CLG862 Wheel Loader 6 Work Device and Frame

Maintenance Manual Page 6－a

Manual for Work Device and Frame Maintenance

Contents

Safety Notice...……………………………………….……………………6—b
I. Hitch……………….……………………………………………………6—1
II. Work Device…………………………………………………………6—3
III. Frame…………………………………………………………………6—4
IV. Lubrication Points Distribution Diagram for Complete Machine……6 —5
V. Central Lubrication Points System (optional)………………………6—6
CLG862 Wheel Loader 6 Work Device and Frame
Maintenance Manual Page 6－b

Safety Notice

Many accidents on products’ operation and maintenance etc. are resulted from that basic safety
regulations and countermeasures are not fully obeyed. Accidents can be usually avoided if the potential of
them accidents and their places are fully cared previously. Operators shall be aware of those potential of
accidents. And essential training, skills and tools are needed for successful accomplishments of those
work..

Warning
！
Relevant safety countermeasures and warnings shall be read and fully understood before
operating and maintaining the product.

It is impossible for us to list all possible hazards (including potential hazards). This manual and
warning of the product does not include all hazards. If not using our company’s specially recommended
tools, operation procedures, working methods or operation technology, one’s own and others’ safety must
be ensured. And make sure that the operation mode in use, procedure of lubrication and maintenance won’t
do any harm to the product.

The manual shows the latest information, specification and introduction of the product. Specification,
moment, pressure, method of measurement, method of adjustment, figure and other information of the
product may be altered at any time. Change of the product’s information will also affect its service. So
please acquire the latest information of the product before work.
CLG862 Wheel Loader 6 Work Device and Frame
Maintenance Manual Page 6－1

I. Hitch 5、 Measure the value of the torsion moment

Attention: lubricate the upper and lower hitch pins
every with molybdenum disulfide lithium base
grease every 50 hours or 1 week. And inspect the
fix status of each bolt of the upper and lower hitch
pins. Once any of them become loose, fasten it
immediately.
needed for the rolling bearing cones. In case
the value of the torsion moment comes
between 2.3N.m and 13.6N.m, install the left 3
bolts(6) and fasten them. In case the value of
the torsion moment is smaller than 2.3N.m or
larger than 13.6N.m, reduce or increase the
spacer to get the right rolling torsion moment
value.

Installation Instruction of Upper Hitch

(Procedure to Assemble the Upper Hitch)

Procedure to Install the Upper Hitch Pin

Upper Articulation Figure

(1)bolt;(2)washer;(3)cover plate;(4)bolt;(5)bushing;(6)bolt;
(7)cover;(8)spacer;(9)tapered roller bearing cup;(10)tapered
roller bearing cone;(11)cover;(12)lip type packing;
(13)upper hitch pin;(14)bearing Upper Articulation Figure

(1)bolt;(2)washer;(3)cover plate;(4)bolt;(5)bushing;(6)bolt;
(7)cover;(8)spacer;(9)tapered roller bearing cup;(10)tapered
roller bearing cone;(11)cover;(12)lip type packing;
Installation Procedure:
(13)upper hitch pin;(14)bearing
1、 First smear a little molybdenum disulfide
lithium base grease on the inner wall of each
hole and the mouth of the lip type packing Installation Procedure:
(12), install the lip type packing (12) in cover
1、 Install the bushing (5) in the articulation
(7)and (11) respectively with its mouth down
hole.
as showed in the figure.
2、 Install the cooled bearing (14) in the hole
2、 Install 3 bolts (6) on the lower cover (11)
as showed in the figure. Its upper face shall
evenly. Cool the bearing cup (9) and bearing
be level with the articulation face of the
(14) down to -750±50C and then install the
frame.
lower bearing cup (9) in the bearing pedestal.
3、 Install the axis in (13) through the
Make it contact the lower cover (11).
bushing (5), upper hitch and bearing (14).
3、 After lubricating the two bearing cones (10)
4、 When fixing the cover plate, fasten the
with oil, install them in the bearing pedestal.
two bolts on opposite angles with
Then fix the cooled upper bearing cup (9) on it
equivalent moment. Then fasten another
Make sure that there is some light contact
two bolts with the fasten moment:
pressure between the bearing cup (9) and the
90±12N.m.
bearing cone.
4、 Install the spacer (8) and the upper cover(7),
fasten 3 bolts (6), its fasten moment is:
120±10N.m. Procedure to Assemble the Lower Hitch
1
CLG862 Wheel Loader
Maintenance Manual
Lower Articulation Figure
(1)lower hitch pin;(2distance sleeve;(3)lip type packing;
(4)bolt washer; (5) upper cover;(6) spacer;(7) tapered roller
bearing cup;(8) tapered roller bearing cone;(9) lip type
packing;(10)lower cover;(11)distance sleeve;(12)spacer;
(13)bolt;(14)washer;(15)Locking plate;(16)bolt;(17)washer
Installation Procedure:
1、First smear a little molybdenum disulfide
lithium base grease on the inner wall of each
hole and the mouth of the lip type packing (9)
and (3), install the lip type packing (3) in the
upper cover (5) and install the lip type packing
(9) in the lower cover (10) with their mouth up
as showed in the figure.
2、Install 4 bolts on the lower cover(10) evenly.
Cool the bearing cup (7) down to -750±50C and
then install the lower bearing cup (7) in the
bearing pedestal. Make it contact the lower
cover (10).
3、After lubricating the two bearing cones (8)
with oil, install them in the bearing pedestal.
Then fix the cooled upper bearing cup (7) on it.
Make sure that there is some light contact
pressure between the bearing cup (7) and the
bearing cone.
4、Install the spacer (6) and the upper cover(5),
fasten 4 bolts (4), its fasten moment is:
120±10N.m.
5、Measure the value of the torsion moment
needed for the rolling bearing cones. In case
the value of the torsion moment comes
between 7.9N.m and 22.6N.m, install the left 4
bolts(4) and fasten them. In case the value of
6 Work Device and Frame
Page 6－2
the torsion moment is smaller than 7.9 N.m or
larger than 22.6N.m, reduce or increase the
spacer to get the right rolling torsion moment
value.
(Procedure to Install the Lower Hitch Pin)
Lower Articulation Figure
(1)lower hitch pin;(2)distance sleeve;(3)lip type packing;
(4)bolt washer; (5)Upper Cover;(6) spacer;(7) tapered
roller bearing cup;(8) tapered roller bearing cone;(9) lip
type packing;(10)lower cover;(11)distance sleeve;
(12)spacer;(13)bolt;(14)washer;(15)locking plate;(16)bolt;
(17)washer
Installation Procedure:
1、Fix distance sleeve (2).
2、Fix distance sleeve (11) through lower
articulation hole.
3、Install the lower hitch pin(1) in through the
distance sleeve(2), lower hitches and distance
sleeve(11) as showed in the figure.
4、Fix the locking plate(15), install two bolts(16)
with the angle 1800. Its fasten moment is:
68±14N.m. Install the spacer(12) on the
locking plate 3600 around the clearance
between the measurement frame and the
locking plate. The thickness of the spacer
equals to the value of minimum measured
internal clearance minus 0.25. Install all bolts
left and fasten them.
2
CLG862 Wheel Loader 6 Work Device and Frame
Maintenance Manual Page 6－3

II. Work Devices

Attachment and Pin

Table:
Atta
chm Maximum Measures Need to
Inspecti Intended
ents Position of Clevis Pins on Size
Fit up Gap Tolerable Gap Be Taken after the
after Wear Maximum Value
and
Pins
Axis with Heads Item (mm) (mm) (mm) Be Exceeded
Drag bars and rock arm Replacing pins or
1 Gap φ90 0.220~0.394 0.90
hitch pins axle sleeves
Drag bars and bucket Replacing pins or
2 Gap φ90 0.220~0.394 0.90
hitch pins axle sleeves
Movable arms and Replacing pins or
3 Gap φ63 0.190~0.338 0.80
bucket hitch pins axle sleeves
Movable arms and rock Replacing pins or
4 Gap φ110 0.240~0.414 1.00
arm hitch pins axle sleeves
Tilting oil cylinders and Replacing pins or
5 Gap φ90 0.220~0.394 0.90
rock arm hitch pins axle sleeves
Movable arms and frame Replacing pins or
6 Gap φ90 0.220~0.394 0.90
hitch pins axle sleeves
Boom cylinders and 与 Replacing pins or
7 Gap φ75 0.220~0.348 0.85
Movable arm hitch pins axle sleeves

Attention: ensure that each moving components can move

1. Lubricate each pin of the work device with
molybdenum disulfide lithium base grease every
50 hours or 1 week to make its life longer and
3
freely. (See Complete Machine Lubrication)
2. After every 500 hours’ work of the complete
machine, it is needed to clean each component of
CLG862 Wheel Loader 6 Work Device and Frame
Maintenance Manual Page 6－4

the work device, inspect whether there is any loose 3、Install new teeth sleeve on the teeth;
bolt and whether there is any deformation, 4、Beat the pin into the closing ring, teeth
unsolder and crackles on each weld assembly, and teeth sleeve from the side of the
especially on the joint of movable arm beams. closing ring.
Once found, it shall be repaired in time.
III. Frame
3. After every 2000 hours’ work of the complete
machine, the gap between each pin and axle sleeve
shall be inspected. In case it exceeds the max
tolerable gap listed in the table above, replacement
of the pins or axle sleeves is required.
Buckets and Bucket Teeth
Warning
Make sure the bucket is steady when
replacing bucket teeth and repairing the bucket, front turning pin
rear turning pin grease pipe
or it may result in casualties

bucket teeth Sleeve

pin
closing ring
teeth
The bucket teeth are flat buckets with teeth
style. The main cutting edges and side cutting
edges are antifriction plates. It can prolong the life
of the buckets. The teeth are welded on the main
cutting edge and the teeth sleeve connecting pins
are fixed. The connection style of the teeth sleeve
and the teeth is shown in A-A section view of the
figure above.
Attention:
Inspect whether there is any deformation,
unsolder and crackles on the bucket and whether
the teeth sleeves and cutting edges are abraded
periodically. Once found, it shall be repaired or
replaced in time.
The frame mainly consists of two large
components: front frame and rear frame (see the
figure above). Both of them can move with an
angle of 380 which is achieved by the steering oil
cylinder. Articulated type frame can turn freely
with a small turning radius and a high efficiency of
loading.
Attention:
1 、 Lubricate the front, rear, left and right
turning pin every 50 hours or 1 week’s work
of the complete machine.(See Complete
Machine Lubrication Figure)
2 、 After every 500 hours’ work of the
complete machine, it is needed to inspect each
place of the front and rear frame under stress
to see whether there is any crackles and
deformation. Once found, it shall be repaired
in time.
3、When hoisting or transporting the complete
machine, the fixed link shall be fixed strictly
according to the figure below.
fixed link

Replacement Procedure of Bucket teeth:

1、Beat the pin out from the side of the
closing ring of the bucket teeth. Remove
the teeth sleeve and the closing ring;
2、Clear the teeth, pin and closing ring,
install the closing ring in the slot on the
side of the teeth;
4
CLG862 Wheel Loader 6 Work Device and Frame
Maintenance Manual Page 6－5

IV. Lubrication Points Complete Machine

Distribution Diagram of the

Distribution Diagram of the Complete Machine’s Lubrication Points

Lubrication point’s distribution of the complete

machine is show in the figure above:
Oil No.: No.3 molybdenum disulfide lithium
base grease.
Lubrication Time: Every 10 hours or 1 day’s
work time of the complete machine for lubrication
points 4, 5, 6, 9, 11, 12, 13, 14 and 15, while every
50 hours or 1 week for other lubrication points.

5
 CLG862 Wheel Loader
Maintenance Manual
V ． Centralized Lubricating
System (Optional)
This machine uses BEKA Centralized
Lubricating Device of Germany. The system
includes the pumps, allotters, pipe lines, joints and
steady rests etc. Ensure no pollution in the process
of lubrication. Lubrication can be taken with fixed
quantities at fixed times automatically while the
bearing is in operation and so to reduce friction
and abrasion, prolong its life and reduce its daily
maintenance time and working intensity. The time
for lubrication and its interval is set in the factory.
It’s better not to change it yourself.
(I) General View of Centralized
lubrication
electric pump plunger pump safety valve
①,②,③……indicates each lubrication point
respectively, and they corresponds to each point on
the lubrication chart of the complete machine.
Centralized lubricating system adopts Step-up
working mode which means to provide oil to one
lubrication point after another. This system can
control itself through a safety valve connected with
the plunger. In case any of the lubrication points
blocked and cannot work, the pressure of the
whole system will rise until a rear pressure of
280bar is established. Then the safety valve will
open automatically to ensure the safety of the
system.
Lubrication point’s distribution of the complete
machine is show in the figure above:
Oil No.: No.3 molybdenum disulfide lithium
base grease.
Lubrication Time: Every 10 hours or 1 day’s
work time of the complete machine for lubrication
6 Work Device and Frame
Page 6－6
points 4, 5, 6, 9, 11, 12, 13, 14 and 15, while every
50 hours or 1 week for other lubrication points.
(II). Composition of the System
BEKA-MAX Centralized Lubrication System
is composed of a EP-1 electric pump, pump unit,
distributors, filters, pipe lines and connecting
fittings.
1. EP-1 Electric Pump
EP-1 type of BEKA-MAX Centralized Lubricating
System is a kind of electric multipoint output
pump. When transporting NLG12# lubricating
grease with step-up distributors, the max work
pressure can reach 300bar. What’s more, the pump
can also transport oil and sliding grease.
EP-1 Electric
Pump
Main
Distributor Secondary
Distributor
Range of Operational Temperature: -35℃~+80℃
Lubricant Recommended: Lithium base grease
NLGI 2#.
Export Number: 3 at most
Delivery of a Single Pump: 0.12cc (1.8cc/min) at
most for each time.
Direction of Rotation: as the arrow shows.
Installation Position: the oil box shall be place
upright.
Case: IP 65
6
CLG862 Wheel Loader
Maintenance Manual
Electric Machine: 220V AC or DC 24V (work
rotation speed 15rpm)
Max Power Consumption (300 rear pressure): 1A
at most.
2. Installation of Pump Unit PE-120
The pump can only be installed or
disassembled when it is not working.
The plunger keeps partly bear when installed.
The plunger shall be inserted into the opening
of the pump chamber with an angle to the up. (See
Figure A)
When the plunger comes into contact with the
thrust collar, the pump unit shall rotate to the level
position. (See Figure B)
Confirm the pump unit is tightly fixed by the
plunger when it is in the slot of the guiding collar.
Figure A
Figure B
Attention
The work of the pump will be influenced in case
the operation order is changed. Make sure the
plunger is not left in the pump when assembling
the pump unit.
6 Work Device and Frame
Page 6－7
Warning
Do keep the environment clean when the
operation is in process.
3. MX-F Step-up Style Distributor:
Step-up plunger distributor controls oil
distribution through hydraulic pressure order.
Movement of the distributor plunger is controlled
by the lubricating oil provided. This distributing
mode makes lubricating oil discharged from each
hole in proper order. In case the movement of the
lubricating oil is not normal, for example, when
some lubricating oil pass or some lubricating point
is blocked, the distributor will stop working and
the hand pump will produce an intolerable rear
pressure. As to EP-1 electric pump, its safety valve
will inject oil to reduce the pressure when the
pressure is too high.
Warning:
Ensure that the plunger of the distributor
keeps level when installing the distributor.
And the installation face shall be smooth
without any obstructs.
4．Installation of the Pipe Lines:
Connection of burst resisting hoses
7
CLG862 Wheel Loader 6 Work Device and Frame
Maintenance Manual Page 6－8

case burst resisting hose

Spindle Coat

Connected

8
 micro switch for
controlling the safety valve centralized alarm +
switch proximity switch for proximity switch for controlling
controlling time and the oil level of the grease
motion
(III) Wire Connection

Br Bla

Blue
Br Bl Bla
ow ck ow ue ck
n n
Cable Connection Figure――all interfaces

Blue
Plug for connecting proximity
switches, micro switches, Black
starter reset relays or
controlling centralized alarm
systems and oil levels.

Brown Earth terminal31

Black fire wire terminal 15

Plug for connecting the
pump, panel and outer Yellow
switches.
Green signal lamp

forcing start button

F1=6.3A (5x20) embedded type fuse wire

(IV) Operation for Start up Technical Parameter:
1. The oil box shall be full of grease before Supply Voltage: 10-55V
the first start up or overhaul. The pump shall work Maximum Load Power: I=6.0A
continuously until oil comes out from each Assurance (Not Include the Equipments): F6.3A
terminal of the pipe lines of each lubrication (5x20) Embedded Fuse Wire
points. Some requirements: 1.Before connecting Output Power of the Signal Lamp: I=1A
the pipe lines, especially before connecting long Temperature Range: -35 °C to +75°C
pipe lines and pumps with little flow, the pipe lines Insulation Protection: IP65
shall be filled with grease previously. 2. The Different interval time and lubricating time
terminal of the main line is open at the beginning; range can be set in the control system.
it cannot be connected until the grease removed all Parameter Setting:
gas bubble from pipe lines. Interval Time: 0．5- 8 hours
2. Setting of lubricating time Lubricating Time:
When pressing the start button on the case of Time Range I: 1-16 min
the electric machine or the panel to start operation, Time Range II: 2-32 min
the lubrication cycle starts. When the lubrication Disassemble the red frame with a screw driver
cycle ends, the lubrication pump electric pump is and loosen the 4 cross screws when the time need
off and the stop time starts. to be adjusted. Then dismount the transparent
In case the electric machine is turned off cover plate one after another and set the time
within the stop time, the cycle will be terminated, needed according to the picture below. Mount the
but its time is saved. When it starts up again, the cover plate after setting.
operation process will go on and start from the Attention:
saved time. In case the cover plates are not closed
As to the interrupted lubrication cycle, the properly, water may come to the control
lubrication pump can be started up at any time by unit and result in harm.
pressing the forcing start button.
The interval of the machine’s lubricating time is setting of interval time (16
set 1 hour while the lubricating time is 12 min. parts, 0.5 hour for each part)

cycle

lubricating time
stop time

integrated electronic control device S-EP4

setting of lubricating time I (16

parts, 1 min for each part)

forcing start button for

starting lubricating
operation with intervals

Yellow LED for

displaying functions
dial switch for setting dial switch for setting
lubricating time interval time
setting of lubricating time I (16
Indication of
lubrication cycle
parts, 2 min for each part)
0.5 second

Yellow LED on/off

0.5 second
Wire Connection Figure of Outer Pressure Control Switch

brown
earth terminal 31
black
fire wire terminal 15
green
forcing start button
F1=6.3A (5x20) embedded type fuse wire
(V) Maintenance A) General inspection or clean be in accordance
with the regulations above.
1. Brand of the oil used: B) In case of unknown failure or maintenance
needed, please contact Beijing East-Tsanhair
Its viscosity does not exceed NLGI2#.
Company Ltd. (63819751) or Liugong Technical
2. Way of Filling Oil: Service Centre.
Fill oil from the grease nozzle with a grease
gun. Make sure the oil box is clean. Fake dirty oil
is strictly prohibited.

3. Oil Supply Test:　

A) Check the indication of the main oil
pressure gauge. (Range: 10～50bar);　
B) There is grease nozzle on each of the four
axle ends. One can press the ball core of the
grease nozzle. If there is grease coming out from
the ball core, it indicates that the oil pump
lubrication is normal. Or certain inspection is
needed.　
C) Check the consumption of lubricating
grease. (≥120ml/h).

4. Special Countermeasures:
In case the blender cannot stop when the oil
pump lubricating system breaks down or be in
overhaul, grease shall be added through the four
grease nozzles at four axle ends with a grease gun.

5. Cleaning Method of the Distributor:

A) First remove the single way oil nozzle and
blow wash it with the air pressure 3 bar;
B) Remove the distributing valve core, and
then wash it with gauze after dipping in 0# diesel
oil for 5 min;
C) Dismount the 2 hexagonal at the top of the
distributor flow divider. Separate the four layers of
valves, and dip the valve in the 0# diesel for 5
minutes. Then blow wash each hole with the air
pressure 3bar. After the cleaned pieces dry out
naturally, fix them rear in proper order.

6. Clean Method of Oil Pipes:

A) First stop the oil feed pump, remove the
heads and ends of oil pipes.
B) Tie up the air gun head with green material
belts to ensure good air tightness between the air
gun and the oil pipe head.
C) Blow wash it with an air pressure of about
5bar with intervals for 1 to 2 minutes.

7. Maintenance Provisions for the Lubrication

System:
(VI) Failures’ Courses, Reasons and Measures

Failures Causes Measures

Only the authorized electricians can be
entitled to do the following jobs:
Control power hasn’t be 1． Check whether the wire is tightly
connected to the electric connected
machine. 2． Check whether the wiring is correct
The electric 3． Check the power’s voltage
machine of the 4． Check the safety fuse is fused
pump refuses to The power should be cut off when the following operations are
work when undergoing:
powered Dissemble the pump and operate by hand.
If there is still resistance, replace the pump
The pump is damaged with electric machine rotated by hand; if
there is a high resistance, replace the electric
machine. All the replacing parts can adopt
the products from BEKA.
Incorrect lubricating oil Replace the lubricating grease of the entire
(refer to technical conditions) system. At first, empty the old grease and clear
the system with correct methods.
The electric Carry out a full inspection to see whether each
machine is hard The pressure is too high grease distributor and pipe line are blocked,
to run at low ensure the smoothness between each
speed lubrication points.
The pump or the electric Clean the pump or repair the equipment.
machine are locked
There is air in the main pipe Empty the air
line
The pile line breaks Replace pipe line
The use of inadvisable Replace the grease of the entire system;
Pressure cannot be
lubricating grease (such as firstly empty the oil grease and then clean the
set in the main
NLGI 3# Grease) system with correct methods.
pipe line
The lubricating grease is not Fill up grease to maximum level
enough
Failures of pump or electric Replace the pump and electric machine or
machine send them for repair
The electric machine refuses Refer to the above mentioned “the electric
to rotate or becomes machine is hard to run”
insensitive