to heat
air into the engine at low temperature, thus improving start performance. The preheating system consists
of electric lock, fuse, preheating contactor, preheating indicator and preheating unit. Turn the electric
lock to "I" position (see “Starter Switch (Electric Lock)”) before start; at the moment, the electric lock
sends signal to the coil terminal of preheating contactor to close the contact terminal of preheating
contactor, the battery power passes 150A fuse to supply power to the preheating unit, and the
preheating indicator in the cab comes on at the same time. The preheating process will keep about 45s,
and the electric lock needs to be maintained at "I" position manually all the time.
Schematic diagram
ELECTRIC LOCK PREHEATING INDICATOR
G1 M G2 S
P 01 2
B1 B2
108OR1.25
487WH
203GY
560WH
224GY
149OR15.0
488OR15.0
10A
560WH
487WH
5A
+24V PREHEATER R8 PREHEATING CONTACTOR
NEGATIVE TERMINAL SWITCH 149OR15.0 100OR15.0
FUSE 150A
BK50.0 BK50.0 RD50.0 100OR15.0
LG421507097
5-64
Preheating system April 17, 2019
Alarm Light CLG4215
Overall dimension drawing - preheating contactor
85.5
66 56
38 26
2-M8
2-M4
24.5
88
2-M5.5
37 2
47±0.1
LG421507098
Overall dimension drawing - preheating indicator

21
30
13 E
54
58
LG421507099
Installation position diagram – preheating device
PREHEATING
DEVICE
LG421507100
5-65
April 17, 2019 Preheating system
CLG4215 Alarm Light
Installation position diagram – preheating contactor and fuse are installed in
PREHEATING
CONTACTOR
FUSE 150A
LG421507101
QUARTZ
HOURS
1/2 24 28 1
20 10
1/1 32
VOO
VOO
人✣᤽⽰⚥
LG421507102
Technical parameter table - preheating contactor
31B0011 Start relay parameter table

Rated voltage 24V
Rated load current of main contact circuit 200A
Specification for main contact terminal 2-M8
Specification for coil terminal 2-M4

5-66
Main Circuit Fuse April 17, 2019
Alarm Light CLG4215
Main Circuit Fuse
The CLG4215 grader is provided with four main circuit fuses, which are screw-down plate fuses. They
protect the charging circuit, complete vehicle main power circuit, air conditioning system and preheating
system. Their settings are 80A, 60A, 30A and 150A respectively.

5
5

LG421507103
TWO-WAY
FUSE BOX
TWO-WAY
FUSE BOX
LG421507104
Technical parameters
30A fuse piece 60A fuse piece 80A fuse piece 150A fuse piece
37B0776 37B0708 37B0709 37B0710
Rated voltage 32V 32V 32V 32V
Color Orange Yellow White Gray

5-67
April 17, 2019 Main Power Circuit
CLG4215 Alarm Light
Main Power Circuit
The main power circuit consists of battery, disconnect switch, fuse, electric lock and main power
contactor. When the disconnect switch is closed and the electric lock is turned to "ON" position, the
battery supplies power to the electrical appliances of complete vehicle.
Schematic diagram
ELECTRIC LOCK
CENTRAL MAIN POWER SUPPLY
CONTROL BOX CONTACTOR
G1 M G2 S TWO-LEVEL
P 01 FUSE
2
B1 B2
200GY1.25
108OR1.25
123OR1.25
123OR1.25
122OR8.0
180OR8.0
105OR8.0
1.ELECTRIC LOCK
10A
108OR1.25
FUSE 80A
100OR15.0 102OR15.0 B+
105OR8.0
FUSE 60A E GENERATOR
NEGATIVE TERMINAL SWITCH

D+
100OR15.0 RD50.0 BK50.0 BK50.0
LG421507105
5-68
Main Power Circuit April 17, 2019
Alarm Light CLG4215
Schematic diagram introduction
When the disconnect switch is closed, the battery supplies power to the electric lock through #100 wire,
60A fuse and #105 wire first and then through #118 wire and 10A fuse; when the electric lock is turned to
"ON" position (see “Starter Switch (Electric Lock)” for the description of positions), the main power
contactor coil supplies power through #123 wire of electric lock, the main power contactor contacts are
closed, and #122 wire is energized through #105 wire and supplies power to the complete vehicle as it is
connected with the control box of complete vehicle; at the moment, electrical appliances can work
normally. Before the engine starts, the battery supplies power to electrical appliances. After the engine
starts, the #102 wire at B+ terminal supplies power to electrical appliances, and charges the battery at
the same time.
Fault detection of main power circuit
If there is no power on the complete vehicle after turning on the electric lock, check according to the
following steps.
1. Turn on the electric lock, and listen to the pull-in sound of main power contactor; if any, go to next
step; if not, go to Step 4.
2. Detect whether 60A fuse is blown, and replace the fuse if blown; if the fuse is ok, measure whether
there is 24V voltage at #105 wire of contactor terminal; if any, go to next step; if not, check whether
the wiring of #100 and #105 wires is loose or open.
3. The contact terminal of main power contactor is faulty, replace main power contactor.
4. Repeat Step 2, detect whether 60A fuse is blown, and replace the fuse if blown; if the fuse is ok,
measure whether there is 24V voltage at #118 wire of electric lock fuse terminal; if any, go to next
step; if not, check whether the wiring of #100 and #105 wires is loose or open.
5. Check the 10A fuse of electric lock is blown; if any, replace the fuse; if not, go to next step.
6. Measure whether there is 24V voltage at #108 wire of electric lock terminal; if not, check whether
#108 wire is loose; if any, go to next step.
7. Measure whether there is 24V voltage at the terminal 123 of electric lock; if not, it is judged that the
electric lock is faulty, and replace it; if any, go to next step.
8. Measure whether there is 24V voltage at #123 wire of main power contactor coil terminal; if not,
check whether #123 wire is loose; if any, go to next step.
9. Measure whether #200 earthing wire of main power contactor coil terminal is conducted; if not, check
whether #200 wire is loose; if any, it is judged that the main power contactor is faulty, and replace it.
5-69
April 17, 2019 Main Power Circuit
CLG4215 Alarm Light
Fault detection flow chart
OPEN ELECTRIC
LOCK , CHECK IF
MAIN POWER
SUPPLY CONTACTOR
IS PULLED IN
YES NO
CHECK IF CHECK IF 60A

60A FUSE IS FUSE IS BLOWN
BLOWN
NO YES NO YES
CHECK IF CHECK IF
CONTACTOR END REPLACE FUSE END 118# REPLACE
105# WIRE HAS 24V THE FUSE WIRE HAS 24V THE FUSE
VOLTAGE VOLTAGE
NO YES YES NO
REPLACE THE CHECK IF

WIRE LOOSE 10A FUSE IS WIRE LOOSE
CONTACTOR
BLOWN
REPLACE NO YES
CONTACTOR WIRE LOOSE
CHECK IF 108# REPLACE

YES NO WIRE HAS 24V THE FUSE
VOLTAGE
CHECK IF
CONTACTOR
END 200# WIRE WIRE LOOSE NO
TO EARTH IS YES
CONNECTED
CHECK IF
ELECTRIC LOCK
YES NO END 123# WIRE WIRE LOOSE
HAS 24V
VOLTAGE
CHECK IF
CONTACTOR
END 123# WIRE YES NO
HAS 24V
VOLTAGE
ELECTRIC
LOCK FAULT
LG421507106
5-70
Starter Circuit April 17, 2019
Alarm Light CLG4215
Starter Circuit
The start circuit consists of battery, disconnect switch, fuse, start contactor, neutral interlock relay,
electric lock, start motor, gear selector, etc. Close the disconnect switch, turn the electric lock to "START"
position when the gear selector is in N position, and the complete vehicle will start.
Schematic diagram
MAIN POWER START NEUTRAL GEAR ELECTRIC LOCK

SUPPLY CONTACTOR CONTACTOR INTERLOCKING RELAY
G1 M G2 S
P 01
2
B1 B2
87A
30
86
85
87
125OR1.25
423WH1.25
108OR1.25
424WH8.0
220GY1.25
105OR8.0
118OR8.0
121OR8.0
423WH1.25
200GY1.25
125WH1.25
512WH
50A
10A
GEAR SELECTION
NEUTRAL GEAR SIGNAL
30
424WH8.0
100OR15.0
50
105OR8.0
FUSE 60A START

NEGATIVE TERMINAL SWITCH M MOTOR
BK50.0 BK50.0 RD50.0 RD50.0
LG421507107
5-71
April 17, 2019 Starter Circuit
CLG4215 Alarm Light
The CLG4215 grader can be started only when the handle is in N position. If the disconnect switch is
closed, a signal is outputted to the neutral interlock relay when the handle is in N position, and the
neutral interlock relay is closed. When the electric lock is turned to "START" position (see “Starter Switch
(Electric Lock)” for the description of positions), #125 wire of electric lock is energized, the start contactor
coil terminal 423 is energized through neutral interlock relay contact terminal, the start contactor is
closed, the battery supplies power to the start motor control terminal through #100 wire, 60A fuse, #105
wire, #118 wire, 50A fuse, #121 wire and #424 wire, the solenoid switch in start motor is closed, the main
circuit of start motor is connected, the battery supplies large start current to the start motor through the
battery cable (+), and the start motor starts so as to start the engine.
Fault detection of start circuit
Fault phenomenon: unable to start

1. Detect whether the battery cable (+) is loose or broken; if any, tighten immediately or replace the
cable.
2. Measure whether the voltage at the terminal 30 of start motor is above 24V with digital multimeter; if
not, check whether the battery is undercharged (see 7.3) according to the battery detection method.
3. Measure whether there is 24V voltage at the terminal 50 of start motor; if any, the start motor is
damaged, and let the dealer detect the start motor; if not, go to next step.
4. Measure whether there is 24V voltage at the terminal 121 of start contactor; if not, go to next step; if
any, go to Step 6.
5. Check whether 50A and 60A fuses are blown; if any, replace fuses; if not, check whether No.100,
No.105, No.118 and No.121 wires are loose.
6. Measure whether there is 24V voltage at the terminal 423 of start contactor when turning the electric
lock to START position; if any, go to next step; if not, go to Step 8.
7. Measure whether the terminal 220 of start contactor is conducted to earth; if any, it is judged that the
start contactor is faulty, and replace it; if not, No.220 wire is loose.
8. Measure whether there is 24V voltage at the terminal 125 of neutral interlock relay when turning the
electric lock to START position; if any, go to Step 12; if not, go to next step.
9. Measure whether there is 24v voltage at the terminal 125 of electric lock when turning the electric
lock to START position; if any, No.125 wire is loose; if not, go to next step.
10. Check whether there is 24V voltage at the terminal 108 of electric lock; if any, the electric lock is
faulty, and replace it; if not, go to next step.
11. Check whether 10A fuse is blown; if any, replace fuses; if not, check whether wires are loose.
12. Measure whether there is 24V voltage at #512 wire of neutral interlock relay terminal; if any, go to
next step; if not, the gear selector is faulty, and detect according to the detection method of gear
selector (see “SG-6S gear selector”).
13. Measure whether neutral interlock relay #200 wire is connected to earth; if connected, the neutral
interlock relay is faulty, and replace it; if not, check whether the wire is loose or open.
5-72
Starter Circuit April 17, 2019
Alarm Light CLG4215
CHECK IF START
MOTOR 30 END
HAS MORE THAN
24V VOLTAGE
NO
YES
YES
BATTERY
UNDERVOLTAGE CHECK IF START
START MOTOR MOTOR
50 END HAS DAMAGED
24V VOLTAGE
NO NO
CHECK IF START CHECK IF 50A,

CONTACTOR END 60A FUSE IS
YES 121 HAS 24V BLOWN
VOLTAGE
CHECK IF START
CONTACTOR 423
HAS 24V NO YES
VOLTAGE
REPLACE
WIRE LOOSE
THE FUSE
YES NO
CHECK IF START CHECK IF NEUTRAL

GEAR
CONTACTOR 220 INTERLOCKING YES
TO EARTH IS RELAY 125 END HAS
CONNECTED 24V VOLTAGE
CHECK IF 512
NO YES NO WIRE HAS 24V
VOLTAGE
CHECK IF
REPLACE START ELECTRIC LOCK
WIRE LOOSE CONTACTOR 125 END HAS YES NO
24V VOLTAGE
NO YES
CHECK IF 200# GEAR
WIRE TO EARTH SELECTION
IS CONNECTED FALUT
REPLACE CHECK IF 108#

THE FUSE WIRE LOOSE WIRE HAS 24V WIRE LOOSE
VOLTAGE YES NO
YES NO NO YES REPLACE

NEUTRAL GEAR WIRE LOOSE
INTERLOCKING
RELAY
REPLACE
10A FUSE POWER
IS BLOWN SUPPLY
LG421507108
5-73
April 17, 2019 Shutdown Circuit
CLG4215 Alarm Light
Shutdown Circuit
The schematic diagram circuit consists of battery, disconnect switch, electric lock, shutdown contactor,
fuse and shutdown valve. It controls the throttle to pen during start, and to close during parking.
Schematic diagram
ELECTRIC LOCK
FLAMEOUT MAIN POWER
CONTACTOR SUPPLY CONTACTOR
G1 M G2 S
P 01
2
B1 B2
108OR1.25
125OR1.25
123OR1.25
125OR1.25
200GY1.25
425WH3.0
120WH3.0
105OR8.0
118OR8.0
30A
105OR8.0
10A
60A
100OR15.0
NEGATIVE TERMINAL
SWITCH
BK50.0 BK50.0 RD50.0
123OR1.25 A COIL MANAGER A

425WH3.0 B B
Cail
221GY3.0 C Commander C
X63 XH
FLAMEOUT MAGNETIC VALVE
LG421507109
5-74
Shutdown Circuit April 17, 2019
Alarm Light CLG4215
Close the disconnect switch, turn the electric lock to "ON" position (see “Starter Switch (Electric Lock)”
for the description of positions), and the battery supplies power to the holding coil of shutdown valve
through 100, 60A fuse, 105, 118, 108 and 123. When the electric lock is turned to "START" position, the
terminal 125 of electric lock is energized, the shutdown contactor is closed, the pull and push coil 425 of
shutdown valve is energized, the shutdown valve is pulled in, and the throttle opens, so the complete
vehicle is started. After start process, the electric lock returns to "ON" position, and the terminal 123 of
shutdown valve holding coil is still energized to keep the shutdown valve in working state, so the
complete vehicle can keep operating. When parking is needed, turn off the electric lock, the power of
terminal 123 is cut off, the shutdown valve is powered off, and the fuel supply to engine is cut off, so as to
realize choking.
Fault detection of shutdown circuit
Fault phenomenon: unable to start

1. Turn the electric lock to "ON" position, measure whether there is 24V voltage at #123 wire of
shutdown valve terminal by digital multimeter; if not, go to next step; if any, go to Step 5.
2. Measure whether there is 24V voltage at #123 wire of electric lock terminal; if any, #123 wire is loose;
if not, go to next step.
3. Measure whether there is 24V voltage at the terminal 108 of electric lock; if any, the electric lock is
faulty, and replace it; if not, go to next step.
4. Check whether 10A and 60A fuses are blown; if any, replace fuses; if not, check whether wires are
loose or open.
5. Turn the electric lock to "START" position, and measure whether there is 24V voltage at #425 wire of
shutdown valve terminal; if any, the shutdown valve is damaged, and contact the dealer; if not, go to
next step.
6. Measure whether there is 24V voltage at #425 wire of shutdown contactor terminal; if any, #425 wire
is loose or open; if not, go to next step.
7. Measure whether there is 24V voltage at shutdown contactor terminal 120; if not, go to next step; if
any, go to Steps 9.
Check whether 30A and 60A fuses are blown; if any, replace fuses; if not, check whether wires are
loose or open.
8. Measure whether there is 24V voltage at #125 wire of shutdown contactor; if any, go to next step; if
not, repeat Steps 3 and 4.
9. Measure whether #200 wire of shutdown contactor is conducted to earth; if any, the shutdown
contractor is faulty, and replace it; if not, check the wire is loose or open.
5-75
April 17, 2019 Shutdown Circuit
CLG4215 Alarm Light
WHEN ELECTRIC
LOCK IS ON, CHECK
IF FLAMEOUT VALVE
END 123Y HAS 24V
VOLTAGE
NO
YES
YES
CHECK IF
ELECTRIC LOCK
END 123 HAS 24V
VOLTAGE WHEN ELECTRIC LOCK
IS START, CHECK IF FLAMEOUT
FLAMEOUT VALVE 425 MAGNETIC
HAS 24V VOLTAGE VALVE IS
DAMAGED
NO YES
NO
CHECK IF CHECK IF
ELECTRIC LOCK FLAMEOUT CHECK IF 30A
108 END HAS WIRE LOOSE CONTACTOR 425 YES FUSE IS
24V VOLTAGE END HAS 24V BLOWN
VOLTAGE
YES NO NO NO YES
CHECK IF
ELECTRIC CHECK IF 10A, FLAMEOUT REPLACE
LOCK FAULT 60A FUSE IS CONTACTOR 120 WIRE LOOSE
BLOWN END HAS 24V THE FUSE
VOLTAGE
YES NO NO YES
CHECK IF
REPLACE CHECK IF 30A, FLAMEOUT
THE FUSE WIRE LOOSE 60A FUSE IS CONTACTOR 125 YES
BLOWN END HAS 24V
VOLTAGE
CHECK IF
FLAMEOUT
NO CONTACTOR 200
END TO EARTH
IS CONNECTED
CHECK IF
ELECTRIC LOCK
108 END HAS
24V VOLTAGE
NO YES
YES NO
WIRE FLAMEOUT
LOOSE CONTACTOR
FALUT
CHECK IF 10A,
ELECTRIC 60A FUSE IS
LOCK FAULT BLOWN
YES NO
CHECK IF 10A, CHECK IF 10A,

60A FUSE IS 60A FUSE IS
BLOWN BLOWN
LG421507110
5-76
Schematic Diagram of Electrical Units April 17, 2019
Alarm Light CLG4215
Schematic Diagram of Electrical Units
3 6
5
2
1
23
4 7
14 8
10

21 9

15
LG421507111
13

19
16
12
11

22
12

23

24

17

18
LG421507112
1. Front combination light 9. torque converter oil pressure switch 17.Battery

2. Work light of blade 10.Rear combination light 18.Disconnected switch
3. Front dome light 11.Engine water temperature sensor 19.Air filter clogging alarm switch
4. Work light 12.Speaker 20.
5. Front wiper 13.Radio 21.Reverse alarm
6. Rear dome light 14.Service brake pressure switch 22.Electric horn
7. Engine oil pressure switch 15.Parking brake pressure switch 23.
8. Torque converter oil temperature 16.Oil level sensor 24.Dome light
sensor 25.Central control box
5-77
April 17, 2019 Schematic Diagram of Electrical Connector Positions
CLG4215 Alarm Light
Schematic Diagram of Electrical Connector Positions
4 4 22 3
3 1
LG421507113
3
4
2
1
LG421507114
No. 1: X1,X2,X3,X5,X6,X7,X8
No. 2: X9,X10,X11,X12
No. 3: X4,X13,X14,X15,X16,X17,X18,X19
No. 4:X53
5-78
Schematic Diagram of Electrical Connector Positions April 17, 2019
Alarm Light CLG4215
6-1
April 17, 2019 Air Conditioning System
CLG4215
Air Conditioning System

A/C System Overview......................................................................................................6-1
A/C System Parameters ........................................................................................................................6-1
Working Principle for A/C ......................................................................................................................6-1
Introduction for All Parts of A/C..............................................................................................................6-3
Removal and Installation of A/C.....................................................................................6-4

Installation position introduction of A/C components .............................................................................6-4
Removal and Installation of A/C Components .......................................................................................6-6
Compressor Removal ......................................................................................................................6-6
Installation Steps of Compressor ...................................................................................................6-13
Removal and Installation of Evaporator Mounting Assembly .........................................................6-14
Installation Steps of Evaporator .....................................................................................................6-15
Replacement of A/C Control Panel ................................................................................................6-16
Check and Replacement for A/C Fuse...........................................................................................6-17
Removal and Replacement for Fluid Reservoir .............................................................................6-18
Removal and Eplacement for Evaporation Fan .............................................................................6-19
Removal and Installation for Expansion Valve ...............................................................................6-20
Removal and Installation for Condensate Fan ...............................................................................6-21
Installation of Condensate Fan ......................................................................................................6-22
Removal and Installation for Condenser Element..........................................................................6-22
Heater System Overview...............................................................................................6-24

Heater System Introduction .................................................................................................................6-24
Heater System Parameters............................................................................................................6-24
Heater Working Principle ...............................................................................................................6-24
Introduction of All parts of Heater System......................................................................................6-24
Removal and Installation All Part of Heater System ............................................................................6-24
Introduction of Mounting Positions of Heater System Parts ...........................................................6-24
Removal and Installation of All Parts of Heater System.................................................................6-25
A/C Maintenance............................................................................................................6-29
A/C Detection ......................................................................................................................................6-29
Tension Check of A/C Compressor Pulley...........................................................................................6-30
A/C Regular Maintenance ....................................................................................................................6-30
Fault Diagnosis and Maintenance of A/C System ......................................................6-31

6-2
Air Conditioning System April 17, 2019
CLG4215
Fault Diagnosis Process and Troubleshooting.....................................................................................6-31

Fault Diagnosis Process ................................................................................................................6-31
Overhauling Method.......................................................................................................................6-33
Electrical Schematic of A/C System.....................................................................................................6-37
A/C Refrigerant Filling Method .............................................................................................................6-38
Tightening Torque for Pipelines Connectors of A/C System................................................................6-39
6-1
April 17, 2019 A/C System Overview
CLG4215 A/C System Parameters
A/C System Overview
A/C System Parameters
Working medium Engine cooling water

Heating system Heating capacity 5000 W
Max. wind speed
Refrigerant R134a
A/C System Refrigerating capacity 3500 W
Refrigerant filling quantity 950±50 g
Voltage 24 V
Working Principle for A/C
1. Compression process
Refrigerant absorbs heat in the evaporator and then changes into low-temperature low-pressure
refrigerant vapor, is sucked into the compressor and compressed into high-temperature high-pressure
refrigerant vapor, and then is discharged into the condenser.
2. Condensation process
After high-temperature high-pressure refrigerant vapor enters the condenser, air is forced by the
condenser fan unit to pass the condenser surface and take away refrigerant heat, and refrigerant is
condensed into medium-temperature high-pressure refrigerant liquid.
3. Throttling process
Medium-temperature high-pressure refrigerant liquid is filtered by dryer and throttled through the
expansion valve (refrigerant is sprayed from the pores of expansion valve and expanded suddenly),
changes into low-temperature low-pressure refrigerant mist, and then enters the evaporator.
4. Evaporator process
Low-temperature low-pressure refrigerant liquid formed by the throttling of expansion valve is vaporized
in the evaporator, the air in the cab is driven by the evaporator fan unit to pass the evaporator surface,
refrigerant absorbs the heat of air in the cab to reduce the air temperature, and condensate water is
separated out. Refrigerant absorbing heat is evaporated into low-temperature low-pressure refrigerant
vapor, is sucked into the compressor and compressed again, and one refrigeration cycle is completed.
The compressor keeps rotating, the above refrigeration process is cycled continuously, and the heat in
the cab is taken away by refrigerant in the evaporator, so as to complete cooling and dehumidification of
the complete vehicle.
6-2
A/C System Overview April 17, 2019
Working Principle for A/C CLG4215
Working principle diagram for A/C system
COLD WIND
EXPANSION VALVE
EVAPORATOR
HIGH TEMPERATURE &HIGH PRESSURE GAS

LOW TEMPERATURE HIGH PRESSURE GAS
LOW TEMPEATURE & HIGH PRESSURE LIQUID
WET&WARM AIR
WARM AIR
HIGH TEMPEATURE & HIGH PRESSURE AIR

LOW TEMPERATURE &
LOW PRESSURE GAS
LOW TEAMPARATURE&
LOW PRESSURE AIR COMPRESSOR
CONDENSER
SIGHT GLASS
HOT AIR
STORAGE TANK
TANK RECEIVER
CONDENSER FAN AIR
WIND OF CONDENSOR FAN
LG816C08001
6-3
April 17, 2019 A/C System Overview
CLG4215 Introduction for All Parts of A/C
Introduction for All Parts of A/C 6. A/C pipeline: the connection lines of A/C
system include high-pressure pipes and low-
pressure pipes. Among them, the
1. Compressor: the compressor is a core compressor to condenser pipe, condenser to
component of the A/C system. It is used to receiver pipe, and receiver to evaporator pipe
compress low-temperature low-pressure are high-pressure pipes, and the evaporator
refrigerant vapor into high-temperature high- to compressor pipe is low-pressure pipe.
pressure refrigerant vapor. The compressor
used for the system is a swash plate one. 7. Pressure switch: the pressure switch,
The type is SE-5H14, the displacement is connected in series in the compressor circuit,
138cm³, the refrigeration oil is PAG100. controls the turn-on and turn-off by
monitoring the system pressure, so as to
2. Evaporator: The evaporator is used to allow realize the purpose of protecting the
throttled low-temperature low-pressure compressor. The pressure switch is used to a
refrigerant liquid to absorb large heat from high/low-pressure combination switch, the
the surrounding air during evaporation in the upper limit value of high pressure is 2.65Mpa,
evaporator, so as to realize the purpose of and the lower limit value of low pressure is
cooling or cooling and dehumidification in the 0.196Mpa.
cab. Evaporators, according to different
structures, fall into: serpentine type 8. Thermostat: the thermostat is used to detect
evaporator, fin and tube type evaporator and the temperature of evaporator core surface
laminated type evaporator. The evaporator of and control the turn-on and turn-off of
A/C system is a laminated type evaporator. compressor, which can effectively avoid
evaporator freezing which may damage the
3. Receiver drier: The receiver drier is a evaporator core. When the temperature is
necessary unit to ensure the normal lower than 0°C, the compressor is off and
operation of compressor and refrigerating stops working; when the temperature
system. Its functions include: 1. storage, 2. reaches above 5°C, the compressor is on
filtration, 3. drying. again.
4. Condenser: the condenser is a heat-
exchange unit which absorbs the heat of
high-pressure overheated refrigerant vapor
from the compressor, condenses into liquid
and overcools. The condenser is generally
air-cooled. Condensers, according to
different structures, can fall into fin and tube
type condenser, serpentine type condenser,
parallel flow condenser, ect.
5. Expansion value : the expansion value is a
throttling unit, used for throttling and step-
down as well as flow adjustment; meanwhile,
it can also prevent wet compression, liquid
impact and abnormal overheating. Common
throttling units include internal balanced
thermostatic expansion valve, external
balanced thermostatic expansion valve, H
type thermostatic expansion valve,
expansion throttle pipe, etc.
6-4
Removal and Installation of A/C April 17, 2019
Installation position introduction of A/C components CLG4215
9. A/C control panel: the A/C panel is located on Removal and Installation of A/
the cab top and below the seat. The top is air
supply and cold air control panel; the left is C
air supply knob, which can be operated when
the electric switch lock is turned on, including
three positions, i.e. high-speed position,
Installation position introduction
medium-speed position and low-speed of A/C components
position in order; the right knob is a cooling
switch and cooling temperature adjusting 1. Compressor: installed on the engine, is
knob, which can be operated when the driven to work by directly using the driving
engine is working, and turning the knob will force of engine through belt connection.
increase the cooling effect gradually. There Mounting position refer to below figure.
are three indicators on the panel, which are
power, fault and cooling indicators Compressor mounting of A/C
respectively, refer to below figure.
A/C Control Panel
120±1
POWER TROUBLE COOL

60±1
L
M LG421508003
H 0 0 COOL
LG421508002
LG421508003
6-5
April 17, 2019 Removal and Installation of A/C
CLG4215 Installation position introduction of A/C components
2. Evaporator assembly: the system of air

conditioner is overhead, and the evaporator
as is installed on the top of cab. The
evaporator as includes evaporator,
condenser, receiver, pressure switch,
thermostat, etc. Such integrated installation
effectively saves installation space, refer to
below figure.
Installation position of evaporator condensation
assembly
A/CEVAPORATOR
CONDENSER
MOUNTING ASSY.
LG421508004
3. Air outlet and control panel: the air

conditioner is overhead, and the air outlet
and control panel are installed on the top of
cab. This installation method omits the
design of air duct, which effectively saves the
cab space, refer to below figure.
Installation position of A/C air outlet and control
panel
LG421508005
6-6
Removal and Installation of A/C Components CLG4215
Removal and Installation of A/C Components
Compressor Removal
Drain Refrigerant From the A/C System
To avoid the injury of refrigerant, goggles and gloves should be worn and naked light or smoking is
prohibited.
Recycle the refrigerant if there are appropriate equipments.
Introduction to refrigerant recycle method for 34711-2K machine produced by US SPX.ROBINAIR

Company
The recovered refrigerant will pass through the oil separator and the filter dryer in turn, and finally into
the refrigerant tank. When the dried refrigerant flows through the humidity indicator, it will turn green.
If possible, it is better to run the A/C system for about 10 minutes before recycling the refrigerant. Then
shut down the system to start recycling the refrigerant.
1. Connect the multipurpose power supply

2. Turn on the main power switch, and empty the refrigerant recovery tank on the right of the device .
Lubricating oil
recycle tank
LG421508020
3. Press the recycle switch.

4. If more than 150Ib (68kg) refrigerant has been recollected since last replacing dry filter, the
instrument will display: filtered weight is xxx Ib (xx kg). Press the start button.
5. Connect the high and low pressure conduits to the A/C system, and open the connection valves.
6-7
CLG4215 Removal and Installation of A/C Components
6. Rotate both the low and high pressure valves to the Recover / Vacuum location, and then press the
Start button to continue.
HIGH/LOW
PRESSURE
VALVE SWITCH
LG421508021
7. If the system pressure is below 25psi (1.72bar), the instrument will display: The system pressure is
low until the pressure rises or press the Start button. You can press the button to exit.
8. If there is refrigerant in the low pressure conduit of the device, the instrument will start cleaning
program and display: being cleaned. If you want to skip or stop cleaning program, you can press the
Start button again.
9. When amount of the system recovery reaches 13in.Hg. (0.44bar) , the vacuum compressor will
automatically shut down.
10. Next, the instrument will automatically recover lubricant, and the instrument will show: lubricant is
being recycled. Oil recovery needs 90s or so.
11. After completion of the recovery of lubricant, check the lubricant recovery tank, and write down
amount of the lubricant recovered from the system. The system needs to be charged with more
lubricant after being vacuumed.
12. To confirm whether the refrigerant is completely recollected, wait for 5 minutes and observe whether
the pressure of the multifunction instrument will rise higher than 0 in.Hg. (0bar) after the recollection.
If the pressure is picked up , you need to press the start button again to repeat the recovery process
until the system pressure can be maintained for 2 minutes, then press the stop button to exit the
recovery .
6-8

1. Before operation, close the high-pressure and
low-pressure valves at the instrument of manifold
meter, unscrew high-pressure and low-pressure
CLOSE HIGH/LOW
PRESSURE
connector valves completely (turn
VALVE AT THE
INSTRUMENT counterclockwise to end);
LG421508006
CLOSE HIGH/LOW
PRESSURE JOINT VALVE,
AND ROTATE IT COUNTER
CLOCKWISE COMPLETELY
LG421508007
6-9

2. Unscrew the plugs from the high-pressure and
low-pressure filling fillers of compressor, and
UNSCREW
THE PLUG connect the high-pressure and low-pressure
valves of manifold meter respectively to the high-
pressure and low-pressure filling fillers of
compressor (or fillers of high-pressure and low-
pressure pipes). Open the connector valves after
connection (tighten clockwise);
LG421508008
OPEN JOINT VALVE,

AND TIGHTEN IT
CLOCKWISE
LG421508009
6-10

3. Slightly loosen high-pressure and low-pressure
valves on the manifold meter to let refrigerant flow
out slowly. When loosening the valves, loosen the
HIGH low-pressure valve first and then the high-
PRESSURE
pressure valve. As the pressure at the high-
pressure valve end is high, refrigerant flows fast.
Pay attention to controlling the valve opening.
High flow speed will cause the injection of
refrigerant oil along with refrigeration, so control to
avoid injection of the oil. Refrigerant can be
drained for about 10-15 min;
LOW
PRESSURE
LG421508010
REFRIGERANT
FLOW
LG421508011
4. After draining refrigerant, take down high-pressure

and low-pressure valves, and install plugs;
×2
LG421508012
6-11
Removal for Pipe of Compressor

1. Loosen connecting threads of the compressor
pipe by wrench (thread specification is 7/8-14UNF
and 3/4-16UNF), and take down the pipe;
LG421508013
LG421508014
6-12

2. Seal the compressor fillers and lines to prevent
foreign matters from entering.
×2
LG421508015
×2
LG421508016
6-13
Removal and Replacement for Compressor

1. Loosen the nut of adjusting screw rod M14;
LG421508017
2. Loosen the M16 mounting bolts connecting the

compressor bracket and swing link, and take
down the compressor belt;
LG421508018
3. Remove 4 M10 mounting bolts of compressor, and

then take down the compressor for overhaul or
replacement?
LG421508019
Installation Steps of Compressor
Install the compressor just opposite to the removal steps.

6-14
Removal and Installation of Evaporator Mounting Assembly

1. Drain refrigerant from the A/C system, refer to
above section “Drain refrigerant from the A/C
system”;
2. Remove the A/C air outlet in the cab: Remove 10
screws of top air outlet in the cab by a Philips
screwdriver;
LG421508022
3. After removing the air outlet, disconnect two

harnesses butted with the air conditioner;
LG421508023
4. Remove two pipes connected on the evaporator

as by a monkey wrench or proper wrench. Make
sure to seal the pipes and pipe connectors on the
evaporator after removal, to prevent foreign
matters from entering;
LG421508024
6-15

5. Unscrew 6 fixing nuts on the evaporator by a
wrench, take down the nuts, and then remove the
evaporator as for overhaul or replacement;
LG421508025
Installation Steps of Evaporator
Install the evaporator just opposite to the removal steps.

6-16
Replacement of A/C Control Panel

1. Remove the A/C air outlet in the cab: Remove 10
screws of top air outlet in the cab by a Philips
screwdriver;
LG421508022
2. After removing the air outlet, disconnect two

REMOVE A/C connecting harnesses, and then take down the A/
PANEL FOR
OVERHAULING OR C panel for overhaul or replacement.
REPLACE IT
LG421508026
6-17
Check and Replacement for A/C Fuse

1. Find the grey A/C fuse box located at the cab
bottom;
LG421508027
LG421508028
2. Open the fuse box, take down the fuse (30A), and
check if fuse is blown. If not blown, install the fuse
back to the original place. If the fuse is blown,
replace it.
LG421508029
6-18
Removal and Replacement for Fluid Reservoir

system”;
2. Unscrew off 8 bolts from the A/C glass fibre
reinforced plastic cover on cab roof with a cross-
screwdriver;
LG421508030
3. Remove the glass fibre reinforced plastic cover;
LG421508031
4. Unscrew off two mounting nuts from fluid

reservoir;
×2
LG421508032
6-19

5. Pull out wire harness connector;
6. Replace with a new fluid reservoir.
LG421508033
Removal and Eplacement for Evaporation Fan

screwdriver; Remove the glass fibre reinforced
plastic cover; Refer to section “Removal and
replacement for fluid reservoir”;
2. Pull out harness connector of evaporator motor;
LG421508034
3. Unscrew off two mounting nuts from evaporator

motor;
×2
LG421508035
6-20

4. Take out the motor for service or replacement;
5. Install the evaporator motor.
LG421508036
Removal and Installation for Expansion Valve

system”;
3. Unscrew off two mounting nuts from expansion
valve, and take down the expansion valve for
service or replacement.
LG421508037
6-21
Removal and Installation for Condensate Fan

2. Remove four mounting bolts form condenser core
with a cross-screwdriver;
LG421508038
3. Remove the wire mesh;
LG421508039
4. Take out the condenser motor;
LG421508040
6-22

5. Pull out motor harness connector, and maintain or
replace the motor directly.
LG421508041
Installation of Condensate Fan
Install the condenser motor in the reverse order of removal.
Removal and Installation for Condenser Element

system”;
3. Remove four mounting bolts form condenser core
with a cross-screwdriver;
LG421508042
6-23

4. Remove the connecting screw between
condenser core and fluid receiver;
LG421508043
5. Take out the condenser core for cleaning, service

or replacement.
LG421508044
6-24
Heater System Overview April 17, 2019
Heater System Introduction CLG4215
Heater System Overview Introduction of All parts of Heater

System
Heater System Introduction 1. Heater assembly: it is a component
integrated by the heat exchanger core,
blower and controller. Among them, the heat
Heater System Parameters
exchanger core is used for heat exchange,
i.e., release of heat from engine coolant; the
Engine blower is used to quicken air flow, so as to
Working
cooling increase the heat exchange efficiency of heat
medium
Heating water exchanger; the controller controls the turn-on
system Heating and turn-off of blower.
5000 W
capacity
2. Heater water taking valve: it is connected to
Voltage 24 V
the engine, functioning as opening and
closing. Manual valve is used in this A/C
Heater Working Principle currently.
3. Heater exchanger: It leads water into the
The heating system uses engine coolant as
heater exchanger in the cab, and then takes
heat source. It realizes heat exchange between
cooled water back to the engine.
the air blown in by the blower as and engine
coolant through its heat exchanger (generally
called heater core), and heated air is blown into
the cab. Removal and Installation All Part
Working principle of heater system of Heater System
ENGINE Introduction of Mounting Positions of

ENGING
Heater System Parts
HIGH TEMPEATURE & WATER
LOW TEMPEATURE & WATER
High TEMPERATURE water

The heater as is installed at the bottom of seat,
lOW TEMPERATURE WATER and services as seat support. See below figure:
HOT AIR
HEAT EXCHANGER
WIND OF BLOWER LG421508045
LG421508046
6-25
April 17, 2019 Heater System Overview
CLG4215 Removal and Installation All Part of Heater System
Removal and Installation of All Parts of Heater System
Removal of Heater Assembly
Because the evaporator and fan heater are integrated in one component, it is necessary to stop
the engine, turn off water intake valve on the engine and cool the engine to natural state or near
nature state before removing the vaporator.

1. Clamp two water pipes by clamp device to prevent
engine coolant from excessive runoff, and remove
two heater water pipes at the cab bottom;
×2
LG421508047
2. Remove seat. Remove 4 mounting bolts of M10

seat by an air gun or 16# wrench;
×4
LG421508048
6-26
Removal and Installation All Part of Heater System CLG4215

3. Move way the seat and remove 4 M8 mounting
bolts of heater as, disconnect the harness
connected from the heater to cab, and remove the
heater as for overhaul or replacement.
×4
LG421508049
Installation Steps of Heater
Install heater just opposite to the removal steps.

6-27
April 17, 2019 Heater System Overview
CLG4215 Removal and Installation All Part of Heater System
Removal and Installation of Motor

1. Remove the heater as according to section
“Removal of heater assembly”;
2. Place the heater upside down, and unscrew off
the mounting screw from the silver-white bottom
plate;
LG421508050
3. Take out the silver-white bottom plate;
LG421508051
4. Pull out the connector of connecting harness

between motor and panel;
LG421508052
6-28
Removal and Installation All Part of Heater System CLG4215

5. Remove the motor mounting screws;
6. Take out the motor for service or replacement, and
then install it in the reverse order of removal.
LG421508053
Removal and Installation of Heater Panel

1. Remove the heater as according to section
“Removal of heater assembly”;
2. Place the heater upside down, and unscrew off
the mounting screw from the silver-white bottom
plate; Take out the silver-white bottom plate; Pull
out the connector of connecting harness between
motor and panel?refer to above section “Removal
and installation of motor”;
3. Remove the mounting screw from heater control
panel with a cross-screwdriver;
4. Take down the heater control panel for service or
LG421508054 replacement.
6-29
April 17, 2019 A/C Maintenance
CLG4215 A/C Detection
A/C Maintenance
A/C Detection
Breathing in refrigerant vapor by lighted cigarette or other smoking methods or smoke from
flame in contact with refrigerant will cause death. Smoking is not allowed during maintenance of
air conditioner or at the place where refrigerant vapor may exist.
1. Start the engine, and keep the engine running at high idle speed.
2. Turn on the A/C switch, adjust the air conditioner to cooling mode, and control the air supply speed at
high speed by adjusting the air speed switch.
3. Keep the A/C system operating stably for 2 min.
4. In order to check the refrigerant in the system, check sight glass on the top of fluid receiver normally,
a great number of bubbles can be seen by sight glass. If a great number of bubbles is seen or it is
spumescence, it means refrigerant in A/C system is insufficient, see below figure.
FILTER
Drying agent
Gaseous
REFRIGERANT
Liquid
REFRIGERANT
SIGHT GLASS Insufficient
Continuous bubbles
Appropriate
Few bubbles
Excessive
or none
No bubbles seen
LG421508055
6-30
A/C Maintenance April 17, 2019
Tension Check of A/C Compressor Pulley CLG4215
Tension Check of A/C A/C Regular Maintenance

Compressor Pulley
Maintenance every 50 working hours or every
Tension of A/C compressor belt: Apply a load week:
W=1.5Kg on the center of tangent edge of belt
Clean the strainers of evaporator return air outlet
and two pulleys (compressor pulley and engine
and new air outlet; check the tension of
pulley), perpendicular to the belt edge, and the
compressor drive belt, and check the condenser
deflection f of belt shall be 5 ± 1 mm. See below
for oil stains, dirt and other foreign matters which
figure.
will affect the heat dissipation of condenser.
Maintenance every 250 working hours or

every month:
W
1. Check the tension and damage of the drive
belt of the engine and the belt of the
compressor of the air conditioner.
F
A/C COMPRESSOR
belt pulley 2. Check whether there is sufficient refrigerant
in the A/C receiver.
ENGINEA/C
belt pulley 3. Clean the inner and outer air filters of the
cab.
LG421508056
Maintenance every 1,000 working hours or

When the belt cannot be tensioned (apply a load every six months:
W=1.5Kg on the center of tangent edge of belt
and two pulleys (compressor pulley and engine Replace the outer air filter of cab.
pulley), perpendicular to the belt edge, and the
deflection f of belt is greater than 5 ± 1mm), Maintenance every 2,000 working hours or
replace the belt. If the belt has rough edges or every year:
cracks, replace the belt.
Check whether the cooling pipe and water pipe
of A/C system are broken, worn out or immersed
by oil stains, and check whether the connector
and clamp are loose.
6-31
April 17, 2019 Fault Diagnosis and Maintenance of A/C System
CLG4215 Fault Diagnosis Process and Troubleshooting
Fault Diagnosis and Maintenance of A/C System
Fault Diagnosis Process and Troubleshooting
Fault Diagnosis Process
Refrigerating
abnormal
CHECK ifEVAPORATOR
has wind or not
Wind comes out of

Less wind theEVAPORATOR
or no wind
Running
conditions
of the
Running compressor
conditions of fan
motor
The
COMPRESSOR COMPRESSOR
Fan motor Fan motor runs but running normally does not run
does not run air quantity is small or runs hard
CHECK according CHECK

CHECK according to Item 2 CHECK according
REFRIGERANT to Item 3
to Item 1
REFRIGERANT
amount normal or excessive Insufficient
REFRIGERANT
Test
PRESSURE
CHECK according
PRESSURE PRESSURE to Item 4
abnormal normal
CHECK according CHECK according

to Item 5 to Item 6
LG421508057
6-32
Fault Diagnosis and Maintenance of A/C System April 17, 2019
Fault Diagnosis Process and Troubleshooting CLG4215
Refrigerating
abnormal
CHECK ifEVAPORATOR
has wind or not
Wind comes out of

Less wind theEVAPORATOR
or no wind
Running
conditions
of the
Running compressor
conditions of fan
motor
The
COMPRESSOR COMPRESSOR
Fan motor Fan motor runs but running normally does not run
does not run air quantity is small or runs hard
CHECK according CHECK

CHECK according to Item 2 CHECK according
REFRIGERANT to Item 3
to Item 1
REFRIGERANT
amount normal or excessive Insufficient
REFRIGERANT
Test
PRESSURE
CHECK according
PRESSURE PRESSURE to Item 4
abnormal normal
CHECK according CHECK according

to Item 5 to Item 6
LG421508057
6-33
Overhauling Method
Item Symptom Reasons Troubleshooting

1. Repair or replacement
1.Poor contact of connector
2.Repair or replace relay;
2.Damaged air volume switch,
1 The fan doesn't run 3.Replace the fuse, see 8.2.2.4
relay.
section for inspection and
3.Blown fuse or low battery voltage.
replacement methods of fuse
1.Obstacles at suction side.
2 Abnormal fan operation Clogged fins of evaporator or 1. Cleaning
condenser by dust.
1.Failed pull-in of compressor
1. Check and repair
clutch due to open circuit or poor
2. Adjust belt tension or replace
contact.
belt
2.Loose or fallen compressor belt
3. Repair or replace the coil
Failed operation or difficult tensioner, or loose belt.
3 4. Drain or fill refrigerant, see
operation of compressor 3.Open or failed compressor clutch
8.2.2.1 section for compressor
coil.
replacement, and see 8.5.3
4.Active high-pressure and low-
section for refrigerant filling
pressure switches of receiver, but
method
excessive or insufficient refrigerant.
Eliminate air leakage and fill
1. Refrigerant leakage.
sufficient refrigerant, see 8.5.3
4 Insufficient refrigerant 2. Insufficient refrigerant filling
section for refrigerant filling
amount.
method;
6-34

When the temperature is 32ºC--37,
The determination of high compressor speed is 1800--2000
pressure and low pressure rpm
depends on the readings of high The pressure on high pressure
pressure and low pressure gauge is 1.27Mpa—1.52Mpa
gauges. The pressure on low pressure
gauge is 0.12Mpa—0.15MPa
Too large opening of expansion 1. Replace expansion valve, see
Low-
There is frost on valve. method 8.2.2.7
pressure
low-pressure pipe Poor contact of expansion valve 2. Install the sensing bulb
is on the
surface. sensing bulb. correctly.
high side
Excessive refrigerant in the system. 3. Drain part of refrigerant
1. Locate the leak by a leak
Low-pressure gauge Loose pipe connector due to
detector and tighten the loose
value is lower than vibration, and leakage to cause
part carefully. Add refrigerant to
normal value insufficient refrigerant.
the specified amount.
1. Discharge the system, replace
5
The pressure of low refrigerant receiver, and refill
pressure gauge is in Clogged low-pressure hose or ice refrigerant, for replacement
negative pressure blockage in expansion valve. method for refrigerant receiver,
state occasionally. see 8.2.2.5; for filling method of
Low- refrigerant, see 8.5.3
pressure The evaporator is
Thermostat failure Replace thermostat
is on the frozen.
low side The expansion valve Clean or replace expansion
inlet side is cold, Expansion valve has block valve, replace method see
with frost attached. 8.2.2.7
The expansion valve
outlet side is not
cold, and the
Air leakage of expansion valve Replace expansion valve, see
pressure of low
sensing pipe or sensing bulb. method 8.2.2.7
pressure gauge is in
negative pressure
state occasionally.
6-35

Drain the system, re vacuumize,
hold pressure and fill refrigerant,
Air into the A/C system.
see 8.5.3 section for refrigerant
filling method
Discharge a certain amount of
High-
refrigerant to keep the
pressure Refrigerant Too much refrigerant is charged
refrigerant amount in the system
is on the
proper.
high side
Clogged fins of Wash the condenser, and
condenser by dust remove impurities.
Poor condensation effect of
or impurities. Check and replace fault
condenser.
Condenser motor is condenser motor. see method
damaged. 8.2.2.8
5
Locate the leak by a leak
detector and tighten the loose
Loose pipe connector due to
part carefully. Add refrigerant to
vibration, and leakage to cause
the specified amount and fill
insufficient refrigerant.
refrigerant 8.5.3 method
High- reference.
pressure
Low pressure is in
is on the Clogged or damaged low-pressure
negative pressure Clean or replace pipelines
low side line.
state occasionally.
Replace with a new compressor,
Neither compressor
and see 8.2.2.1 section for
nor high-pressure Compressor has fault
compressor replacement
pipe is not hot.
method
The cooling of system is good at
the beginning, and cold air is Locate the leak by a leak
insufficient after a period of time; Loose connector due to vibration as detector, tighten the loose part
6 there are bubbles in the receiver the vehicle is traveling on bad road carefully, and add refrigerant, fill
observation hole; the "readings" often, leakage. refrigerant 8.5.3 method
of high and low pressure gauges reference.
are low.
The system does not cool, warm
Replace the expansion valve,
air comes from air outlet, there is
and fill refrigerant again. See
no temperature difference Improper use. Worn-out and leaked
8.2.2.7 section for expansion
7 between the expansion valve expansion valve sensing bulb, to
valve replacement method, and
inlet and outlet through hand cause closed valve hole.
see 8.5.3 section for refrigerant
feeling, and the reading of low
filling method.
pressure gauge is very low.
Turn on the A/C system
intermittently, which can
The air at outlet is not cold, and
eliminate instantaneous clogging
the compressor temperature
Impurities in the system, clogged if clogging is not serious. Or
rises. The pointer of low pressure
8 strainer of expansion valve, light remove the expansion valve,
gauge drops quickly, close to "0",
frost or “sweat” at expansion valve. clean with alcohol, empty the
and the reading of high pressure
system and fill refrigerant again.
gauge is high.
fill refrigerant 8.5.3 method
reference.
6-36

Empty the system, replace the
expansion valve, and fill
The cold air volume is
refrigerant again. See 8.2.2.7
insufficient, and the evaporator is
9 Inactive orifice in expansion valve. section for expansion valve
frosted; the readings of high and
replacement method, and see
low pressure gauges are low.
8.5.3 section for refrigerant filling
method.
The cooling capacity decreases
gradually after the system
Saturated drying agent in the Empty the system, replace the
operates for a period of time, the
receiver, and ice blockage at the receiver, and fill refrigerant
10 reading of high pressure gauge is
throttling position of expansion again. the fill refrigerant 8.5.3
high, and the reading of low
valve method reference.
pressure gauge is lower than
0.4MPa.
1. Check by a multimeter
After turning on the A/C system,
Poor contact of thermostat or whether the thermostat is
there is air rather than cold air,
11 damaged compressor magnetic damaged ;
and the reading of high pressure
clutch coil. 2. Replace the compressor
gauge is unchanged.
magnetic clutch.
The compressor clutch acts
frequently, the engagement time Small opening of thermostat to
is short, the temperature in the automatically force the compressor Check the thermostat, and keep
12
cab does not drop, and the to stop, causing insufficient cold air it open to the coldest position.
readings of high and low volume.
pressure gauge are normal.
6-37
CLG4215 Electrical Schematic of A/C System
Electrical Schematic of A/C System
30A
DC24W
R1.5
4
U1.5
1
Y1.0
2 TEMPERATURE
S1.0 Anti-frosting TEMPERATURE controller Relay Blower unit SENSOR
3
G1.0
5
B1.0
6 R1
V1.0 M1
8
W1.0
7
POWER DR1.0
9
COOL
PRESSURE
Magnetic clutch of compressor SWITCH
Condensate Condensate
TROUBLE fan fan
M21 M22
LG421508058
6-38
A/C Refrigerant Filling Method CLG4215
A/C Refrigerant Filling Method 7. Press the charge system.
Refrigerant recycle method and related

precautions for 34711-2K machine produced by
US SPX.ROBINAIR Company are as following. Filling
1. Drain or recycle refrigerant already in A/C

system before refilling. See “Drain refrigerant Stop
from the A/C system” section for drain

Start
method, and see “Introduction to refrigerant
recycle method for 34711-2K machine
produced by US SPX.ROBINAIR Company”
for recycle method.
Valve
2. Place valves of the multifunction device in SWITCH
the closed state, and connect the high and LG421508060
low pressure conduits to the A/C system,

then open the connection valves. 8. Rotate the low pressure valve to the Closed
position, and the high pressure valve to the
3. Connect the main power of the multifunction
Oil Inject / Charge position. Press the start
device and then turn on the main power
button.
switch.
9. Enter the amount of refrigerant 0.95kg
4. Press the vacuum button, and then press the
required to charge by number buttons, and
start button.
then press the Start button again.
10. The instrument will show after filling: charge
Vacuum
pumping has completed, the amount of filling is x.xx lb
(kg).
11. Close high and low pressure valves, and
remove the filling conduits.
When the remaining refrigerant in the

refrigerant storage tank is less than 3 lbs
High/low PRESSURE
valve SWITCH
(1.36kg), it can't charge the system with
LG421508059
refrigerant, the refrigerant storage tank
should be supplied with refrigerant at this
time.
5. Press the start button again to confirm
vacuuming for 15 minutes, or change time to
vacuum by numeric buttons, and then press
the Start button once more.
6. When the set time is up , the vacuuming will
automatically stop . Press the stop button to
exit the process. Press the start switch to
resume continue vacuuming , or exit by
pressing the stop button. Now it is ready to
charge the system with refrigerant.
6-39
CLG4215 Tightening Torque for Pipelines Connectors of A/C System
The following is reference table of pressure &

temperature correspondence relationship
Indicating Indicating
Ambient
range of the range of the
temperat
high pressure low pressure
ure
gauge gauge
ºC Kg.f/cm2 Kg.f/cm2
15.5ºC 8.4~10.5 1.57~1.9
21.1ºC 10.5~12.6 1.57~1.9
26.6ºC 12.6~14 1.67~2.1
32.2ºC 14~15.4 1.67~2.1
35ºC 15.4~16.4 1.77~2.1
37.7ºC 16.1~17.5 1.77~2.1
40.5ºC 17.5~19.3 1.9~2.4
43.3ºC 18.2~21.8 1.9~2.6
Tightening Torque for Pipelines

Connectors of A/C System
Tightening
Thread size
torque
5/8-18UNF,M16×1.5 15.7~19.6Nm
3/4-16UNF,M22×1.5 19.6~24.5Nm
7/8-14UNF,M24×1.5 29.4~34.3Nm
Water inlet and outlet threads 19.6~24.5Nm

6-40
Tightening Torque for Pipelines Connectors of A/C System CLG4215
7-1
April 17, 2019 Frame System
CLG4215
Frame System
Frame Overview...............................................................................................................7-1
Frame Structural Drawing...............................................................................................7-1
Structural Drawing of Articulated Hitch ........................................................................7-2
Hitch Detection Requirements ...............................................................................................................7-4
Removal of Articulated Hitch..................................................................................................................7-5
Installation of Articulated Assembly .....................................................................................................7-10
Front Counterweight .....................................................................................................7-11

Overview and Structure of Front Counterweight ..................................................................................7-11
Removal Steps of Front Counterweight ...............................................................................................7-11
Installation of Front Counterweight ......................................................................................................7-11
Rear Counterweight ......................................................................................................7-12

Overview and Structure of Rear Counterweight...................................................................................7-12
Removal Steps of Rear Counterweight................................................................................................7-13
Installation of Rear Counterweight .......................................................................................................7-14
Ripper (optional)............................................................................................................7-15
Removal for Ripper ..............................................................................................................................7-15
Installation for Ripper ...........................................................................................................................7-15
Hood Assembly .............................................................................................................7-16

Overview and Structure of Hood .........................................................................................................7-16
Introduction of Connection of Hood and Rear Frame ..........................................................................7-16
Removal Steps of Hood .......................................................................................................................7-17
Installation of Hood ..............................................................................................................................7-21
7-2
Frame System April 17, 2019
CLG4215
7-1
April 17, 2019 Frame Overview
CLG4215
Frame Overview
The frame system includes front frame and rear frame . Front frame is a welded box type structure for
mounting cab, front axle system, working implement system, front counterweight or mouldboard and
other parts. Rear frame is a welded frame structure for mounting engine system, Transmission and
torque converter system, rear axle assembly, cooling system, engine cowling assembly, rear
counterweight or ripper and other parts.
Frame Structural Drawing

Frame system
1
2
LG421509001
1. Front frame
2. Rear frame
7-2
Structural Drawing of Articulated Hitch April 17, 2019
CLG4215
Structural Drawing of Articulated Hitch
The articulated hitch assembly is the key part to connect front frame and rear frame and make front and
rear frames to function in relatively steering.
A
1 15 16
3 17
5 4
18
(21) 6
9
7
20
8
21 (29)
9
10 11 22
23
12
13 14
A
LG421509002
7-3
April 17, 2019 Structural Drawing of Articulated Hitch
CLG4215
Structure diagram of articulated hitch
26 B 27
25 24
28 29
30 (4)
LG421509003
S/N Name Quantity S/N Name Quantity S/N Name Quantity

1 Shaft 1 11 Shim 3 21 Washer 10
Support
2 Cap 1 12 Cap 1 22 1
sleeve
Radial spherical plain
3 1 13 Bolt 6 23 Cover 1
bearing
4 Washer 4 14 Washer 6 24 Washer 1
Adjustable
5 Nut 1 15 6 25 Bolt 1
shim
Adjustable Pressing
6 Bolt 4 16 3 26 1
shim plate
7 Pallet 2 17 Bolt 1 27 Locking piece 4
8 Location sleeve 1 18 Grease fitting 2 28 Washer 8

Radial spherical plain
9 1 19 Shaft bushing 1 29 Bolt 14
bearing
10 Adjustable shim 6 20 Shaft 1 1 30 Bolt 3
7-4
Hitch Detection Requirements CLG4215
Hitch Detection Requirements
1. The clearance between bearing cover and

front frame is adjusted to the range of 0-
0.05mm.
LG421509004
2. Apply thread locking adhesive to No. 25, 29

and 30 bolts, and No.29 and 30 bolt of which
to required torque values.
LG421509005
7-5
CLG4215 Removal of Articulated Hitch
Removal of Articulated Hitch

Instructions to disassemble:
First to disassemble the following before disassemble articulated hitch assembly: mouldboard
assembly, front axle assembly, working implement assembly, cab, hydraulic fluid tank, disassemble
engine cowling assembly, radiator assembly, fuel tank assembly and engine assembly on rear frame ,
remain rear axle, rear frame and tyre.
Removal and installation steps:

1. Lift front frame with steel wire rope and make rear
frame at horizontal state;
Hold against rear axle to prevent it from
spinning or it may cause safety issues.
LG421509006
2. Remove fixing screws and nuts from left and right

articulated cylinders;
LG421509007
3. Knock out the connecting axle pin from below with

a long iron bar and hammer;
LG421509008
7-6
Removal of Articulated Hitch CLG4215

4. Screw out the 4 fixing nuts on the press plate of
the lower hinges axle pin;
LG421509009
5. Screw out the screws and nuts from the upper

hinges axle pin with a open end wrench (
disassemble tool: 24mm);
LG421509010
6. Screw out one bolt P1 from the lower hinge pin

axle, remove the thin pressure plate; Screw out 3
bolts P2; remove 4 locking plates with a straight
screw driver; screw out 8 bolts, remove the thick
pressure plate;
P2 P3
P1
LG421509011
7-7

7. Install tooling on rear frame with the 8 bolts
fastening the thick plate before; Force out lower
hinge axle pin with the bolts of the tooling;
Remove hinge pin; remove tooling;
LG421509012
LG421509013
LG421509014
7-8
Removal of Articulated Hitch CLG4215

8. Place a piece of paper or wood board under lower
hinge pin of the rear frame in order to prevent
upper hinges axle pin dropping into the hole in
later removal;
LG421509015
9. Knock the upper hinges axle pin out of the fitting

hole with a long iron bar ;
LG421509016
10. Move front frame up and down to separate with

rear frame smoothly;
In the process of front and rear frames
separation, keep clear within 0.5m, or safety issue
may arise;
LG421509017
7-9

11. Lay front frame on ground with brace support;
The ground must be firm, make sure the frame
is steady before removing the steel wire rope;
LG421509018
12. Take out the supporting sleeve from the lower

hinge hole;
LG421509019
7-10
Installation of Articulated Assembly CLG4215

13. Remove screws from articulation cylinders and
remove two articulation cylinders.
LG421509020
LG421509021
Installation of Articulated Assembly

7-11
April 17, 2019 Front Counterweight
CLG4215 Overview and Structure of Front Counterweight
Front Counterweight Removal Steps of Front

Counterweight
Overview and Structure of Front
Counterweight 1. Hook up 2 lifting rings of counterweight with
steel wire rope;Lift slowly to tense the steel
wire rope just right;
Front counterweight is mounted on the front
panel of front frame through binder bolts.
Front counterweight
3
4
LG421509039
LG421509038 2. Screw out 8 fastening bolts on left and right

sides of counterweight in the sequence of
1. Front counterweight No. 3 and 4, and lift front counterweight
2. Lifting eyes away;
3. Washer
4. Bolt (M20)
×8
LG421509040
Installation of Front
Counterweight

7-12
Rear Counterweight April 17, 2019
Overview and Structure of Rear Counterweight CLG4215
Rear Counterweight
Overview and Structure of Rear Counterweight
Rear counterweight is location at the rear side of rear frame through binder bolt.
Rear counterweight
4
5
LG421509041
1. Rear counterweight
2. Bolt (M16)
3. Washer
4. Nut
5. Washer
6. Bolt (M16)
7-13
April 17, 2019 Rear Counterweight
CLG4215 Removal Steps of Rear Counterweight
Removal Steps of Rear Counterweight

1. Open rear counterweight cover, remove electric
wires on left and right batteries, take out two
batteries;
Refer to battery removal procedures in electric

system.
2. Fix it on rear counterweight by two flat ropes.
LG421509042
LG421509043
3. Screw out 4 fastening bolts from the bottom of

counterweight in the sequence of No. 2; Unscrew
2 bolts No. 6 from the bottom of counterweight;
LG421509044
7-14
Rear Counterweight April 17, 2019
Installation of Rear Counterweight CLG4215

4. Slowly lower down, pull out wire;
Rear counterweight must be lower down very
slowly, and pull out wire in the process of
lowering the counterweight, wire will be damaged
if lowering too fast ;
LG421509045
5. Lift away rear counterweight after pulling wire

completely out;
LG421509046
6. Put rear counterweight on the solid ground

surface;
LG421509047
Installation of Rear Counterweight

7-15
April 17, 2019 Ripper (optional)
CLG4215 Removal for Ripper
Ripper (optional) Removal for Ripper

ripper is one working device of the grader; the 1. Place the machine properly.
ripper is teeth density, which is installed between
blade working device and front wheel and 2. Place ripper frame and teeth on the ground.
loosens the soil. It mainly consists of rake frame, 3. Unscrew bolts and nuts on the swing support
rake teeth, swing support, mounting support and and fixed support, pin shaft and bolts of
operating cylinder. It is installed on front frame. It operating cylinder by wrench; then remove
mainly applies to fine and soft soil, light working bolts, shims and nuts in turn, and place them
conditions with less stones. LG grader ripper has properly.
11 teeth in total. The customer can adjust the
quantity of rake teeth according to actual 4. After remove all mounting bolts, place the
requirements. ripper properly with lifting tools.
Configuration scheme of ripper
Installation for Ripper
2
1. Place the vehicle properly.
3
2. Lift the ripper near front hinge of front frame
by appropriate lifting equipment.
3. Aligning mounting holes of the ripper and
front frame, then install washers, bolts and
1
nuts in turn, and install ripper and front frame
together.
4 4. Remove the sling after installation.
5
LG421509022
1. Operating cylinder
2. Swing support
3. Fixed support
4. Rake frame
5. Rake teeth
7-16
Hood Assembly April 17, 2019
Overview and Structure of Hood CLG4215
Hood Assembly Introduction of Connection of

Hood and Rear Frame
Overview and Structure of Hood
Section view of hood
The hood is divided into two major parts of fixed

hood and rear cover and mounted on the surface 1
of rear frame through connecting bolts.
Hood assembly
1 2
2 2 3 3 4
LG421509024
Introduction of connecting location of frame and

LG421509023
hood assembly
1. Fixed cover S/N Position Bolt

2. Rear cover
Connecting location of fixed
1 M10
cover and rear cover
Connecting location of fixed
2 M10
cover and rear frame
Connecting location of rear
3 M12
Connecting location of rear
4 M12
7-17
April 17, 2019 Hood Assembly
CLG4215 Removal Steps of Hood
Removal Steps of Hood
图片操作说明
1. Screw out 4 bolts from exhaust tail pipe, remove
the exhaust tail pipe;
LG421509025
2. Screw out 4 bolts from air pre-filter, remove the air

pre-filter;
LG421509026
3. Unscrew 4 fastening bolts from hood plate;
LG421509027
7-18
Removal Steps of Hood CLG4215
图片操作说明
4. Screw in 2 lift rings, and put lifting rope through
them;
LG421509028
5. Open the left and right door of hood; Hang the 2

handrails of the rear hood by lifting rope; Remove
the 2 bolts P1 under the rear hood firstly, then
remove the 2 bolts P2 above the rear hood;Take
down the rear hood; unplug the harness
connector of plate license light during this
process;
P2
P2
please use lifting rope to lift rear hood and
avoid potential hazard due to manual materials
handling (such as bruised and crushing)!
P1 P1
LG421509029
7-19
CLG4215 Removal Steps of Hood
图片操作说明
6. Unscrew off 4 fastening bolts from engine hood
rear end;
LG421509030
LG421509031
7. Unscrew off 2 fastening bolts at the left and right

side of hood front end;
LG421509032
7-20
Removal Steps of Hood CLG4215
图片操作说明
8. Unscrew off 4 brackets and eight fastening bolts
between the hood, and remove the brackets;
LG421509033
9. Lift the engine hood away from the complete

vehicle;
LG421509034
10. Screw 2 rings into the fixed cover, and put lifting
rope through them;
LG421509035
7-21
CLG4215 Installation of Hood
图片操作说明
11. Unscrew off 4 fastening bolts at the left and right
side of fixing cover;
LG421509036
12. Lift the hood away from the complete vehicle.
LG421509037
Installation of Hood

7-22
Installation of Hood CLG4215
8-1
April 17, 2019 Work Implement
CLG4215
Work Implement
System Parameters of Rolling Disc Work Implement ..................................................8-1
Rolling Disc Work Implement System ...........................................................................8-2
Separation Steps of Work Implement Assembly and Front Frame ........................................................8-3
Assembling for Work Implement Assembly and Front Frame................................................................8-6
Steps for Blade Assembly and the Detachment of Work Implement’s Skeleton....................................8-7
Installation of Blade Assembly As and Work Implement Skeleton.......................................................8-10
Steps for Dismantling the Skeleton of Work Implement.......................................................................8-11
Assembling for the Skeleton of Work Implement .................................................................................8-14
Dismantling Step of Blade Assembly ...................................................................................................8-18
Installation Steps of Blade Assembly ...................................................................................................8-22
Maintenance and Repairment of Grader’s Bushes ..............................................................................8-26
Steps for Dissembling Grader’s Bushes ........................................................................................8-26
Steps for Mounting Grader’s Bushes .............................................................................................8-26
Mouldboard (Optional) ..................................................................................................8-27

Removal Steps of Mouldboard Assembly ............................................................................................8-28
Installation of Mouldboard Assembly ...................................................................................................8-30
Ripper (Optional) ...........................................................................................................8-31

Ripper Removal ...................................................................................................................................8-31
Ripper Installation ................................................................................................................................8-32
8-2
Work Implement April 17, 2019
CLG4215
8-1
April 17, 2019 System Parameters of Rolling Disc Work Implement
CLG4215
System Parameters of Rolling Disc Work Implement
System parameter of rolling disc work implement

Blade width 4270mm
Ascending speed ?150mm/s

Blade’s vertical speed
Descending speed ?100mm/s
Extension ?100mm/s
Blade’s sideshifting speed
Retraction ?150mm/s
Blade’s working angle 90º(Left) 90º(Right)
Maximum lifting height of the blade 450mm
Blade’s maximum down digging depth 555mm

8-2
Rolling Disc Work Implement System April 17, 2019
CLG4215
Rolling Disc Work Implement System

Grader’s work implement is composed of scraping work implement and additional work implement (such
as scarifier and blade).
Grader’s rolling disc work implement adopts a working mechanism of world-wide popular swinging-arm
connecting rod.It features good rigidity, precise positioning, and wide working ranges. It standard
configuration full-sealing and adjusting-free rolling-disc slewing device, the slewing of which is smooth
and accurate, which makes it easy to adapt to terrible working environments. Grader work implement is
shown as Picture 10-1:the head of traction frame is a ball hinge, which is hinged onto the head of the
frame so that traction frame can rotate and swing around the ball hinge in all directions. The turning
circle which is set up on the traction frame can rotate around the traction frame driven by slewing driving
devices, which in turn makes the blade slew in 360°. These two guide plates at the back of blade, which
hold against chute of guide stand, can move sideways under the force which is generated by blade
sideshifting oil cylinder. During the process of shoveling, small blade cutting angles can reduce cutting
resistance while big blade cutting angles can adjust leveling precision and the effect of blending.
work implement system
9 8 7 6 5 4
LG421510001
1. Blade drawing-out cylinder 4. Traction frame 7. Left blade lift cylinder

2. Right blade angle change cylinder 5. Worm box 8. Left blade angle change cylinder
3. Right blade lift cylinder 6. Blade swing cylinder 9. Blade
Work implement ’s operating system can make the blade do the following 6 kinds of movement:
① Blade left side lifting and lowering; ② Blade right side lifting and lowering; ③ Blade swing ④ Blade
sideshift (left shift and right shift relative to swing ring); ⑤ Blade sideshift together with swing ring, that is
pulling out traction frame; ⑥ Change of blade cutting angle.
Among which, ① , ② , ④ , ⑤ are generally controlled by oil cylinder while ③ are controlled by cycloidal
motor and ⑥ adjusted by oil cylinder.
High speed is forbidden when moving on an uneven road.

No abrupt acceleration or deceleration under any conditions.
*
8-3
April 17, 2019 Rolling Disc Work Implement System
CLG4215 Separation Steps of Work Implement Assembly and Front Frame
Separation Steps of Work Implement Assembly and Front Frame
Dismantle worm box or not is dependent on whether you need it; if the worm box only needs to
be dismounted or fixed, then these operations can be executed on the whole machine directly
(for more specific steps please refer to "the disassembling and assembling of worm box").

1. Detach the two tightening bolts on the pipe clamp
(P1) and the mounting plate (P2); detach pipe
clamp and mounting plate in turn;
3
3
LG421510002
2. Hetach the 3 hydraulic hoses on swing motor and

4 hydraulic hoses on the swivel joint;
LG421510003
8-4
Separation Steps of Work Implement Assembly and Front Frame CLG4215

3. Pull the seven hydraulic hoses out from the
traction frame, and put them in appropriate
places, then screen each oil port.;
LG421510004
4. Hoist the work implement by two lifting rope;
LIUGONG
LG421510005
8-5
CLG4215 Separation Steps of Work Implement Assembly and Front Frame

5. Unscrew off four fastening screws from bearing
inner cover; And then knock out bearing inner
cover;
LG421510006
LG421510007
8-6
Assembling for Work Implement Assembly and Front Frame CLG4215

6. Hoist away the work implement by proper lifting
appliances to finish the assembling of work
implement and the detachment of front frame. Put
the assembly of work implement in an appropriate
place;
NG
LIUGO
LG421510008
LG421510009
LG421510010
Assembling for Work Implement Assembly and Front Frame

8-7
CLG4215 Steps for Blade Assembly and the Detachment of Work Implement’s Skeleton
Steps for Blade Assembly and the Detachment of Work Implement’s

Skeleton

1. Knock out the cotter pin of left and right angle
shifting oil cylinder and screw out nuts. Remove
the four hydraulic hoses on the left and right angle
shifting oil cylinder;
LG421510011
2. Knock out the cotter pin on the left and right

blade’s bearing and screw out the nuts;
LG421510012
3. Knock out the cotter pin from poppet cylinder, and

then screw out the nuts; Remove two hydraulic
hoses from poppet cylinder;
LG421510013
8-8
Steps for Blade Assembly and the Detachment of Work Implement’s Skeleton CLG4215

4. Remove the fastening bolt from mounting bottom
plate under the swivel joint;
LG421510014
5. Remove the six hydraulic hoses on the swivel

joint;
LG421510015
6. Unscrew off three fastening bolts from swivel joint,

and place swivel joint properly;
LG421510016
8-9
CLG4215 Steps for Blade Assembly and the Detachment of Work Implement’s Skeleton

7. Knock out the side cotter pin under the left and
right blade’s bearing, and screw out the screw;
LG421510017
8. Put 2 steel wire ropes, shackles and bolts through

the third mounting holes on blade left side and
right side; Lift the blade slowly to tense steel wire
rope just right;
LG421510018
9. Knock out the left bearing of blade from the left

then put it in a proper place;
LG421510019
8-10
Installation of Blade Assembly As and Work Implement Skeleton CLG4215

10. Knock out the right bearing of blade from the right
and put it in a proper place;
LG421510020
11. Hoist the blade away from the turning circle by

0.5m, then put down the blade and detach the
steel wire rope; hoist the work implement away
from the blade and put it in a proper place.
LG421510021
LG421510022
LG421510023
Installation of Blade Assembly As and Work Implement Skeleton

8-11
CLG4215 Steps for Dismantling the Skeleton of Work Implement
Steps for Dismantling the Skeleton of Work Implement
Dismantle worm box or not is dependent on whether you need it; if the worm box only needs to
be dismounted or fixed, then these operations can be executed on the whole machine directly(
for more specific steps please refer to "the disassembling and assembling of worm box").

1. Shield the 4 screw threads on both sides of the
turning circle by nuts;
LG421510024
LG421510025
8-12
Steps for Dismantling the Skeleton of Work Implement CLG4215

2. Slowly lift up the work implement by lifttng ropes;
LG421510026
3. Put the work implement on the ground and turn it

over, then put it on the floor;
LG421510027
LG421510028
LG421510029
8-13
CLG4215 Steps for Dismantling the Skeleton of Work Implement

4. Unscrew out the fastening bolt from inner ring of
dust cover;
LG421510030
5. Unscrew off 36 fastening bolts from swing

bearing;
×36
LG421510031
6. Unscrew off 36 fastening bolts from swing

bearing;
×3
6
LG421510032
8-14
Assembling for the Skeleton of Work Implement CLG4215

7. Screw 2 rings into the gear ring of slewing
bearing, then hoist the slewing bearing away and
put it in a proper place.
LG421510033
Assembling for the Skeleton of Work Implement
You can choose to remove the worm box or not as needed; if only remove and repair the worm
box, remove it from the complete machine directly, refer to "removal and installation of worm
box" for detailed steps. This section only introduce the installation steps of work device frame
equipped with worm box.

1. Screw two M18 lifting rings into swing bearing
gear ring, and then lift the swing bearing to the
traction fame. Apply screw thread-locking
adhesive onto 36 fastening bolts on swing
bearing; and then pre-tightening these bolts.
Air gun pre-tightening torque should be
controlled below the maximum torque, that is less
than 380 N.m.
LG421510034
8-15
CLG4215 Assembling for the Skeleton of Work Implement

2. Set the torque wrench to the torque of 415±35N.m
and tighten bolts in order with star-shaped
8
method;
12
4
5
11 9
3 2
6
7 10
LG421510035
3. Hang the circle above the traction frame with

lifting rope, align the circle with the screw hole of
swing bearing by using a crowbar, and then lower
the circle and remove the lifting rope;
LG421510036
4. Install 36 fastening bolts on to swing bearing, pre-

tightening them with a air gun, and tighten them in
order with star-shaped method after set the torque
wrench to the torque of 305±25 N.m;
LG421510037
8-16
Assembling for the Skeleton of Work Implement CLG4215

5. Install fastening bolt onto dust cover inner ring
properly;
LG421510038
6. Overturn the traction frame by 180° with lifting

rope;
LG421510028
7. Tighten the grease joints at both sides;
LG421510039
8-17
CLG4215 Assembling for the Skeleton of Work Implement

8. Tighten three fastening bolts (socket spec: 16
mm) on the swivel joint, and install the swivel joint
properly;
LG421510040
9. Install six hydraulic hoses on to the swivel joint,

and only tighten two hoses at the left lower side.
The other end should be shield properly to avoid
impurities causing pollution;
LG421510041
8-18
Dismantling Step of Blade Assembly CLG4215
Dismantling Step of Blade Assembly

1. Removed the joint hinge pin of the left and right
angle oil cylinder, then detach the left and right
angle shifting oil cylinde;
LG421510042
2. Lift the blade with proper hoisting gear and turn it

over.
Don’t stand anywhere near the blade by 0.5m
while it is turned over, otherwise there would be
potential risk!
LG421510043
LG421510044
8-19
CLG4215 Dismantling Step of Blade Assembly

3. Remove fastening bolt from upper plate of left
blade support;
LG421510045
4. Remove the fastening bolt from lead-out cylinder

with a socket;
LG421510046
8-20
Dismantling Step of Blade Assembly CLG4215

5. Tilt the lead-out cylinder by a crowbar to make it
put in a horizontal state, then knock the bearing of
left blade out by an iron rod;
LG421510047
LG421510048
6. Detach the outlet oil cylinder by a crowbar;
LG421510049
8-21
CLG4215 Dismantling Step of Blade Assembly

7. Pull out the bearing of the left blade along the
guide rail by hand;
LG421510050
8. Pull out the lead-out cylinder from the bearing of

the right blade.Hoist the outlet oil cylinder by
hoisting gears and then put it in a proper place.
LG421510051
LG421510052
LG421510053
8-22
Installation Steps of Blade Assembly CLG4215
Installation Steps of Blade Assembly

1. Press the U-groove plate into blade right bearing
rail, and fasten the U-groove with bolts and
washes;
LG421510054
2. Push the right blade bearing into the blade body

rail, pay attention to the direction: outwards the
bearing seat, and then fasten the plate with bolts
referring to the first step. Install left blade bearing
in the same way as installation of right blade
bearing. Install the blade lead-out cylinder into the
blade left bearing;
LG421510055
3. Tighten with nuts first, insert the cotter pin, and

install the plate, then fasten the plate with bolts
and gaskets;
LG421510056
8-23
CLG4215 Installation Steps of Blade Assembly

4. Take two steel wire ropes, shackle and screws
through the mounting hole on the left and right
side of the blade; slowly hoist blade until the wire
ropes become tight;
LG421510057
5. Connect left bearing and circle, first install gaskets

and shims to the circle, then move the left bearing
on to the circle, and install parts like gaskets and
nuts. Tighten the nuts and then loosen the nuts
just right to insert pin. Finally put the bolt through
the circle and left bearing, install gaskets and nuts
in turn, and tighten the nut. Make sure that
clearance between gasket and blade support is
2±1 mm;
LG421510058
2±1 LG421510059
8-24
Installation Steps of Blade Assembly CLG4215

6. Install blade left and right angle changing
cylinders: install the bigger chamber end of left
blade angle changing cylinder on to the work
device, and the other end to the left bearing, and
knock the pin into the hinge hole between cylinder
and left bearing, with screws, locknuts, locating
pins, and tightening nuts. Install the right angle
changing cylinder in the same way;
LG421510060
7. Connect 4 hoses to the left and right blade angle

A2 B8
changing cylinders respectively, and the other 2
B9
A9
hoses to blade sideshift cylinder, and then tighten
A8
them;
A12 B11
A13 B13
A11 B12
A12
B11
B12
A11
B13
A13
LG421510061
8. Install joint bottom plate onto swivel joint;
LG421510062
8-25
CLG4215 Installation Steps of Blade Assembly

9. nstall the washer to the introducing cylinder, and
start the complete machine to protrude the
introducing cylinder passing through the support
hole, and then tighten the lead-out cylinder with
washers, shims, nuts, and pins.
LG421510063
8-26
Maintenance and Repairment of Grader’s Bushes CLG4215
Maintenance and Repairment of 4. Mount washer and screws,fix pressure plate.

Grader’s Bushes 5. Mount other bushes onto their places
following step 1 to step 4.
Once the grader has been used for a while, the The configuration diagram of grader bushing
blade would begin to swing as a result of the
abrasion of the bushes, which would affect the
working precision of the grader, in which case
the bush should be changed in time.
Steps for Dissembling Grader’s Bushes
1. Put the machine and the blade in proper

place.
2. Detach the screws on the fixing pressure
plate by a spanner.Detach the screws,
spacer and pressure plate in order and put 5 4 3 2 1
them in proper places. LG421510065
3. Take the bush out and adjust these washers.

1. Bolt
4. Detach other bushes following the directions 2. Washer
3. Pressure plate
of Step 2 and Step 3. 4. Adjustable shim
5. Bushing
Steps for Mounting Grader’s Bushes
1. Mount the adjusting washers onto the guide

stand according to your needs.
2. Mounting bushes.
3. Mount pressure plate avoid that bushes
would come off from the guide stand.
LG421510064
8-27
April 17, 2019 Mouldboard (Optional)
CLG4215 Maintenance and Repairment of Grader’s Bushes
Mouldboard (Optional)
Mouldboard is one of optional work devices of grader, it consists of mounting bracket, work cylinder and
linkage device connected to mounting bracket, blade body connected to linkage device and cutting edge
located at the bottom of blade body.
Mouldboard structure drawing
6 3
5 2 1
LG421510066
1. Cutting edge 4. Linkage

2. Mouldboard 5. Link
3. Operating cylinder 6. Mounting support
8-28
Mouldboard (Optional) April 17, 2019
Removal Steps of Mouldboard Assembly CLG4215
Removal Steps of Mouldboard Assembly

1. Put the lifting rope through cylinder and then hang
it on the crane hook; Lift the crane slowly to tense
the lifting rope just right.
Don't tense the lifting rope too hard,
otherwise, there will be potential risk when
remove hose with high hydraulic oil pressure.
LG421510067
LG421510068
2. Unscrew off 6 fastening bolts from front frame

cover, and remove the cover;
LG421510069
8-29
April 17, 2019 Mouldboard (Optional)
CLG4215 Removal Steps of Mouldboard Assembly

3. Remove two hoses A14 and B14 from cylinder
and remove hose close to the hydraulic lock inside
front frame;
B14 B14
A14 A14
LG421510070
4. Unscrew off 3 fastening bolts with an air gun;
LG421510071
LG421510072
8-30
Mouldboard (Optional) April 17, 2019
Installation of Mouldboard Assembly CLG4215

5. Knock out other six nuts with air gun and open-
end wrench, but no need to remove the bolt;
It is not allowed to take down the 6 bolts after
their nut are removed, otherwise, security
incidents may caused due to blade sudden falling
during removal.
LG421510073
LG421510074
6. No person is allowed to stand between blade as

and front parts, and to stay away more than 0.5 m
from blade when separate blade assembly from
front frame;
Put blade as on the solid ground surface;
When separating blade as from front frame, no

person is allowed to stand between mouldboard
assembly and front parts, and to stay 0.5 m away
from mouldboard, otherwise, there exists
potential risk.
LG421510075
Installation of Mouldboard
Assembly

8-31
April 17, 2019 Ripper (Optional)
CLG4215 Ripper Removal
Ripper (Optional) Ripper Removal
Ripper is also one of optional work devices of 1. Place the machine properly.
grader, with simple and maintenance friendly 2. Hitch the ripper with proper lifting tools to
single-link structure, generally used to loosen avoid it falling.
hard soil, break road surface or split rocks. It
mainly consists of tip, teeth, mounting bracket, 3. Unscrew off the bolt and nut with wrench,
work cylinder connected to mounting bracket, remove the bolt, shim and nut orderly and
ripper frame connected to rear frame.。 place them properly.
Ripper structure drawing
6 5 4 3
LG421510077
LG421510076 4. After remove all mounting bolts, place the

ripper properly with lifting tools.
1. Tip
2. Tooth
3. Ripping tooth holder
4. Ripper frame
5. Ripper mounting bracket
6. Operating oil cylinder
8-32
Ripper (Optional) April 17, 2019
Ripper Installation CLG4215
Ripper Installation
1. Place the machine properly.

2. Lift ripper with proper lifting tools to the
position corresponding to the hole on rear
frame.
3. Align the ripper to the hole on rear frame, and
install the washers, bolts, nuts, etc. orderly to
connect ripper and rear frame.
LG421510078
4. Remove the sling after installation.

9-1
April 17, 2019 Cab System
CLG4215
Cab System
Cab Overview...................................................................................................................9-1
Possible Damage of Cab.................................................................................................9-1
Maintenance and Inspection of Cab .............................................................................9-2
Removal for Cab System ................................................................................................9-2
Removal for Control Box ........................................................................................................................9-2
Control Box Structure Description ....................................................................................................9-2
Removal Procedure of Control Box..................................................................................................9-4
Removal of Cab .....................................................................................................................................9-6
Cab Structure Sketch ......................................................................................................................9-6
Cab Removal ...................................................................................................................................9-7
Removal of Driver Seat .................................................................................................9-11

Removal of Interior Trim ...............................................................................................9-12
Convertible Cab (Optional) ...........................................................................................9-12
9-2
Cab System April 17, 2019
CLG4215
9-1
April 17, 2019 Cab Overview
CLG4215
Cab Overview Possible Damage of Cab

Cab assembly If machine is turned over or cab frame is
damaged (for example, it corrodes sharp objects
during transportation), the cab needs to be
replaced in order to be kept in a protective state.
Please check the cab after accident, including
cab frame, seat, safety belt, all auxiliary
equipment, and all lines in cab. Before re-
operation of the machine, all the damaged
elements must be replaced.
Do not weld or rectify cab frame.

LG421511001
Cab assembly consists of cab, adjustable shock-

absorbing seat, control box, platform and
decoration; it is fixed on front frame by bolts and
rubber cushion (see above figure). The cab has
two-door structure, door frame is sealed by
rubber seal strips. The roof is provided with
sound insulation and heat shield materials; Cab
glass is pasted on cab frame with special glass
cement,have a good effect of heat insulation and
noise reduction; at the same time, it provides a
wide operation view and good visibility.
The cab is provided with adjustable shock-
absorbing driver seat; the driver seat can be
adjusted up and down or back and forth; in
addition, seat backrest angle and headrest
height can be adjusted to achieve comfort of
driving. Correct use and wear of seat belt can
help you get higher safety performance. Control
box is provided on right side of driver seat. Shift
controller, hand accelerator, electric lock and
related instrument switches are arranged on
control box, which provides easy and
comfortable operating environment.
ROPS and FOPS are one of optional items for
the cab. Selecting the cab with ROPS and FOPS
functions and wearing seat belt can better
protect the operator’s safety.
9-2
Maintenance and Inspection of Cab April 17, 2019
Removal for Control Box CLG4215
Maintenance and Inspection 2. Check mounting bolt of cab assembly (for

bolt position detail, see chapter 11.4), confirm
of Cab fastening state of mounting bolt; if it is
impossible to tighten them, please replace
with new mounting bolts.
3. Check parts that are easily damaged and
rusty on the cab; Aged parts may damage
Incorrect inspection or maintenance of cab and parts; please replace aged, rusty or
ROPS may lead to injury or even death. damaged parts in time.
If cab must be replaced, the
replacement of cab parts or installation
of fasteners must be in accordance Removal for Cab System
with the required procedures.
Do not modify cab in any ways. Removal for Control Box
Informal modification of cab, such as
welding, drilling, cutting or increasing
the device etc, will reduce the Control Box Structure Description
protection strength of cab structure.
Do not repair the cab except that the Control box consists of box, cover and
cab is damaged and needs to be instrument panel (see below figure); it is fixed on
replaced. the cab platform by three mounting brackets on
the bottom of housing; The cover has two
If complete machine is turned over sections, front end is provided with shift
during operation process, operator may controller and hand throttle and rear end is
be injured or even died in the absence provided with instrument panel; both of them are
of ROPS. Removal of ROPS is only fixed by bolts.
allowed for maintenance or cab
replacement. Do not start the machine Structural diagram of control box
in the absence of ROPS.
Wearing seat belt is safer practice. 3 2
Your machine is configured with roll
over protection cab, or ROPS can 4
1
protect you. Correct use and wear of
5
seat belt can help you get higher safety
performance.
Operate the followings after your machine runs

the first 20 hours and per 500 hours:
1. Check mounting parts of driver seat and seat
belt, tighten mounting bolt of seat belt; If LG421511002
mounting parts (such as mounting bolt) are

damaged, aged or impossibly fastened, 1. Mounting bolt group of box cover
please replace them in time to ensure your 2. Cover
safety. 3. Instrument panel
4. Mounting bolt group of box body
5. Box
9-3
April 17, 2019 Removal for Cab System
CLG4215 Removal for Control Box
9-4
Removal for Cab System April 17, 2019
Removal for Control Box CLG4215
Removal Procedure of Control Box

1. Loosen bolt sets (M6) of cover and instrument
panel and remove them by cross-screwdriver;

LG421511003
2. Loosen front end cover and move it back stably,

loosen bolts (M8) on the bottom of control box by
extension socket and wrench, and then remove
them ;

LG421511004
LG421511005
9-5
CLG4215 Removal for Control Box

3. Lift instrument panel, find out wire harness plug
and release it, and then remove instrument panel
slowly;
LG421511006
LG421511007
4. Loosen mounting bolt group on the bottom of

control box by extension socket and wrench and
remove it ;
LG421511008
9-6
Removal of Cab CLG4215

5. Install instrument panel, cover and box, and then
remove control box to a flat ground.
LG421511009
Removal of Cab
Cab Structure Sketch
3
6
LG421511010
1. Front frame 4. Driver seat

2. Platform 5. Cab
3. Cab mounting bolt group 6. Platform assembly
9-7
CLG4215 Removal of Cab
Cab Removal

1. Detach pipe joint of A/C, loosen ground wire nut
and pull out the joint ;
LG421511011
2. Pull out plugs of central control box wire harness

on rear left and rear right side of the cab;
LG421511012
LG421511013
9-8

3. Depress the control lever, and pull the steering
wheel to tilt the control platform backward to end;
LG421511014
4. Loosen and remove cab mounting bolt by air

pressure gun or wrench;
LG421511015
LG421511016
9-9

5. Use a ladder with the same height, install lifting
rings on lifting eyes at the cab top, and connect
steel wire ropes to the lifting rings;
LG421511017
LG421511018
9-10

6. Lift up the cab slowly by lifting equipment and
place it on a safe and flat ground; Note: nobody is
allowed to stand under the lifted cab around 2m
and the cab shall not be shaked sharply to avoid it
from colliding with operation panel and driver seat
.
LG421511019
LG421511020
9-11
April 17, 2019 Removal of Driver Seat
Removal of Driver Seat
Driver Seat Removal Step:

1. Screw out mounting nuts for driver seat by air
pressure gun or wrench;
LG421511021
2. Pass ropes through both side armrest, and check

whether the lifting ropes are reliable;
3. Lifting the seat away.
In the process of lifting away, no persons shall
be in the range of 1 m from the driver seat or
below the driver seat, or they may be injured by
falling seat.
LG421511022
9-12
Removal of Interior Trim April 17, 2019
Removal of Interior Trim Convertible Cab (Optional)
Remove the trim cap from the top trim by a Convertible cab is optional for this type of
straight screwdriver, unscrew mounting screws vehicle.
by a cross-screwdriver, and remove the top trim.
LG421511024
LG421511023

CLG4215 Motor Grader: Applicable Type and Model: CLG4215 (DCEC Engine + Meritor Axle + ZF Gearbox)

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CLG4215 Motor Grader: Applicable Type and Model: CLG4215 (DCEC Engine + Meritor Axle + ZF Gearbox)

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201904001

General Hazard Information ...........................................................................................1-4

Unit Conversion Table ..................................................................................................1-22

Tire Inflation Pressure...................................................................................................1-31

Technical Specifications for Lubricant .......................................................................1-33

Transportation of Vehicle .............................................................................................1-35

New Vehicle Running-in................................................................................................1-43

Complete Machine Inspection Table ...........................................................................1-49

How to Use the Manual User's Guidance

● Because the influences from area or

Other reference manuals

● Parts Manual of Grager

Important Safety Information Safety Signs

LiuGong cannot anticipate every possible

Diesel engine exhaust and some of its

General Hazard Information

Be familiar with all safety cautions, failure to

Wear relevant personal protective equipment

Do not operate the machine if you feel sick,

Using goggles, safety glasses or full face mask

pressure liquids, when maintaining storage

batteries, by flying scraps when the engine is in

operation or you are using tools. When you

remove springs or resilient parts, add acid/

electrolyte to batteries, you should wear a full

face protective mask. When carrying out welding

Pay attention when opening fluid compartments

When working under high noise conditions, wear

Report all required repairs in time.

Compressed air can cause personal injury. When

Avoid injury from high-pressure oil. When

Breathing asbestos dust can be hazardous to

Crushing and Cutting If the machine must be repaired with engine

Some parts of the machine become hot during

Keep hands and objects away from moving fan

Hot oil and components can cause personal

Fire & Explosion Prevention

All fuels, most lubrication and some coolant

A fire extinguisher that meets with all local fire

Tire Explosion Prevention

Maintenance, removal, repair and installation of

Attachment Cautions Face the machine when getting on or off, grab

Check the condition of safety guards such as

doors, guards and covers. Repair any damage

Check the condition of hoses and pipes.

Before Operating the Machine

Before operating the machine on roads, check

Only operate the machine while seated. The seat

Before operating the machine, you should

During continuous operation after rain, always

Avoid any conditions that can lead to the

Parking the Machine

When possible, choose flat level ground to park

Lowering the Attachment/ Implement with

Understand and obey all regulations relating to

Standard Recommended Torque

Standard Thread Torque in Metric System

Standard torque (N•m)