LiuGong CLG835H, Service Manual

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