Disassembly and

Assembly
CLG856III Service Manual
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to
observe safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions
properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warning are not heeded, bodily injury or death could occur to your or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER” “WARNING” “CAUTION”.

The definitions of the safety signs with the words such as “danger”, “Warning” and “Caution” which
appear on the machine are as follows:
Danger: this word denote the impendent danger, and that death or serious injuries would
be caused if failure.
Warning: this word denote the potential danger, and that death or serious injuries would be
caused if failure.
Caution: this word denote the potential danger, and that minor to medium degree of injuries
would be caused if failure.
“Caution” is also used to indicate the safety information relating to unsafe operations which may
cause personal injuries. “Danger” represents the most serous dangerous conditions. The safety
signs “Danger” or “Warning” are placed near particular dangerous places. General notice
information is placed on the safety sign “Caution.”
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
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
WARNING: 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,
terminals and related accessories contain lead and lead compounds. Always wash hands
after handling.
CALIFORNINA PROPOSITION 65
WARNING: Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and reproductive
harm. Wash hands after handling.

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Brake Control Valve (Service Brake )-
CONTENTS Disassembly and Assembly .....................50
Pedal Unit — Disassembly and Assembly
Steering Frame Lock-Separate and Connect 5
.................................................................53
System Pressure - Release ..................... 6
Parking Brake Cylinder -Remove.............54
Hydraulic Tank – Remove ....................... 7
Parking Brake Cylinder -- Disassembly....55
Hydraulic Tank – Disassemble ................ 8
Parking Brake Cylinder - Assembly .........58
Hydraulic Tank – Assemble ..................... 9
Parking Brake Cylinder - Install................60
Hydraulic Tank – Install ........................... 9
High-Pressured Filter of Brake
Working Pump and Steering Pump - Remove
System—Remove ....................................60
and Install ................................................ 11
High-pressured Filter of Brake
Working Pump - Disassembly & Assembly
System-Disassembly ...............................61
................................................................ 12
High-pressured Filter of Brake
Steering Pump — Disassembly & Assembly
System--Assembly ...................................62
................................................................ 16
High-pressured Filter of Brake System--Install
Secondary Steering Pump- Remove and
.................................................................62
Install ....................................................... 18
Cab – Remove.........................................63
Metering Pump-- Remove and Install ...... 19
Cab – Install.............................................66
Steering Wheel—Remove and Install...... 21
Window Wiper and Wiper Motor (Front) –
Pilot Valve-Remove and Install................ 22
Remove ...................................................69
Pilot Feed Valve—Remove and Install .... 24
Window Wiper and Wiper Motor (Front) –
Priority Valve—Remove and Install ......... 25
Install .......................................................70
Steering cylinder—Remove ..................... 26
Window Wiper and Wiper Motor (Rear) –
Steering cylinder—Remove ..................... 27
Remove ...................................................71
Steering Cylinder - Disassemble ............. 28
Window Wiper and Wiper Motor (Rear) –
Steering Cylinder - Assemble .................. 29
Install .......................................................72
Steering cylinder—Install ......................... 30
Seat – Remove and Install.......................73
Main Control Valve (triple) – Remove and
Front and Rear Frame – Separate ...........74
Install ....................................................... 31
Front Frame and Rear Frame-Connect....77
Lift Kickout Switch - Remove and Install.. 34
Rear Fender - Remove and Install...........81
Bucket Positioner Switch - Remove and Install
Bucket – Remove and Install ...................82
................................................................ 35
Bucket Link – Remove and Install............83
Bucket Tilting Cylinder - Remove ............ 36
Bucket Lever – Remove and Install .........85
Bucket Tilting Cylinder - Disassemble ..... 38
Boom—Remove ......................................87
Bucket Tilting Cylinder - Assemble .......... 39
Boom – Install ..........................................90
Bucket Tilting Cylinder - Install ................ 40
Diesel Engine-Remove ............................91
Boom Cylinder —Remove ....................... 41
Diesel Engine -Install ...............................93
Boom Cylinder —Disassemble ................ 42
Radiator Group– Remove and Install.......95
Boom Cylinder —Assemble..................... 43
Fan Motor—Remove and Install ..............97
Boom Cylinder —Install ........................... 44
Drive Shaft (Front) – Remove and Install.98
Ride Control Accumulator-Remove and Install
Drive Shaft (Center) - Remove and Install
................................................................ 46
.................................................................100
Brake Accumulator-Remove and Install .. 47
Drive Shaft (Rear) – Remove and Install .101
Brake Control Valve (Service Brake )-Remove
Tire and Rim (Front) – Remove and Install
................................................................ 48
.................................................................102
Brake Control Valve – Install ................... 49
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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Tire and Rim (Rear) - Remove and Install104 TRANSMISSION &TORQUE CONVERTER
Front Axle – Remove and Install.............. 105 ASSEMBLY –Remove and Install............109
Rear Axle –Remove and Install ............... 106

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Steering Frame Lock-Separate

1
and Connect

Connection Procedures

2 3
Personal injury or death can result from
machine articulation or movement. 2. Move the steering frame lock link (3) in position to
the front frame. Install clevis pin (1) and locking
Machine frames can move and a person can
pin (2).
be crushed.
Note: To align the pin with bores, move the front
Connect the steering frame lock link between
frame.
the front and rear frames before working on
machine. Secure clevis pin with locking pin. Separation Procedure
Before operating the machine, fasten the
steering frame lock link into the stored
position and secure the clevis pin with
Personal injury or death can result from
locking pin.
machine articulation or movement.
Failure to lock into the stored position before
Machine frames can move and a person can
operating can result in loss of steering.
be crushed.
Note: The steering frame lock is located on the
Connect the steering frame lock link between
left side of the machine.
the front and rear frames before working on
machine. Secure clevis pin with locking pin.

Before operating the machine, fasten the

steering frame lock link into the stored
1 position and secure the clevis pin with
locking pin.

Failure to lock into the stored position before

operating can result in loss of steering.
2 3 Note: The steering frame lock is located on the
left side of the machine.
1 Remove locking pin (2) from clevis pin (1).

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

System Pressure - Release

1
Release Procedure

Personal injury can result from hydraulic oil

2 3
pressure and hot oil.

Hydraulic oil pressure can remain in the

1. Remove locking pin (2) and clevis pin (1). Move
hydraulic system after the engine has been
steering frame lock link (3) to the storage position.
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
1
Make sure all of the work implements have
been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
2 3
touch with your bare hand.

2. Install clevis pin (1) and locking pin (2)

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

1. Lower the bucket to the ground.

2. Engage the parking brake.
3. Stop the engine.
Note: For machines with electrohydraulic control,
turn the engine start switch to the ON position
after the engine stops. Place the implement
lockout switch in the UNLOCKED position.
4. Move the control levers repeatedly through the
full range of travel. This will relieve any presure
that may be present in the implement hydraul
system.

5. Depress the brake pedal repeatedly to release

6
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
brake system pressure. hydraulic system after the engine has been
stopped. Serious injury can be caused if this
6. Push down the relief valve rod on the hydraulic
pressure is not released before any service is
tank until all pressure is released.
done on the hydraulic system.
Note: Slowly remove the hydraulic tank filler cap
Make sure all of the work implements have
when releasing tank pressure. It is also safe
been lowered to the ground, and the oil is cool
enough to use the relief valve rod to release
before removing any components or lines.
hydraulic tank pressure.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
Hydraulic Tank – Remove touch with your bare hand.

Removal Procedure 1. Drain the hydraulic oil into a suitable

container for storage or disposal.
Start By:

a. remove the rear fender. Refer to “rear

fener-remove “.

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system. 2. Disconnect hose assembly (1), (2), (3), (4)
from hydraulic tank.
NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

3. remove bolt (6), （ 7 ） and remove hose

assembly (8) from the oil tank.

Personal injury can result from hydraulic oil

pressure and hot oil.

Hydraulic oil pressure can remain in the

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

4. Remove bolt (5).

5. Attach a proper lifting device to oil tank to

2. Remove retaining ring (1) (7), and take out the
remove it. The weight of the oil tank is about
cover (2), O-ring (3), return oil element (4),
272Kg（600lb）.
O-ring (5) and suctioin oil flange (6) in turn.

Hydraulic Tank – Disassemble

Disassembly Procedure
Start By:

a. Remove the hydraulic tank. Refer to

Disassembly and Assembly, "Hydraulic Tank
- Remove".

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This 3. Remove bolt (8) and take out the air filter
will help to prevent dirt from entering the internal (9).
mechanism.

1. Remove bolt (1), take out return oil filter

element (2) and O-ring (3).
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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Hydraulic Tank – Assemble

Assembly Procedure

Note: Cleanliness is an important factor. Before

assembly, all parts should be thoroughly
cleaned in cleaning fluid. Allow the parts to air
dry. Wiping cloths or rags should not be used to
dry parts. Lint may be deposited on the parts
which may cause later trouble. Inspect all parts.
If any parts are worn or damaged, use new parts
for replacement.

3. Install return oil filter (2) and O-ring (3) with bolt
(1).

End By:

a. Install the hydraulic tank. Refer to

Disassembly and Assembly, "Hydraulic Tank
- Install".

1. Use bolts (8) to install air filter (9).

Hydraulic Tank – Install

Installation Procedure

Note: Cleanliness is an important factor. Before

assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
2. Use bolt (1) (7) to install cover (2), O-ring (3), replacement.
return oil element (4), O-ring (5) and suction
flange (6) in return.

9
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
5. Refill the hydraulic tank with clean oil. Refer to
Operation and Maintenance Manual, "Refill
Capacities".

End By:

a. install the rear fender. Refer to the “rear fender

–install “section.

1. Use a suitable lifting device to position

hydraulic tank, as shown. The weight of
hydraulic tank is approximately 272 kg (600
Ib).

2. Install bolt (5).

3. Use bolt (6) to install hose assembly (8) and

fixed with bolt (7).

4. Connect hose assembly (1) (2) （3）（4）to

hydraulic tank .

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Working Pump and Steering Pump

- Remove and Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all 2. Disconnect hose assembly (6) (7).
hoses, on all wires, and on all tubes for
3. Loose stud (8) to remove work pump (9) and
installation purposes. Plug all lines, hoses, and
steering pump (10).
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.
Installation Procedure
NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

1. Use stud (8) to connect work pump (9) and

steering pump (10)

2. Connect hose assembly (6) (7)

1. Disconnect hose assembly （1）（2）（3）（4）

（5）.

3. Connect hose assembly （1）（2）（3）（4）

11
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
（5） 3. Unscrew the 4 bolts.

Working Pump - Disassembly &

Assembly

Disassembly & Assembly Procedure

4. Remove the housing.

1 .The above figure is breakdown drawing of

working pump

2. Install the pump on the table. Two bolts will

help to unscrew the 4 pump bolts.

5. Disassemble the cartridge / front cap with an

extractor.

12
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

A: Remove the retaining ring.

B: Extract the shaft / bearing assembly.

Notice: Take a protection cone to prevent

seal damage.

If you don’t, change the shaft seal.

If not new, the shaft seal should be replaced.

If the shaft Ø is bigger than the shaft seal Ø,

7. Install the shaft assembly.
please contact DENISON (TPI).
A: Protective cone on the shaft assembly.

B: Shaft assembly + protective cone into the front

cap. Slightly rotate the shaft to avoid the shaft
seal lip(s) to be deteriorated.

C: Retaining ring into the front cap.

Notice: To avoid damaging the shaft seal,

do not forget to put a protective cone on the shaft

Push on the external bearing “cage”.

6. Install the shaft seal (special tool dimensions,).
If the shaft Ø is bigger than the shaft seal Ø,
please contact DENISON (TPI)
Notice: Press carefully to avoid damaging
the seal.

8. Fit the cartridge into the housing.

13
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

10. Assemble the front cap assy on the housing &

9. Check if the dowel pin is in its position in the cartridge assy.
housing by trying to rotate the cartridge.
Notice: Position the shaft / front cap assy
Notice: Put some grease on the seals to only if the cartridge is well positioned, dowel pin in
prevent them from moving. the housing dowel pin hole.

If the cartridge does rotate, the dowel pin is not in Put some grease on the seals to prevent them
the hole. Take the cartridge out and try again. from moving.

If the cartridge does not fit in the housing correctly,

check the concentricity of the three elements = 11. Finalassy.
port plates (rear & pressure) & cam ring.
Notice:
Warning: Never use a hammer. The
a) Always check if the shaft rotates freely. If not,
cartridge is to fit into the housing without any
disassemble and go back to the previous step.
tools.
b) Flip / rotate the pump to fit the 4 screws.

c) Fix the pump to the table before tightening the

pump’s bolts.

14
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
d) Check the porting configuration

e) Tighten the 4 bolts Step by step

to avoid damaging the seals.

f) Always check if the shaft rotates freely. If not,

disassemble and go back to the previous step.

TORQUE REQUIREMENTS.

T6C-T6CM-T6CP 159 Nm 117 ft.Lbs

T6D-T7D 187 Nm 138 ft.Lbs

T6E-T7E 187 Nm 138 ft.Lbs

T7B-T7BS 187 Nm 138 ft.Lbs

15
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Steering Pump — Disassembly &

Assembly

Disassembly & Assembly Procedure

4. Unscrew the 4 bolts.

1 .The above figure is breakdown drawing of

steering pump

2. Remove the coupling. 5. Remove the front cap/ cartridge assembly.

3. Install the pump on the table. Two bolts will 6. Disassemble the cartridge from the front cap
help to unscrew the 4 pump bolts. with an extractor.

16
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Notice:

a) Always check if the shaft rotates freely. If not,

disassemble and go back to the previous step.

b) Check the porting configuration (see table

page 29).

7. All needed sub-assemblies are obtained.

c) Tighten the 4 bolts. Step by step
to avoid damaging the seals.

d) Always check if the shaft rotates freely. If not,

disassemble and go back to the previous step.

TORQUE REQUIREMENTS.

T6C-T6CM-T6CP 159 Nm 117 ft.Lbs

T6D-T7D 187 Nm 138 ft.Lbs

T6E-T7E 187 Nm 138 ft.Lbs

8. Assemble the new cartridge in the housing. T7B-T7BS 187 Nm 138 ft.Lbs

Notice: Check if the dowel pin is in its

position in the housing by trying to rotate the
cartridge.

9 . Install the front cap & shaft assembly. Orient

the P1 to obtain the correct porting.

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Secondary Steering Pump-

Remove and Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for 2. Remove bolt (4) and nut (5), remove secondary
installation purposes. Plug all lines, hoses, and steering pump (1)
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system. Installation Procedure
NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

1. Use bolt (4) and nut (5) to install secondary

steering pump (1)

1. Remove hose assembly (2) (3)

18
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
2. Install hose assembly (2）(3). pressure is not released before any service is
done on the hydraulic system.

Make sure all of the work implements have

Metering Pump-- Remove and been lowered to the ground, and the oil is cool
before removing any components or lines.
Install Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
Removal Procedure touch with your bare hand.

Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering
Frame Lock - Separate and Connect".

b. Release the hydraulic system pressure. Refer

to Disassembly and Assembly, "Hydraulic
System Pressure - Release".

c. Remove the rear fenders.

NOTICE

Care must be taken to ensure that fluids are

1. Remove hose assembly (2) (3) (4) from the
contained during performance of inspection,
metering pump (1)
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids.

Dispose of all fluids according to local regulations

and mandates.

Note: Put identification marks on all hoses, on all

hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.
2.Remove hose assembly (5)（6）

Personal injury can result from hydraulic oil

pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this

19
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

3. Remove bolt (7) and metering pump (1).

3. Install hose assembly (2) (3) (4).

Installation Procedure

1. Install metering pump (1) with bolt (7)

2. Install hose assembly (5) (6).

20
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Steering Wheel—Remove and

Installation Procedure

Install

Removal Procedure
Start By

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect". 2 3

1. Install steering wheel (2) and nut (3). Tighten

nut (3) to a torque of 50 ± 4 N-m (37 ± 3 lb ft).

1. Remove button (1).

1

2. Install button (1).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
2 3 Lock - Separate and Connect".

2. Remove nut (3) from steering wheel (2).

3. Remove steering wheel (2).

21
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Pilot Valve-Remove and Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this 1. Remove bolt (11), remove cover (10)
helps to keep contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are 12

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids. Dispose of all fluids according 2. Disconnect harness (12)
to local regulations and mandates.

Personal injury can result from hydraulic oil

pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.

Make sure all of the work implements have

been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine 3.Disconnect hose （1）（2）（3）（4）（5）
is stopped, and the filler cap cool enough to （6）（7）（8）（9）.
touch with your bare hand.

22
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

13 14

4. Remove bolt (13), remove pilot valve (14).

Installation Procedure
Note: Cleanliness is an important factor. Before
2. Connect hose（1）（2）（3）（4）（5）（6）
assembly, all parts should be thoroughly cleaned
（7）（8）（9）.
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
12
replacement.

3. Disconnect harness (12).

13 14

1. Install bolt (13) to secure pilot valve (14).

4. Install cover (10) and secured with bolt (11).

23
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
touch with your bare hand.
Pilot Feed Valve—Remove and

Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

1.Disconnect hose assembly （1）（2）（3）.
hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
2. Remove bolt (4), remove pilot feed valve.
suitable containers before opening any
compartment or disassembling any component Installation Procedure
containing fluids. Dispose of all fluids according
Note: Cleanliness is an important factor. Before
to local regulations and mandates.
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
Personal injury can result from hydraulic oil are worn or damaged, use new parts for
pressure and hot oil. replacement.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.

Make sure all of the work implements have

been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to 1. Install bolt (4) to secure pilot feed valve to

24
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
frame.

2. Connect hose assembly （1）（2）（3）

Priority Valve—Remove and Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids. Dispose of all fluids according
to local regulations and mandates.

Personal injury can result from hydraulic oil

pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been

25
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
stopped. Serious injury can be caused if this 3．Remove bolt (6), remove priority valve (7).
pressure is not released before any service is
done on the hydraulic system.
Installation Procedure
Make sure all of the work implements have
been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
touch with your bare hand.

1. Install bolt (6) to secure priority valve (7) to the

frame.

1.Disconnect hose （1）（2）.

2. Connect hose（3）（4）（5）.

2. Disconnect hose （3）（4）（5）.

3.Connect hose （1）（2）

26
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
contaminants from entering the system.
Steering cylinder—Remove

Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering
Frame Lock - Separate and Connect".

b. Release the hydraulic system pressure. Refer

to Disassembly and Assembly, "Hydraulic
System Pressure - Release".

c. Remove the rear roading fenders. Refer to

Disassembly and Assembly, "Roading Fender
１. Use Tooling A to remove hose assembly (1)
(Rear) - Remove and Install".
and hose assembly (2).

Cylinders equipped with lock valves can

remain pressurized for very long periods of
time, even with the hoses removed.

Failure to relieve pressure before removing a

4 3
lock valve or disassembling a cylinder can
result in personal injury or death.

Ensure all pressure is relieved before

2. Remove grease fitting (4) and bolt (3).
removing a lock valve or disassembling a
cylinder.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any 5
compartment or disassembling any component
containing fluids.
3. Remove pin (5) on the piston rod.
Dispose of all fluids according to local regulations
and mandates.

Note: Put identification marks on all hoses, on all

hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
27
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Start By:
8
a. remove the bucket tilting cylinder. Refer to
“bucket tilting cylinder-remove”secion in
disassembly and assembly.

7 6
Care must be taken to ensure that fluids are
contained during performance of inspection,
4. Remove bolts (6) and pin (7) on oil tank. maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
5. Attach a suitable lifting device to steering
suitable containers before opening any
cylinder (8). Remove steering cylinder (8).
compartment or disassembling any component
containing fluids.
Steering Cylinder - Disassemble
Dispose of all fluids according to local regulations
Disassemble Procedure and mandates.

Note: Cleanliness is an important factor. Before

Required Tools the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
Tool Part Description Qty will help to prevent dirt from entering the internal
sleeve 1 mechanism.
double-end spanner 1
oil press 1
wrench B30 1

28
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
1. Place the steering cylinder on the stand. 15. Remove the two blocks (22) on the two
sides of the cylinder body (11).
2. Remove all of the pipes that connect with the
steerting cylinder. 16. Remove the knuckle bearing (23) from
the cylinder body (11) with oil press.
3. Remove bolt (20) and washer (21) that secure
cover (3) to cylinder body (11).
Steering Cylinder - Assemble
4. Remove piston rod assembly (10) from the
cylinder bdoy (11). Assemble Procedure
5. Remove lock nut (16) and take piston (12) out Required Tools
of the piston rod (10).
Tool Part Description Qty
6. Take out O-ring (13) in piston rod (10).
sleeve 1
7. Remove the two retainers (15) and ring (14) double-end spanner 1
from piston (12). oil press 1

8. Remove cover (3) from piston rod (10). Note: Cleanliness is an important factor. Before
9. Remove O-ring (5) from cover (3). assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
10. Remove retainer (4) and seal (9) from cloths or rags should not be used to dry parts.
cover (3). Lint may be deposited on the parts which may
11. Remove dust ring (1) from cover (3). cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
12. Remove lip ring (2) from cover (3) replacement.
13. Remove block (22) from piston rod (10).

14. Remove knurckle bearing (23) from

piston rod (10) with oil press.

29
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

1. Perform all necessary repairs to the hydraulic bolt (20) and washer (21) to secure cylinder cover
cylinder before assembly. Check the bore of (3) to cylinder body (11). Tighten the bolt to
cover (3) bevel edge of piston (12) for burr. torque 150±20N.m.
Remove the burr with file or blade.

2. The parts surface should be free from particle

Steering cylinder—Install
when viewed with eyeballing. Wash the particle
Installation Procedure
with clean lamp oil and wipe the parts surface with
clean silk cloth. Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
Note: Apply a light film of hydraulic oil to all
in cleaning fluid. Allow the parts to air dry. Wiping
components before assembly.
cloths or rags should not be used to dry parts.
3. Vertically align the knuckle bearing (23) with Lint may be deposited on the parts which may
the bore of the cylinder body (11). Start the oil cause later trouble. Inspect all parts. If any parts
press to install the knuckle bearing (23) into the are worn or damaged, use new parts for
bore. replacement.

4. Install the two blocks (22) into the bore of １. Attach a suitable lifting device to steering
cylinder body (11). cylinder (8) and position steering cylinder (8).

5. Vertically align the knuckle bearing (23) with

the bore of piston rod (10). Start the oil press to 8
install the knuckle bearing (23) into the bore.

6. Install the two blocks (22) into the bore of

piston rod (10).

7. Install retainer (4) and seal (9) into cover (3).

7 6
8. Install dust ring (1) and lip seal (2) into cylinder
cover (3).
２. Install pin (7) and bolt (6)
9. Install O-ring (5) to cylinder cover (3).

10. Install cylinder cover (3) to piston rod (10).

11. Install the two retainers (15) and ring (14) to

piston (12).

12. Install O-ring (13) to piston rod (10).

13. Install piston (12) to piston rod (10).

5
14. Install lock nut (16) into thread end of the
piston rod (10), tighten the nut to a torque of 1560
±200. 3. Install pin (5).

15. Install piston rod (10) into the cylinder body

(11).

16. Adjust the cylinder cover (3) position. Install

30
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

c Pneumatic Wrench 1

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
4 3 mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
4. Install bolt (3) and grease fitting (4). installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids.

Dispose of all fluids according to local regulations

5. Use Tooling A to install hose assembly (1) and and mandates.
hose assembly (2)

End By:

a. Separate the steering frame lock. Refer to Hot oil and components can cause personal
Disassembly and Assembly, "Steering Frame injury.
Lock - Separate and Connect".
Do not allow hot oil or components to contact
skin.

Main Control Valve (triple) –

Remove and Install

Removal Procedure
Required Tools

Tool
Part Description Qty 1. Use Tooling (A) in order to support lift arm (1).

A stand 2 2. Release the system hydraulic pressure. Refer

B spanner As 1 to Disassembly and Assembly, "System
Pressure-Release".
31
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
3. Drain the hydraulic oil into a suitable container
or disposal.

7. Remove hose assembly（11）（12）（13）.

4. Remove cover assembly (2).

5. Disconnect tube assemblies (3) （4）（5）

8. Remove hose assembly（14）（15）（16）
from main control valve (6). （17）.

9. Remove bolt (18), take out control valve (19).

6. Disconnect tube assemblies （ 9 ） （ 10 ） ,
disconnect hose assemblies（7）（8）。

32
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Installation Procedure
Required Tools

Tool Part Part Description Qty

Number
Stand
A 2

B Spanner As 1
c Pneumatic Wrench 1

3. Connect hose assembly （11）（12）（13）.

1. Install bolt (18) to secure control valve (19).

4. Connect tube assembly （9）

（10）,connect
hose assembly （7）（8）.

2. Connect hose assembly （14）（15）（16）

（17）.

5. Connect tube assembly （3）（4）（5）（6）

onto control valve (1).

33
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Lift Kickout Switch - Remove and

Install
2
Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".
6. Install cover assembly (2).
Note: The lift kickout switch is located at the rear
7. Refill the system with hydraulic oil. Refer to end of the left lift arm.
Operation and Maintenance Manual, "Refill
Capacities".
2
1

1. Remove harness (1)

1.断开线缆(1)
8. Start the machine in order to raise the lift arms
and remove Tooling (A). 2. Remove bolt (2).

3. Remove nut (4) and the lift kickout switch.

34
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Installation Procedure Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

1. Install the lift kickout control and nuts (4).

2. Connect bolt (2).

2 1. Remove harness (1).

2
3. Install harness (1).

4. Adjust the lift kickout switch. Refer to Testing

and Adjusting, "Lift Kickout - Adjust". 2. Remove bolt (2) and holder (3).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

Bucket Positioner Switch -

4

Remove and Install 3. Remove bolt (4) and bucket positioner switch.

Removal Procedure Installation Procedure

Start By: Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
a. Connect the steering frame lock. Refer to
in cleaning fluid. Allow the parts to air dry. Wiping
Disassembly and Assembly, "Steering Frame
cloths or rags should not be used to dry parts.
Lock - Separate and Connect".
Lint may be deposited on the parts which may

35
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement. Bucket Tilting Cylinder - Remove

Removal Procedure
Start By:

a. Remove the work tool positioner control. Refer

to Disassembly and Assembly, "Tilt Position
Sensor and Mounting (Bucket Positioner Control)
Remove and Install".
4
b.Release the hydraulic system pressure. Refer
to Disassembly and Assembly, "System Pressure
1. Install bolt (4) and bucket positioner switch.
Release".

3 Cylinders equipped with lock valves can

remain pressurized for very long periods of
time, even with the hoses removed.
2
Failure to relieve pressure before removing a
lock valve or disassembling a cylinder can
result in personal injury or death.
2. Install bolt (2) and holder (3).
Ensure all pressure is relieved before
removing a lock valve or disassembling a
1 cylinder.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
3. Install harness (1).
containing fluids. Dispose of all fluids according
4. Adjust the bucket positioner sensor. Refer to to local regulations and mandates.
Testing and Adjusting, "bucket Positioner -
Adjust".

End By:
Personal injury can result from hydraulic oil
a. Separate the steering frame lock. Refer to pressure and hot oil.
Disassembly and Assembly, "Steering Frame
Hydraulic oil pressure can remain in the
Lock - Separate and Connect".
hydraulic system after the engine has been

36
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.

Make sure all of the work implements have

been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
touch with your bare hand.

Note: Put identification marks on all lines, on all

3. Remove hose assembly (4).
hoses, on all wires, and on all tubes. Plug all lines,
all hoses, and all tubes. This will help to prevent
fluid loss and this will help to keep contaminants
from entering the system.
1

4. Attach a suitable lifting device to tilting cylinder

(1).

5
1. Disconnect hose assembly (2) from bucket
tilting cylinder (1).

5. Remove pin assembly (5).

2. Disconnect grease hose assembly (3).

6. Remove rear pin assembly (6).

37
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
7. Use a suitable lifting device to remove the a. Remove the tilting cylinder. Refer to
tilting cylinder from the machine. Disassembly and Assembly, “Bucket Tilting
Cylinder –Remove”

Note: Cleanliness is an important factor. Before

Bucket Tilting Cylinder - assembly, all parts should be thoroughly cleaned
to prevent dust from entering into the innne
Disassemble mechanism.

Disassemble Procedure
Start by:

21
20 18
19

7
6
1716
12
11
13
8 9 05
02
8 14
3 15
4
3

10
25 24

1 23

22
23

1. Place the bucket tilting cylinder on to stand. 4. Remove piston rod (7) assembly from the
The weight of the cylinder is about 160 kg. cylinder body (1).

2. Remove all the pipes that connect to bucket 5. Remove lock nut (02), remove piston (6) from
tilting cylinder. the piston rod (7).

3. Remove bolt (14) and washer (15) that secure 6. Remove O-ring (5) from piston rod (7).
cylinder cover (13) to cylinder body (1).
7. Remove the two retainers (3) and seal ring (4)

38
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
from the piston (6). 3. Vertically align the boom cylilnder bushing (22)
with the bore of the cylinder body (1). Start the oil
8. Remove cylinder cover (13) from the
press and use the special clamp for cylinder
piston rod (7).
bushing to install the the boom cylilnder bushing
9. Remove O-ring (10) from cylinder cover (22) into the bore.
(13).
4. Install the two seals (23) with the lip outside
10. Remove the two rings (8) and seal (9) into the bore of cylinder body (1).
rom the cylinder head (13).
5. Install the retainer (11) into the cylinder cover
11. Remove retainer (17) from the cylinder head (13).
(13).
6. Install Y seal (12) and dust ring (16) into
12. Remove the Y seal (12) and dust ring cylinder cover (13).
(16) from the cylinder head (13).
7. Install the two rings (8) and seal (9) into
13. Remove the retainer (11) from the cylinder cover (13).
cylinder head （13）.
8. Install retainer (17) into cylinder cover (13).
14. Remove the two seals (23) from the
9. Install O-ring (10) onto cylinder cover (13).
clinder body (1).
10. Install cyinde cover (13) onto the piston rod
15. Remove the boom cylinder bushing (22)
(7).
from cylinder body.
11. Install the two retainers (3) and seal ring (4)
Bucket Tilting Cylinder - Assemble on to the piston (6).

12. Install O-ring (5) onto piston rod (7).

Assemble Procedure
13. Install piston (6) onto piston rod (7).
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned 14. Install lock mut (02) into the thread end of
in cleaning fluid. Allow the parts to air dry. Wiping piston rod (7). Tighten the nut to a torque of 3600
cloths or rags should not be used to dry parts. ±360N.m.
Lint may be deposited on the parts which may
15. Apply clean oil to retainer (3), seal ring (4) and
cause later trouble. Inspect all parts. If any parts
O-ring (10).
are worn or damaged, use new parts for
replacement. 16. Attach a suitable lift device to install piston rod
(7) intot he cylinder body (1).
Note: Apply a light film of hydraulic oil to all
components before assembly. 17. Adjust the position of cylinder cover (13).
Install bolt (14) and washer (15) to secure
1. Perform all necessary repairs to the hydraulic
cylinder cover (13) to cylinder body (1). Tighten
cylinder before assembly. Check the bore of
the bolt to a torque of 367±55N-m
cover (3) bevel edge of piston (12) for burr.
Remove the burr with file or blade.

2. The parts surface should be free from particle

when viewed with eyeballing. Wash the particle
with clean lamp oil and wipe the parts surface with
clean silk cloth.

39
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Bucket Tilting Cylinder - Install

5
Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
4. Install pin assembly (5).
are worn or damaged, use new parts for
replacement.

5. Connect hose assembly (4).

1. Lubricate the pin bores with Tooling (L).

2. Use a suitable lifting device to position tilt

cylinder (1). 3

6. Connect grease hose assembly (3).

3. Install rear pin assembly (6).

40
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
7. Connect hose assembly (2).

End By:
Personal injury can result from hydraulic oil
a. Install the bucket positioner. Refer to
pressure and hot oil.
Disassembly and Assembly, “Bucket
Positioner -Remove and Install". Hydraulic oil pressure can remain in the
hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
Boom Cylinder —Remove Make sure all of the work implements have
been lowered to the ground, and the oil is cool
Removal Procedure
before removing any components or lines.
Start By: Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
a. Connect the steering frame lock. Refer to
touch with your bare hand.
Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect". Note: Put identification marks on all lines, on all
hoses, on all wires, and on all tubes. Plug all lines,
all hoses, and all tubes. This will help to prevent
fluid loss and this will help to keep contaminants
Cylinders equipped with lock valves can from entering the system.
remain pressurized for very long periods of
time, even with the hoses removed.

Failure to relieve pressure before removing a

lock valve or disassembling a cylinder can
result in personal injury or death.

Ensure all pressure is relieved before

removing a lock valve or disassembling a
cylinder.

NOTICE
1. Position the lift arm on brakcet (A), as shown.
Care must be taken to ensure that fluids are
2. Release the pressure in the hydraulic system.
contained during performance of inspection,
Refer to Disassembly and Assembly, "System
maintenance, testing, adjusting and repair of the
Pressure - Release".
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

41
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
6. Remove nuts (6) and fender assembly (5).

8 9

3. Disconnect hose assemblies (3) from boom

7. Remove grease fitting (7) from pin assembly
cylinder (2).
(8).

8. Remove bolt (9) from pin assembly (8).

9. Remove pin assembly (9).

10. Use the lifting device to remove the boom

cylinder (2)

4. Attach a suitable lifting device to lift cylinder (2), Boom Cylinder —Disassemble
as shown.
Disassemble Procedure
Start by:

a. remove the boom cylinder. Refer the “boom

cylinder –remove” section in assembly and
disassembly.

Note: Cleanliness is an important factor. Before

4
assembly, all parts should be thoroughly cleaned
to prevent dust from entering into the innne
mechanism.
5. Remove pin assembly (4).

5 6

42
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

16

03
11 04
03
10
17 08
12
15 14
21 13
09
19
18 06
20 02
01

07
23
05

22
23

1. Place the boom cylinder onto the stand. The 12. Remove retainer (17) from cylinder head
weight of the boom cylinder is about 160 kg. (13).

2. Remove all the pipes that connect to boom 13. Remove retainer (12) and dust ring (16)
cylinder. from cylinder head (13).

3. Remove bolt (14) and washer (15) that secure 14. Remove the two seal rings (23) on both
cylinder cover (13) onto cylinder body (1). sides of cylinder body (1).

4. Remove piston rod assembly (7) from cylinder 15. Use oil press to remove bushing (22) from
body (1). cylinder body.

5. Remove lock nut (02). Remove piston (6) from

piston rod (7).
Boom Cylinder —Assemble

6. Remove O-ring (5) from piston rod (7). Assemble Procedure

7. Remove the two retainers (3) and seal ring (4) Note: Cleanliness is an important factor. Before
from piston (6). assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
8. Remove cylinder cover (13) from piston
cloths or rags should not be used to dry parts.
rod (7).
Lint may be deposited on the parts which may
9. Remove O-ring (9) from cylinder cover cause later trouble. Inspect all parts. If any parts
(13). are worn or damaged, use new parts for
replacement.
10. Remove retainer (8) and seal ring (10)
from cylinder cover (13) Note: Apply a light film of hydraulic oil to all
components before assembly.
11. Remove Y seal ring (11) from cylinder
head (13). 1. Perform all necessary repairs to the hydraulic

43
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
cylinder before assembly. Check the bore of
cover (13), busing (22) and bevel edge of piston
（6）for burr. Remove the burr with file or blade. Boom Cylinder —Install
2. The parts surface should be free from particle
Installation Procedure
when viewed with eyeballing. Wash the particle
with clean lamp oil and wipe the parts surface with Required Tools
clean silk cloth. Qty
Tool Part Description
3. Vertically align the bushing (22) with the bore of
the cylinder body (1). Start the oil press and use A stand 1
special clamp for bushing to install boom cylinder
bushing (22) into the bore. B spanner assembly 1

4. Install the two seals (23) with its lip outside into
C grease pump 1
the bore of cylinder body (1).

5. Install Y seal (11) into cylinder cover (13). Note: Lubricate the bores and the pins with
6. Install seal ring (10) and retainer (8) into Tooling (C) before installation.
cylinder cover (13).

7. Install retainer (12) and dust ring (16) into

cylinder cover (13).

8. Install retainer (17) into cylinder cover (13).

9. Install O-ring (9) into cylinder cover (13).

2
10. Install cylinder cover (13) into piston rod (7).

11. Install retainers (3) and seal ring (4) into

piston (6). 1. Use a suitable lifting device to position lift
12. Install O-ring (5) into piston rod (7). cylinder (2).

13. Install piston (6) into piston rod (7).

14. Install lock nut (02) into the thread end of 7

piston rod (7). Tighten the bolt to a torque of 3600
±360N.m.

15. Apply clean oil to retainer (3), seal ring (4) and
O-ring (9).
8 9
16. Attach a suitable lift device to install piston rod
(7) into cylinder body (1).
2. Install pin assembly (8).
17. Adjust the position of cylinder cover(13).
Install bolt (14) and washer (15) to secure 3. Install bolt (9) to sercure pin assembly (8).
cylinder cover (13) to cylinder body (1). Tighten 4. Install grease fitting (7) to pin assembly (8).
the bolt to a torque of 367±55N-m.

44
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

5. Install pin (4). 9. Start the machine. Raise the lift boom and
remove brakcet (A).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".
5 6

6. Use a suitable lifting device to position fender

assembly (5) and install nuts (6).

7. Connect hose assembly (3) with boom

cylinder (2)

8. Lubricate the pin bores of the lift cylinder with

Tooling (M).

45
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Ride Control

Accumulator-Remove and Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, cleanethe surface of
the component thoroughly. This will help to
prevent dirt from entering the internal
mechanism.
1. Disconnect hose (1).
Note: Put identification marks on all lines, on all
hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with 2. Remove U bolt (3), remove accumulator (2).
suitable containers before opening any
compartment or disassembling any component
containing fluids. Dispose of all fluids according Installation Procedure
to local regulations and mandates.
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Personal injury can result from hydraulic oil
Lint may be deposited on the parts which may
pressure and hot oil.
cause later trouble. Inspect all parts. If any parts
Hydraulic oil pressure can remain in the are worn or damaged, use new parts for
hydraulic system after stop the engine. replacement.
Serious injury can be caused if this pressure
is not released before any service is done on
the hydraulic system.

Make sure all of the implements have been

lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
touch with your bare hand.

46
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
1. Install U-bolt (3) to secure accumulator (2).

3. Connect hose (1).

2. Disconnect hose assemblies (2) (3) (4).

Brake Accumulator-Remove and

Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal 3. Remove U-bolt (5).
mechanism.
4. Remove brake accumulator (6)。
Note: Put identification marks on all lines, on all
hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
Installation Procedure
helps to keep contaminants from entering the
system. Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

１. Open door assembly (1).

47
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Brake Control Valve (Service

Brake )-Remove

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the
1. Install brake accumulators (6) and install U-bolt internal mechanism.
(5).
Note: Put identification marks on all lines, on all
hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to prevent contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of Inspection,
maintenance testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
2. Connect hose assemblies（2）(3)（4）.
containing fluids.

Dispose of all fluids according to local

regulations and mandates.

Personal injury can result from hydraulic oil

1 pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
２. Close door assembly (1).
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.

Make sure all of the work implements have

been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
48
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
is stopped, and the filler cap is cool enough to
touch with your bare hand.

12

１. Remove cable (12).

4. Disconnect hose assembly （8）（9）（10）

5. Remove nut (11) and brake control valve (1).

２. Disconnect hose assembly （2）（3）

Brake Control Valve – Install

Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
3. Disconnect hose assembly （4）（5）（6）
Lint may be deposited on the parts which may
（7）
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

49
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

1. Position brake control valve (1) and install nut

(11). 4. Connect hose assembly（2）（3）

12

5. Connect cable (12).

2. Connect hose assembly（8）（9）（10）

Brake Control Valve (Service

Brake )- Disassembly and

Assembly

Disassembly Procedures
Start By:

a. Remove brake control valve. Please refer to

3. Connect hose assembly（4）（5）（6）（7）
Disassembly and Assembly, “Brake Control
Valve –Remove” section.

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
50
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
mechanism.

51
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

1.0. Housing 72. Pedal unit

1.22. Spool 73. Locking nut
1.23. Spool 76. Solenoid valve
1.25. Spool 82. Compression spring
1.47. Jet 83. Screw
4. Sleeve 84. Screw
9. Sleeve LV 86. Relief valve unit
12. Spring retainer 87. Sleeve LV
14. Spring retainer 88. Sleeve LV
18. Compression sprigng 90. Check valve
21. Spring retainer 91. Nut
26. Compression spring 105. Retaining washer
27. Compression sprigng 36.80. O-ring
28. Compression sprigng 36.128. Shaft seal
29. Compression sprigng 36.129. Guide ring
30. Compression sprigng 111. Sleelve
31. Compression sprigng 150. Pressure switch
32. Compression sprigng 151. Pressure switch
36. Sleeve unit 152. Sealing ring
40. Locking screw 115. Locking screw
41. Locking screw 116. Locking screw
42. Locking screw 85. Cap
43. Locking screw 104. Cap
48. Blind rivet
49. Identification plate
59. Connector assembly
9. Remove pressure switch (151) and sealing
1. remove bolt （83）（84）and washer (105),
ring (152).
remove pedal assembly (72).
10. Remove connector assembly (59).
2. Remove sleeve unit (36)
11. Remove compression spring (31) and
3. Remove sleeve（111） from sleeve unit (36)
spool (1.23)
4. Remove compression spring (26) and
12. Remove compression spring (30) and
spring retainer (14).
spool (1.22)
5. Remove compression spring (82) and
13. Loose nut (104) and remove group (C)
spring retainer (21)
14. Remove solenoid valve (76).
6. Remove lock nut (41) and take out
compression spring (18). 15. Remove pression switch (150) and sealing
ring (152).
7. Remove lock nut (41); take out spool (1.25)
and compression spring (32). 16. Remove lock nut (43) and jet (1.47)

8. Remove lock nut (42) and take out group

(A)

52
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Assembly Procedures 11. Install compression spring (82) and spring
retainer (21) into housing (1.00).
Note: Cleanliness is an important factor.
Before assembly, all parts should be 12. Install compression spring (26) and spring
thoroughly cleaned in cleaning fluid. Allow the retainer (14) into housing (1.00).
parts to air dry. Wiping cloths or rags should
13. Install sleeve (111) and sleeve unit (36).
not be used to dry parts. Lint may be
Tighten the sleeve unit (36) to a torque of
deposited on the parts which may cause later
20N.m.
trouble. Inspect all parts. If any parts are worn
or damaged, use new parts for replacement. 14. Install cap (85) to pedal unit (72).

Note: Apply a light film of hydraulic oil to all 15. Install bolt （83）（84）and washer (105)
components before assembly. to secure pedal unit (72) to housing (1.00).
Tighten bolt (83) to a torque of 22N.m.
1. Install locking screw (43) and jet (1.47) onto
housing (1.00), tighten the locking screw (43)
to a torque of 60N.m.

2. Install pressure switch (150) and sealing

Pedal Unit — Disassembly and
ring (152) to housing (1.00)
Assembly
3. Install solenoid valve (76) to housing (1.00),
tighten the solenoid valve (76) to a torque of Disassembly Procedures
10N.m
Note: Cleanliness is an important factor.
4. Install group C onto housing (1.00) and Before the disassembly procedure, the
install cap (104). exterior of the component should be
thoroughly cleaned. This will help to prevent
5. Install compression spring (30) and spool
dirt from entering the internal mechanism.
(1.22) into housing (1.00).

6. Install compression spring (31) and spool

(1.23) into housing (1.00)

7. Install connector assembly (59) into housing

(1.00). Tighten the connector assembly (59) to
a torque of 60N.m.

8. Install pressure switch (151) and sealing

ring (152) to connector assembly (59).

9. Install group (A) onto housing (1.00).

Tighten the locking screw (42) to a torque of
100N.m.

10. Install compression spring (32) and spool

(1.25) into housing (1.00). Tighten the locking
screw (41).

11. Install compression spring (18) into

housing (1.00); tighten locking screw (41) to a
110. Plate
torque of 60N.m.
53
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
112. Segment (121), washer (122) to secure plate (112) to
113. Plate plate (113).
114. Bolt
4. Install plate (123) to plate (113).
115. Bending spring
116. Grub screw 5. Install spring (115), bolt (114) and retainer
117. Hexagon screw (1) to secure plate (112) to plate (10).
118. Hexagon screw
120. Hexagon screw
121. Hexagon screw
122. Washer
Parking Brake Cylinder -Remove
123. Plate
Removal Procedure
Start By:
1. Remove retainer (1), take out bolt (114) and
spring (115). a. Connect the steering frame lock. Refer to
Disassembly and Assembly, "Steering
2. Remove screw (121) and washer (122),
Frame Lock - Separate and Connect".
remove hexagon screw (120).
NOTICE
3. Separate plate （112）
（113）and plate（123）
Care must be taken to ensure that fluids are
4. Remove hexagon screw (117) and screw
contained during performance of inspection,
(118).
maintenance, testing, adjusting and repair of
5. Remove hexagon screw (116) and screw the product. Be prepared to collect the fluid
(118). with suitable containers before opening any
compartment or disassembling any
Assembly Procedures
component containing fluids.
Note: Cleanliness is an important factor.
Dispose of all fluids according to local
Before assembly, all parts should be
regulations and mandates.
thoroughly cleaned in cleaning fluid. Allow the
parts to air dry. Wiping cloths or rags should
not be used to dry parts. Lint may be
deposited on the parts which may cause later
Personal injury can result from hydraulic
trouble. Inspect all parts. If any parts are worn
oil pressure and hot oil.
or damaged, use new parts for replacement.
Hydraulic oil pressure can remain in the
Note: Apply a light film of hydraulic oil to all
hydraulic system after the engine has been
components before assembly.
stopped. Serious injury can be caused if
Note: apply light film oil to all parts before this pressure is not released before any
assembling. service is done on the hydraulic system.

1. Install hexagon screw (116) and screw (118) Make sure all of the attachments have been
to plate (110). lowered; oil is cool before removing any
components or lines. Remove the oil filler
2. Install hexagon screw (117) and screw
cap only when the engine is stopped, and
（118）to plate (110).
the filler cap is cool enough to touch with
3. Install hexagon screw (120) and screw your bare hand.

54
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Note: Put identification marks on all lines, on
all hoses, on all wires and on all tubes for
installation purposes. Plug all lines, all hoses
and all tubes. This helps to prevent fluid loss
and this helps to keep contaminants from
entering the system.

Block the machine to prevent movement

before releasing the brake. The machine
can roll free if it is not blocked.

1. Park the machine on a flat, level surface.

5. Remove pin (4) and shaft (5). Disengage
Lower the bucket to the ground. Chock the
arking brake lever (6).
wheels in order to keep the machine from
rolling when the parking brake is released.

2. Release the hydraulic system pressure.

Refer to Disassembly and Assembly,
"System Pressure -Release".

6. Remove nut (7), washer (8), and parking

brake cylinder (1).

Parking Brake Cylinder --

3. Disconnect hose assembly (2) from parking
brake cylinder (1).
Disassembly

Disassembly Procedure
Start by:

a, remove parking brake cylinder. Refer to

Disassembly and Assembly, “parking brake
cylinder –remove”.
3

4. Disconnect cable (3)

55
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Required Tools
Personal injury can result from being
Tool Part Description Qty struck by parts propelled by a released
spring force.
Double-ended screw stem
A 2 Make sure to wear all necessary protective
M14、L=400
equipment
Pressure Plate
B 2
Follow the recommended procedure and
M14 Nut use all recommended tolling to release the
C 4
spring force.

1. Cylinder body 10． Plug

2．Spring support 11. Sleeve
3．Spring
4. Spring
5．Piston
6．End cap
7 .Bolt
8 Washer
9. Strainer

56
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
2. Install plates (B). Insert the double-end
12. Nut screw stem (A) into the two plate (B), tighten
13. Pin both ends of the stem with nut (C).
14. Washer
3. Loose nuts (7) on the brake cylinder with
15. Sleeve
spanner after tightening the stem.
16. Plate
17. Shaft 4. Slowly loose nuts (C) on right side with
18. Shaft spanner to release the spring force until the
19. Connector spring is loose completely.
20. Seal
5. loose nut （C）， remove plate (B) and
21. Ring
double-end screw stem, take off the end cap
22. Plug
(6).

1. Loose nut (12), remove connector (9) and 6．Remove strainer (9) and retainer (10) from
nut (12). cap (6).

7．Take out outer spring (3) and inner spring

(4).

8．Remove spring seat (2) and piston (5) from

cylinder (1)

9．Remove seal ring (20) and retainer (21)

from piston (5).

57
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Parking Brake Cylinder -

Personal injury can result from being
Assembly struck by parts propelled by a released
spring force.
Assembly Procedure
Make sure to wear all necessary protective
Required Tools
equipment

Tool Part Description Qty Follow the recommended procedure and

use all recommended tolling to release the
Double-ended screw stem spring force.
A M14,L=400 2
Note: Cleanliness is an important factor.
Before assembly, all parts should be
Pressure Plate
B 2 thoroughly cleaned in cleaning fluid. Allow the
parts to air dry. Wiping cloths or rags should
M14 Nut
C 4 not be used to dry parts. Lint may be
deposited on the parts which may cause later
trouble. Inspect all parts. If any parts are worn
or damaged, use new parts for replacement.

58
 CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

1．Install seal ring (20) and retainer (21) into cap (6) onto cylinder (1) after tightening the stem.
piston (5).
7. loose nut （C），remove plate （B） and
2．Install piston (5) into cylinder (1). double-end screw stem （A）

3．Install spring seat （2）into cylinder (1). 8．Install nut (12) and connector (19) on piston (5).
Tighten nut (12) to lock the connector (19).
4．Install outer spring (3) and inner spring (4).

5. Install plates (B). Insert the double-end screw

stem (A) into the two plate (B), tighten both ends
of the stem with nut (C).

6. Install bolt (7) and washer (8) to secure end

59
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
3. 把软管总成（2）连接到停车制动油缸（1）上。
Parking Brake Cylinder - Install

Installation Procedure

4．Install cable (3).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
1. Install nut (7) and washer (8) to secure parking
Lock - Separate and Connect".
brake cylinder (1).

High-Pressured Filter of Brake

System—Remove

Removal Procedure

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.
2. Install shaft (5) to connect parking brake
cylinder lever (6). Install pin (4). Note: Put identification marks on all lines, on all
hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

3. Connect hose assembly (2) to parking brake

cylinder (1).

60
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

High-pressured Filter of Brake

System-Disassembly

Disassembly Procedure
Start by：

A． Remove the filter. Refer the Assembly and

Disassembly,“High-pressured
Filter—Remove”

Note: Cleanliness is an important factor. Before

1、Disconnect hose (5) and (28).
assembly, all parts should be thoroughly cleaned
2、Loose bolt (2) and washer (3) to remove oil in cleaning fluid. Allow the parts to air dry. Wiping
filter.(1) cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

61
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

01

02
04

05
03

06

07
08

1. Remove housing (6), then take off O-ring (3). 3. Install housing (6) and O-ring (3) to head (1).

2. Remove plug (8) and cushion (7) from housing 4. Install cushion (7) and plug (8) to housing (6).
(6).

3. Remove filter element (5) and O-ring (4)

High-pressured Filter of Brake

4. Remove check valve (2) from head (1) System--Install

Installation Procedure

High-pressured Filter of Brake Note: Cleanliness is an important factor. Before

assembly, all parts should be thoroughly cleaned
System--Assembly in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Assembly Procedure Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
Note: Cleanliness is an important factor. Before
are worn or damaged, use new parts for
assembly, all parts should be thoroughly cleaned
replacement.
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

1. Install check valve (2) into head (1).

2. Install element (5) and O-ring (4) to check

valve (2).

62
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
1. Install bolt (2) and washer （3）to secure the done on the hydraulic system.
high-pressured filter (1).
Make sure all of the work implements have
2. Connect hose (5) (28). been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
Cab – Remove touch with your bare hand.

Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

1. Disconnect hose assemblies（2）(3)（4）from
hoses, on all wires, and on all tubes for
metering pump (1).
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

2. Disconnect hose assembly （5）（6）from

metering pump (1)..

Personal injury can result from hydraulic oil

pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
63
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

17

6. Turn valve (17) to the OFF position, remove

the hose on valve (17).
3. Disconnect hose assembly (8) (9) from brake
valve (7).

18

7. Turn valves (10) to the OFF

4. Disconnect hoses (10) （11）

（12）
（13）from
brake valve (7).

19

8. Disconnect harness assembly (19).

5. Disconnect hoses （14）

（15）
（16）from brake
valve(7).

64
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
9. Disconnect plate (20).

32 33

12. Disconnect hose （32）（33）.

34

13. Disconnect harness assembly (34).

10. Disconnect hose assembly（22）（23）（24）

（25）（26）（27）（28）（29）（30）from pilot
valve (21).

35

14. Disconnect harness assembly (35).

31

11. Remove plate (31).

36

15. Disconnect bolt (36).

65
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Cab – Install

Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
37
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
16. Disconnect ground cable (37).
are worn or damaged, use new parts for
replacement.

17. Use a suitable lifting device to remove cab

assembly (38)
1. Use a suitable lifting device to lower cab
assembly (38) to proper position.

37

2. Connect the ground cable (37).

66
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

36 32

3. Install bolt (36). 7. Install plate (32)

35

4. Connect harness assembly (35).

34

5. Connect harness assembly (34).

8. Install hose assembly（22）（23）（24）（25）
（26）（27）（28）（29）（30）on pilot valve
(21).

32 33

6. Connect hose（32）（33）.

67
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

9. Install plate (20).

13.Install hose assembly （14）
（15）
（16）to brake
valve (7).

19

10. Connect harness assembly (19).

14.Install hose assembly （10）（11）（12）（13）

to brake valve (7).

18

11. Install valve (18) to hose.

15.install hose assembly （8）（9）to brake

valve (7).

17

12. Install valve (17) to hose.

68
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
a. Connect the steering frame lock. Refer to
Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

Note: Put identification marks on all wires and on

connectors for installation purposes.

16. Install hose assembly（5）（6） to metering

1
pump (1).

１. Remove nut (1).

17. install hose assembly （2）

（3）
（4）to merting ２. Remove nut (2) and take off the wiper arm
pump (1). (3).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

Window Wiper and Wiper Motor

4 5
(Front) – Remove
3. Remove screws (4). Repeat this step when
Removal Procedure
removing other screws on the plate.
Start By:
4. Remove plate (5).

69
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

6 7 6 7

5. Disconnect harness assemblies (7) from wiper 2. Connect harness assembly (7) of wiper motor
motor. (6).

３. Install plastic cover (13).

4 5
6. Remove bolt (8) on wiper motor (6).

7. Remove wipwer motor (6). ３. Install bolt (4) to secure plate (5).

Window Wiper and Wiper Motor

3
(Front) – Install

Installation Procedure

４. Install nut (2) to secure wiper arm (3).

1. Install bolt (8).

70
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

2 3

1
3. Remove wiper arm (2) and nut (3)
５. Install nut (1).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

4
Window Wiper and Wiper Motor
4. Remove plate (4) of the cab.
(Rear) – Remove

Removal Procedure
Start By:

5
a. Connect the steering frame lock. Refer to
Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".
6

Note: Put identification marks on all wires and on

5. Disconnect harness (6) on wiper motor (5).
all connectors for installation purposes.

１. Move the seat forward.

5 7

1 6. Remove nut (7) that secures the wiper motor

(5). Remove wiper motor (5).
2. Remove nut (1)
71
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Window Wiper and Wiper Motor

(Rear) – Install

Installation Procedure
NOTICE 4
Do not operate the wiper motor before the wiper
３. Install plate (4) to cab.
arm assembly is installed.

A new wiper motor is preset in the parked

position. If the wiper motor is operated before
installation of the wiper arm assembly,
misalignment will occur. This can cause damage
to the wiper motor, the wiper arm assembly,
and/or the window.
2 3
Do not manually rotate the wiper arm assembly
on the shaft.

4. Fix but (3) and install wiper arm (2).

NOTICE

Push the wiper arm assembly straight onto the

tapered shaft. If the wiper arm assembly is not
straight when the shaft turns, the splines will be
5 7 improperly formed and damage will occur.

1. Install but (7) to secure wiper motor (5).

1
5
5. Install nut (1).
6
End By:

a. Separate the steering frame lock. Refer to

2. Connect harness assembly (6) on wiper motor
Disassembly and Assembly, "Steering Frame
assembly (5).
Lock - Separate and Connect".

72
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Seat – Remove and Install

Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering
Frame Lock - Separate and Connect".

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
installation purposes. "Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

2. Install bolt (2) that secures seat assembly (1).

3. Install other bolts by the same way.

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

1. Remove bolt (2) that secures seat assembly

(1).

2. Remove other bolts by using the same ways.

3. Use two people to remove seat assembly (1)

Installation Procedure
1. Use two people to install seat assembly (1)

73
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Front and Rear Frame – Separate

Separation Procedure
Required Tools

Part
Tool Part Description Qty
Number

A Stand
2

B drift pin 1
2. Disconnect hose assembly （1）（2）.
C drift pin 1

Start By:

a. Remove the cab. Refer to Disassembly and

Assembly, "Cab - Remove".

b. Remove the center drive shaft. Refer to

Disassembly and Assembly, "Drive Shaft
(Center) - Remove and Install".

c. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".
3. Disconnect hose assemblies (3), (4)
NOTICE

Care must be taken to ensure that fluids are 5 6 7

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

Note: Put identification marks on all hoses, on all 4. Disconnect hose (5) and pin assembly (6).
hose assemblies, on all wires, and on all tube Keep the steering cylinder (7) away from the
assemblies for installation purposes. Plug all frame.
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.

1. Drain the oil from the hydraulic tank into a

suitable container for storage or disposal.

74
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

14
8

5. Disconnect harness (8). 10. Remove spacer (14) from the lower
articulation joint.
6. Place a suitable support under the rear frame.

7. Attach a suitable lifting device to the front

frame.
18 19 20 21

11. Remove bolt (18) （19）from upper articulation

joint. Remove plate（20）（21）.
9 10 11 12

8. Remove bolts (9) and (10). Remove plate (11)

and washer (12)

22

12. Remove upper articulation pin assembly (22)

from upper articulation joint.

13. Use a suitable lifting device in order to

13
separate the front frame from the rear frame.
9. Remove the articulation pin (13). Use a suitable cribbing in order to support the
front frame and the rear frame.

14. use a suitable lifting device to separate frong

and rear frame.

75
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
articulation joint of rear frame.

24

25 23

30

18. Remove bushing (30) from the lower

articulation joint of the front frame.

26 25 26 23

15. Mark the position of caps (23) and (25).

Remove bolts (24) .Remove seal (26) from cap
(23) （25）. 32

B 33 34 31

27 28
16. Use Tooling (B) in order to remove bearing
cups (27) and bearing (28) from the
35 31
articulation joint of the front frame.

36 33
29
19. Mark the position of caps (31) and (33).
Remove bolts (32). Remove caps (31) and (33)
17. Remove bushing (29) from the upper
and shim (34). Remove lip seal (35) from cap
76
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
(31). Remove lip seal (36) from cap (33). connect the frames. Lubricate all pin bores, all
seals, and all pins with Tooling (K) before
installation.
C
Note: The following steps are for the assembly of
the lower hitch bearings.

37 38
20. Use Tooling (C) to remove bearing cup (37)
and bearing (38) from the lower articulation
joint of the rear frame.
32 35

1. Position cap (35) and install four bolts (33) with

Front Frame and Rear equal space. Ensure that cap (35) is fixex firmly
against the frame.
Frame-Connect

Connection Procedure
Required Tools

Part
Tool Part Description Qty
Number

Stand
A 2

B Drift pin 1 37 38 C
C Drift pin 1
D Driver 1
E Driver 1

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
2. Lower the temperature of lower bearing cup
maintenance, testing, adjusting and repair of the
(37). Use Tooling (C) in order to install lower
product. Be prepared to collect the fluid with
bearing cup (37) so that lower bearing cup (37)
suitable containers before opening any
makes contact with cap (35).
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according 3. Apply clean oil to bearing (38) and install upper
to local regulations and mandates. bearing cone (38). Lower the temperature of
upper bearing cup (37). Use Tooling (C) to install
Note: ApplyTooling (J) to all bores when you
77
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
upper bearing cup (37), so that upper bearing cup lb in). Remove Tooling (D).
(37) can contact with upper bearing cone (38).
Note: The following steps are for the assembly of
4. Remove bolts (32) and cap (35). the upper articulation bearings.

24

35 31 25

36 33 27 28

5. Install lip seal (35) to cap (31). Install lip seal 8. Position cap (25) and install three bolts (24)
(36) to cap (33). with equal space. Ensure that cap (25) is fixex
firmly against the frame.

9. Lower the temperature of lower bearing cup

(27). Use Tooling (B) to install lower bearing
D
cup (27) so that lower bearing cup (27) contact
with cap (25). Apply clean oil to bearing (28)
and install lower bearing (28).

32 10. Apply clean oil to bearing (28) and install

upper bearing cone (28). Lower the
temperature of upper bearing cup (27). Use
33 34 31
Tooling (B) in order to install upper bearing cup
(27) so that upper bearing cup (27) contact
with bearing (28).
6. Position shims (34). Install cap (31) and (33)
11. Remove bolts (24) and cap (25).
with four bolts (32).

7. Install Tooling (D). Use a suitable torque

wrench and Tooling (D) to measure the rolling
torque. Adjust the number of shims (34) in
order to achieve a rolling torque that is
between 22.6 N-m (204 lb in) and 7.9 N-m (71
78
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

26 25 26 23

30
12. Install lip seal (26) to cap (25). Install lip seal
(26) to cap (23).
16. Install sleeve bearings (30) to the lower
E articulation joint.
24
17. Attach a suitable lifting device to the front
frame and apply slight lifting force.
23
18. Remove the support from the front frame. Use
a suitable lifting device to connect the front
frame and the rear frame.
25 39
19. Use a suitable lifting device to align the pin
bores.

13. Position shim (39). Position cap (23) and (25)

and install three bolts (24) with equal space. 18 19 20 21

14. Install Tooling (E). Use a suitable torque

wrench and Tooling (E) to measure the rolling
torque. Adjust the number of shims (39) in order
to achieve a rolling torque that is between 13.6
N-m (124 lb in) and 2.3 N-m (18 lb in). Remove
Tooling (E).

29
22

15. Lower the temperature of sleeve bearings (29)

Install sleeve bearings (29) to the upper
20. Install pin assembly (22), plate（20）（21）
articulation joint.
and Install bolt (18)（19）.

79
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
27. Install bolt (9) (10).

28. Remove the lifting device from the front

frame.

29. Remove the support from the rear frame.

30. Remove bracket (A) from the rear frame.

13

21. Install pin (13).

31. Connect harness (8).

5 6 7
14

22. Install spacer (14) to the lower articulation

joint.

32. Position steering cylinder (7). Install pin

assembly (6) and install hose assembly (6).

9 10 11 12

23. Install plate (11). Install bolts (10).

24. Use a suitable gauge to measure the distance

between the frame and plate (16). Check
completely around the lower articulation mount
plate. Record the minimum measurement
value.

25. Remove plate (11).

33. Connect hose assemblies (3), (4),
26. Install shims (12) under plate (11). The
thickness of shims (12) should be same with
the measurement value in Step 24.
80
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

1 2 3

2. Remove bolts (2) and bolt (3).

3. Remove fender (1)

34. Connect hose assembly（1） (2).

35. Fill the hydraulic tank with oil. Refer to

Operation and Maintenance Manual, "Hydraulic Installation Procedure
System Oil - Change".

End By:

a. Connect the steering frame lock. Refer to

1
Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

b. Install the center drive shaft. Refer to

Disassembly and Assembly, "Drive Shaft
(Center) - Remove and Insall".

c. Install the cab. Refer to Disassembly and 1. Use a suitable lifting device to position
Assembly, "Cab - Install". roading fender (1), as shown.

Rear Fender - Remove and Install

Removal Procedure

1 2 3
1
2. Use bolts (2) to secure fender (1) to the
machine.

1. Attach a suitable lifting device to rear fender

(1).

81
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Bucket – Remove and Install

Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

1. Position the bucket on the flat ground.

6. Use a suitable lifting device to remove bucket

(6) from the machine.

Installation Procedure

2. Attach a suitable lifting device to bucket link

(1).

3. Remove bolt (3), remove pin assembly （2）

1. Use a suitable lifting device to position bucket
(6).

2. Use Tooling (C) to apply grease for all of the

pin bores.

3. Align the bucket bores with the bores of the

boom.

4. Remove bolt (5), remove pin assembly (4).

5. Repeat Step 3 and 4 in order to remove the pin

assembly from the opposite side of the bucket.

82
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
4. Put the washers in position when installing pin
assembly (4).
Bucket Link – Remove and Install

5. Install washer and bolt (5) that holds pin Removal Procedure
assembly (4).
Start By:
6. Repeat Steps 3 through 5 in order to install the
a. Connect the steering frame lock. Refer to
washers and the pin assemblies in the
Disassembly and Assembly, "Steering Frame
opposite side of the bucket.
Lock - Separate and Connect".

1. Position the bucket on the flat ground.

7. Use a suitable lifting device to lower bucket link

(1) into position.
2. Attach a suitable lifting device to bucket link (1)
8. Install pin assembly (2).
3. Remove bolt (3), remove pin assembly (2)
9. Install the spacer, the washer, and bolt (3) to
secure pin assembly (2).

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

4 5

4. Remove bolt (5), remove pin assembly（4）

5. Use the suitable lifting device to remove bucket

link (1).

83
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
1. Lower the temperatures of all bearings before
6 the bearings are installed in the bucket link (1).
1
2. Install the bearing （7）to bucket link (1).
Repeat this step at the opposite end of bucket
link (1).

6 1

6. Remove lip seals (6) from both sides of bucket

link (1). Repeat this step for the opposite end of
the bucket link (1).

3. Install lip seals (6) to both sides of the bucket

link.

4. Use a suitable lifting device to position

bucket link (1).
7 1
5. UseTooling (C) to apply grease to all of the pin
bores.
7. Remove bearing (7) from bucket link (1).
Repeat this step for the opposite end of bucket
link (1).

Installation Procedure
Required Tools
4 5
Tool Part Description Qty

6. Install pin assembly (4), the washer, the

A pneumatic spanner 1
spacer, and bolt (5).
B spanner assembly 1
C grease pump

7 1

84
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
mechanism.

1. Lower the bucket to the ground.

7. Use a suitable lifting device to position bucket

link (1).

8. Install pin assembly (2), the washer, the spacer,

2. Remove bolt (2), the washer, and the spacer
and bolt (3).
from pin assembly (1).
End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

Bucket Lever – Remove and Install

Removal Procedure 1
Required Tools
Tool Part Description Qty 3. Use a suitable lifting device to support the rod
end of the tilt cylinder.
A Pneumatic Spanner 1
B Spanner Assembly 1 4. Remove pin assembly (1).
C Grease Pump
Note: Start the engine and retract the tilt cylinder.
Start By: Lower the piston rod of the tilt cylinder onto the
boom assembly.
a. Remove the bucket positoner sensor. Refer
to Disassembly and Assembly, "Bucket
positioner- Remove and Install".

b. remove the bucket link. Refer to Disassembly

and Assembly, “Bucket link-Remove and Install”

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal

85
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

3
5. Place pin assembly (1) through the pin bore
of lever (3). Use a suitable lifting device to 7
support lever (3).

6. Remove bolt (5), the washer, and the spacer

from pin assembly (4).
Note: Before installation, lubricate the bores and
7. Remove lever (3).
the pins.

1. Lower the temperature of the bearings of the

lever. Install the bearing (7) to to lever (3).
3

6 3

8. Remove lip seal (6) from the center bore of

lever (3). Repeat this step for the opposite side
of the lever.
2. Install lip seal (6) to tilt leve (3). Make sure that
the lip of the seal is facing outward.

3. Repeat Step 2 for the lip seal on the opposite

3
side of the lever.

9. Remove the bearing （7）from lever (3).

Installation Procedure
Note: Cleanliness is an important factor. Before
86
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

4. Use a suitable lifting device to position lever

(3).
7. Install pin assembly (1).
Note: It is very important to aligning the bores of
the lever and the boom. Improper alignment can 8. Install the washer, the spacer, and bolt (2) to
damage the lip seals during the installation of the secure pin assembly (1).
pin assembly.
End By:
5. Carefully install pin assembly (4).
a. Install the bucket positioner sensor. Refer to
6. Install the washer, the spacer, and bolt (5) to Disassembly and Assembly, Bucket
secure pin assembly (4). Positioner -Remove and Install".

Remove the link. Refer to Disassembly and

Assembly, “Bucket Link-Remove and Install” 拆

Boom—Remove
1
Remove Procedure
Start By:

Note: It is very important to aligning the bores of Required Tools

the lever and the boom. Improper alignment can Tool Part Description Qty
damage the lip seals during the installation of the B Drift Pin 1
pin assembly. C Drift Pin 1
D Drift Pin 1

a. Remove the bucket link. Refer to Disassembly

and Assembly, "Bucket link - Remove".

b. Remove the bucket. Refer to Disassembly and

Assembly, "Bucket - Remove".

c. Remove the tilt cylinder. Refer to Disassembly

and Assembly, "Tilt Cylinder - Remove".
87
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
d. Remove the lift kickout switch. Refer to
Disassembly and Assembly, " Lift Kickout
Switch-Remove and Install".

Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
1. Raise the boom until the front pin bores and
tubes. This helps to prevent fluid loss and this
the rear pin bores are level.
helps to keep contaminants from entering the
system. 2. Place a bracket in position under the boom.

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

3. Attach a suitable lift device to boom cylinder

Personal injury can result from hydraulic oil (2).
pressure and hot oil.
4. Remove bolt and washer from pin assembly
Hydraulic oil pressure can remain in the (3).
hydraulic system after the engine has been
5. Place suitable support between lift cylinder (3)
stopped. Serious injury can be caused if this
and the frame. Use the suitable lifting device to
pressure is not released before any service is
lower lift cylinder (3) onto the support.
done on the hydraulic system.

Make sure all of the work implements have

been lowered to the ground, and the oil is cool
before removing any components or lines.
Remove the oil filler cap only when the engine
is stopped, and the filler cap cool enough to
touch with your bare hand.

5
4

88
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
6. Disconnect harness assemblies (4).

7. Remove front light assembly (5).

14. Use Tooling (B) to remove the bearings from

the bucket bore at the boom end.

8. Disconnect hose assembly (6).

9. Repeat Steps 3 through 8 at the other side of

the boom.

15. Use Tooling (C) to remove the bearing from

the boom cylinder pin bores.

10. Attach a suitable lifting device to boom (7).

11. Remove all shafts that connect to boom (7). D

12. Use a suitable lifting device to remove the
boom.

16. Use Tooling (D) to remove the bearing from

7
the frame bore at boom end.

8 9 10

13. Remove lip seals （8）(9)(10) from both sides

of boom (7).

89
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
boom cylinder pin bores.

Boom – Install

Installation Procedure
Required Tools
Tool Part Description Qty
B Drift pin 1 B
C Drift pin 1
D Drift pin 1
4. Use Tooling (D) to install the bearings into the
Note: Cleanliness is an important factor. Before pin bore at the boom end.
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping 7
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

1. Lower the temperature of the bearings of the 8 9 1

boom prior to installation.

5. Install lip seals（8）（9）（10）to boom (7).

2. Use Tooling (D) to install the bearings into the

frame end of the boom.

6. Use a suitable lifting device to position boom

(7) into position.

7. Install shaft of the boom, spacer, washer and

bolt.

8. Use a suitable lifting device to lower the boom

C
onto bracket.

3. Use Tooling (C) to install the bearings into the

90
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

9. Connect hose assembly (6).

16. Raise the boom and remove bracket.

End By:

a. Install the lift kickout switch. Refer to

Disassembly and Assembly, " Lift Kickout
Switch- Remove and Install".
5
4 b. Install the tilt cylinder. Refer to Disassembly
and Assembly, "Tilt Cylinder - Install".

10. Install front light assembly (5). c. Install the bucket. Refer to Disassembly and
Assembly, " Bucket - Install".
11. Connect harness assemblies (4).
d. Install the bucket link. Refer to Disassembly
and Assembly, "Bucket link - Install".

Diesel Engine-Remove

Remove Procedure
NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
12. Use a suitable lifting device to position boom
product. Be prepared to collect the fluid with
cylinder (2).
suitable containers before opening any
13. Install pin assembly (3), bolts, and washers. compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
14. Remove the support that was used to support
to local regulations and mandates
boom cylinder (2).
Note: Put identification marks on all hoses, on all
15. Repeat Steps 12 through 15 at the other side
hose assemblies, on all wires, and on all tube
of the boom.
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This

91
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.

Start by:

a. remove the cab assembly. Refer to

Disassembly and Assembly,” cab
assembly-remove”

3. remove bolt （3）（4）(21), remove bracket (5).

4. Remove bolt (22) and remove plate (10).

1. Tilt the engine hood backwards to the

maximum angle.

5. Remove clamp (6) and remove pre-filter (7).

6. Remove clamp (8) and remove muffler (9).

2. Remove the pre-filter (1) and exhaust pipe (2).

7. Remove bolt (11) and bracket (12).

92
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Diesel Engine -Install

Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
8. Remove hose assembly （13）（14）（15）. replacement.

1. Use a suitable lifting device to move diesel

9. Remove hose assembly （16）（17）（18）.
engine (20) to proper position, install bolt (19).

10. Remove bolt (19). Use a suitable lift device to

remove diesel engine (20) and support it with
suitable device.
2.Connect hose assembly （16）（17）（18）.

93
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

3.Connect hose assembly （13）（14）（15） 7.Install bolt （3）（4）to secure bracket (5).

8. Install bolt（21）（22）to secure plate(10).

4. Install bolt (11) to secure bracket (12) to the

frame.
9. Install pre-filter (1) and exhaust pipe (2).

5. Install pre-filter (7), install clamp (6)

10. Lower the engine hood to the lowest position.
6. Install muffler (9) and clamp (8).
End by:

a. install the cab assembly. Refer to Disassembly

and Assembly, “Cab Assembly –Install”.

94
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Radiator Group– Remove and

Install

Removal Procedure
NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any 3. Disconnect hose （4）（5）（6）（7）（8）.
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

Note: Put identification marks on all hoses, on all

hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.

1. Tilt the engine hood backwards to the

maximum angle.
4. Disconnect hose （9）（10）（11）.

2. Disconnect hose (2) (3) that connect to radiator

group (1). 5. Disconnect hose （12）（13）（14）

6. Disconnect bolt (15) on both sides of radiator

group.

95
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

7. Use a suitable lifting device to remove the 2. Install bolt (15) to secure the radiator group
radiator group (1) and support it with suitable onto the frame.
device.
3. Connect hose （12）（13）（14）.
Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

4. Connect hose （9）（10）（11）.

1. Use a suitable lifting device to move the

radiator group (1) onto frame.

5. Connect hose （4）（5）（6）（7）（8）.

96
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

6. Connect hose （2）（3）.

2．Remove bolt (4), remove motor bracket.
7. Lower the engine hood to the lowest position.

Fan Motor—Remove and Install

Removal Procedure
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.

Note: Put identification marks on all lines, on all

hoses, on all wires, and on all tubes for
3．Remove bolt (5), remove fan (6) and flange (7).
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.

4．Remove bolt (8), remove fan motor (1).

1．Disconnect hose（2）（3） on fan motor (1).

97
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
are worn or damaged, use new parts for
replacement.

3．Install bolt (4) to secure motor bracket to the

radiator.

1．Install bolt (8) to secure fan motor (1) to motor

bracket.

4． Connect hose （2）（3）to the fan motor (1).

Drive Shaft (Front) – Remove and

Install

Removal Procedure
Start By:
2．Install bolt (5) to secure fan (6) to flange (7).
a. Remove the carrier bearing. Refer to
Then fix them onto motor bracket.
Disassembly and Assembly, "Carrier Bearing
(Drive Shaft) Remove and Install".

1. Park the machine on a flat, level surface.

Lower the bucket to the ground. Chock the
wheels in order to prevent the machine from
rolling when removing the drive shaft.

98
 CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Serious component damage could occur. Be
certain that all the joint groups, all the yokes, and
all the lubricating fittings are aligned.

1. Use a suitable lifting device to carefully position

front drive shaft (1), as shown.

3 2 1 1
6
2. Attach a suitable lifting device to front drive shaft
(1). 7
3. Remove nut (3) from yoke (2)
8
1
2. Install bolt (6) and washer (7), washer (8) to
secure drive shaft (1).

4 5

4. Remove nut (4) and bolt (5)

3 2 1
1
6
3. Install nut (3) to secure yoke (2) on drive shaft (1)
to the front axle.
7

1
8

5. Remove bolts (6) and washer (7), washer (8)

6. Carefully remove front drive shaft (1).

4 5
Installation Procedure
4. Install bolt (5) and nut (4) to secure drive shaft
NOTICE
(1).
When the front drive shaft is installed, it must be
5. Remove the lifting device from front drive shaft
installed in phase with the front axle assembly
(1).
yoke. The front drive shaft must be installed in
phase with the center and rear drive shafts.
99
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Installation Procedure
Drive Shaft (Center) - Remove and

Install 5 4 1

Removal Procedure
Start By:

a. Connect steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

1. Use two people to install drive shaft (1). Install

bolt (4) and nut (5) to connect drive shaft (1) and
front drive shaft. Tighten bolts (5) to a torque of
120±25N.m (111±11 lb ft).

1 2 3

1. Remove bolts (3) from yoke（2）of drive shaft

(1). Two people are needed to remove drive
shaft (1). 1 2 3

2. Install nut (3) to secure yoke (2) on the drive

5 4 1
shaft (1) onto the output flange of the gearbox.

End By:

a. Separate the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

2. Remove bolts (4) and nut (5) from front end of

drive shaft (1).

3. Carefully remove front drive shaft (1).

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

Installation Procedure
NOTICE
Drive Shaft (Rear) – Remove and
When the rear drive shaft is installed, it must be
Install installed in phase with the rear axle assembly
yoke. The rear drive shaft must be installed in
Removal Procedure phase with the center and front drive shafts.
Serious component damage could occur. Be
End By:
certain that all the joint groups, all the yokes, and
a. Remove the power train guard. Refer to all the lubricating fittings are aligned.
Disassembly and Assembly, "Power Train Guard
(Transmission) - Remove and Install".

1. Park the machine on a flat, level surface.

Lower the bucket to the ground. Chock the
wheels in order to prevent the machine from
rolling when removing the drive shaft.

1 4

1. Install nut (4) to secure rear end of drive shaft

(1) onto the flange on rear axle. Tighten nut (4)
to a torque of 120±15 N-m.

2 3 1

2. Support rear drive shaft (1). Remove bolt (2)

and nut (3) from front end of rear drive shaft (1).

2 3 1

2. Install bolt (2) and nut (3) to secure the rear

drive shaft (1) to the rear output flange of the
transmission.

1 4 3. Tighten nut (3) to a torque of 120±15 N-m.

4. Support the rear drive shaft (2). Install new

3. Remove nut (4) on the flange, which is
straps (4) and new bolts (3) in yokes (1). Use
connected with drive shaft (1).
Tooling (A) to tighten bolts (3) to a torque of
4. Carefully remove rear drive shaft (1). 150±15 N-m(110±11 lbft).

5. Lubricate the rear drive shaft. Refer to the

Operation and Maintenance Manual, "Drive
Shaft Universal Joints - Lubricate".
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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
End By:
Tire and Rim (Front) – Remove
a. Install the power train guard. Refer to
Disassembly and Assembly, "Power Train and Install
Guard (Transmission) - Remove and Install".
Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

1. Attach a suitable lifting device to Tooling (A)

and fender (1).

1 2

2. Remove bolt (2) and fender (1).

3. Position jack (A) under the front axle housing,

as shown.

4. Use jack (A) in order to raise the machine so

that the front tires are off the ground.

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

4 3
1 2

5. Attach a suitable lifting device to front tire and 4. Use a suitable lifting device to position fender
rim (3), as shown. (1).

6. Remove bolt (4) and use a suitable lifting 5. Install bolt (2).
device to remove front tire and rim (3) from the
End By:
machine.
a. Separate the steering frame lock. Refer to
Installation Procedure
Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

4 3

1. Use a suitable lifting device to position tire

and rim (4).

2. Install bolts (4). Tighten bolts (4) to a torque of

570 ± 80 N-m (420 ± 59 lb ft).

3. Lower the machine onto ground, remove jack

(A)

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
4. Remove bolt (3) and the washers.
Tire and Rim (Rear) - Remove and
5. Use the suitable lifting device to remove tire
Install and rim (2).

Installation Procedure
Removal Procedure
Start By:

a. Connect the steering frame lock. Refer to

Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".

b. Remove the rear roading fender. Refer to

Disassembly and Assembly, "Roading
Fender (Rear) - Remove and Install". 3 2

1. Use a suitable lifting device to position tire and

rim (3).

2. Install bolt (3) and the washers. Tighten bolts

(2) to a torque of 570 ± 80 N-m (420 ± 59 lb ft).

3. Use Tooling (A) to lower the machine to the

1
ground.

4. Remove Tooling (A).

1. Place suitable blocks (1) between the rear axle

housing and the frame. Repeat this step on the
opposite side of the machine. This will prevent
the rear axle housing from oscillating.

5. Remove blocks (1) from both sides of the

machine.

3 2 End By:

a. Separate the steering frame lock. Refer to

2. Position Tooling (A) under the loader frame, as
Disassembly and Assembly, "Steering Frame
shown. Use Tooling (A) to raise the rear of the
Lock - Separate and Connect".
machine so that the rear tires are off the
ground. b. Install the rear roading fender. Refer to
Disassembly and Assembly, "Roading Fender
3. Attach a suitable lifting device to the tire, as
(Rear) - Remove and Install".
shown.

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
keep contaminants from entering the system.
Front Axle – Remove and Install
1. Drain oil from front axle. The capacity of the
Removal Procedure front axle is 65 L (17.2 US gal).

Start By:

a. Remove the front tires and rims. Refer to

Disassembly and Assembly, "Tire and Rim
(Front) - Remove and Install".

a. Remove the front drive shaft. Refer to

Disassembly and Assembly “Front Drive
2
Shaft-Remove”.

NOTICE
2. Disconnect hose assemblies (2).
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids.

Dispose of all fluids according to local regulations

and mandates.

3. Attach a suitable lift device to both sides of

axle.
Personal injury can result from hydraulic oil
pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
3 4
Make sure all of the attachments have been
lowered, oil is cool before removing any
components or lines. Remove the oil filler cap 4. Remove bolt (3) and nut (4) from both sides
only when the engine is stopped, and the filler of axle.
cap is cool enough to touch with your bare
5. Use the suitable lifting device to lower the axle
hand.
from the machine.
Note: Put identification marks on all lines, on all
hoses, on all wires and on all tubes for installation
purposes. Plug all lines, all hoses and all tubes.
This helps to prevent fluid loss and this helps to

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Installation Procedure 4. Connect hose assemblies (2).

Note: Cleanliness is an important factor. Before 5. Fill the front axle with oil to the correct level.
assembly, all parts should be thoroughly cleaned Refer to Operation and Maintenance Manual,
in cleaning fluid. Allow the parts to air dry. Wiping "Refill Capacities".
cloths or rags should not be used to dry parts.
Start By:
Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts a. Install the front tires and rims. Refer to
are worn or damaged, use new parts for Disassembly and Assembly, "Tire and Rim
replacement. (Front) - Remove and Install".

Rear Axle –Remove and Install

Removal Procedure
Start By:

a.Remove the rear tires and the rims. Refer to

Disassembly and Assembly, "Tire and Rim
(Rear) - Remove and Install".
1. Attach a suitable lifting device to each side of
the front axle, as shown. b. Remove the rear drive shaft. Refer to
Disassembly and Assembly, "Drive Shaft
(Rear) - Remove and Install".

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
3 4
suitable containers before opening any
compartment or disassembling any component
2. Install the bolt (3) and nut (4). Tighten bolt (4) containing fluids.
to a torque of 1800 ± 200 N-m(1328 ± 148 lbft).
Dispose of all fluids according to local
3. Remove the lifting device from the front axle. regulations and mandates.

Personal injury can result from hydraulic oil

pressure and hot oil.

Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
2
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Make sure all of the attachments have been
lowered, oil is cool before removing any
components or lines. Remove the oil filler cap
only when the engine is stopped, and the filler
cap is cool enough to touch with your bare
hand.

Note: Put identification marks on all lines, on all

3
hoses, on all wires and on all tubes for
installation purposes. Plug all lines, all hoses and
all tubes. This will help to prevent fluid loss and 4. Disconnect hose assemblies (3) from the rear
this will help to keep contaminants from entering axle.
the system.

1. Drain oil from the rear axle. The capacity of

the oscillating axle is 65 L (17.2 US gal).

5. Attach a suitable lifting device to each side of

1
the rear axle, as shown.

2. Disconnect hose assembly (1) from the rear

axle.

5 4
2
6. Remove bolt (4) and nut (5) that hold rear
axle support to the machine frame.

3. Disconnect tube assemblies (2) from the rear

axle.

7 6

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
7. Remove bolt (6) and nut (7) that hold rear axle
support to the machine frame.

8. Lower the rear axle from the machine.

Installation Procedure
Note: Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
5 4
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may 3. Install bolt (4) and nut (5) that hold rear axle
cause later trouble. Inspect all parts. If any parts support to the machine frame. The torque for
are worn or damaged, use new parts for nuts (5) is 1000 ± 125 N-m (740 ± 90 lb ft).
replacement.
4. Remove the lifting device from both sides of
the rear axle.

3
1. Attach a suitable lifting device to each side of
the rear axle, as shown. Raise the rear axle to
5. Connect hose assemblies (4) to the rear axle.
proper position.

7 6
6. Connect hose assembly (2) to the rear axle.

2. Install bolt (6) and nut (7) that hold rear axle
support to the machine frame. The torque for
nuts (7) is 1000 ± 125 N-m (740 ± 90 lb ft).

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CLG 856III Wheel Loader Service Manual/Disassembly and Assembly

TRANSMISSION &TORQUE

CONVERTER ASSEMBLY

–Remove and Install

1 Removal Procedure
Start By:

7. Connect hose assembly (1) to the rear axle. a. Remove the cab assembly. Refer to
Disassembly and Assembly, “Cab
8. Fill the oscillating axle to the correct level.
Assembly-Remove”
Refer to Operation and Maintenance Manual,
"Refill Capacities". b. remove the center drive shaft. Refer to
Disassembly and Assembly “Drive Shaft
End By:
(Center)—Remove”
a. Install the rear drive shaft. Refer to
c. Remove rear drive shaft. Refer to Disassembly
Disassembly and Assembly, "Drive Shaft
and Assembly (rear)-Remove”
(Rear) - Remove and Install".
d. Remove work pump and steering pump. Refer
b. Install the rear tires and the rims. Refer to
to Disassembly and Assembly “Work Pump and
Disassembly and Assembly, "Tire and Rim
Steering Pump—Remove”.
(Rear) - Remove and Install".
e. Remove the parking brake

NOTICE

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any compoent
containing fluids. Dispose of all fluids according
to local regulations and mandates.

Note: Put identification marks on all hoses, on all

hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and this helps to keep
contaminants from entering the system.

109
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
13
17 14
25
15

25
07 06
15 16
08
06 3
05 18
24 4
19 2
20
23
21 22
01 21 20

1. Disconnect hose (16) from tube (18). torque converter assembly (1) and apply a steady
lifting force to it to keep it stable.
2. Remove tube (18). Remove connector
assembly (19) from the transmission and torque 9. Remove bolt (3), washer (4) and spacer (2).
converter assembly (1).
10. Remove bolt (7) and washer (6) that secure
3. Disconnect hose (17) from connector assembly the trasmission & torque converter assembly (1)
(8). to flywheel.

4. Remove the connector assembly (8) from the 11. Lift the trasmission & torque converter
transmission and torque converter assembly (8). assembly (1) out of the frame and support it with
a suitable device.
5. Place block under the flywheel housing to
support the diesel engine. 12. Remove bolt (20) and washer (21). Remove
left bracket (22) and right bracket (24).
6. Place block under the housing of transmsion &
torque converter assembly (1) to support the
transmsion & torque converter assembly.

7. Remove bolt (5) and washer (6) that secure

transmsion & torque converter assembly (1) to
flywheel.

8. Attach a suitable lifting device to transmsion &

110
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
Installation Procedure Lint may be deposited on the parts which may
cause later trouble. Inspect all parts. If any parts
Note: Cleanliness is an important factor. Before
are worn or damaged, use new parts for
assembly, all parts should be thoroughly cleaned
replacement.
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts.
13
17 14
25
15

25
07 06
15 16
08
06 3
05 18
24 4
19 2
20
23
21 22
01 21 20

1. Install bolt (20) and washer (21) to secure left converter assembly to flywheel.
bracket (22) and right bracket (24) to trasmission
6. Tighten bolt (3).
& torque converter assembly (1)
7. Remove the block under the flywheel.
2. Use suitable lifting device to move the
trasmission & torque converter assembly (1) onto 8. Install the connector assembly (8) to the
the frame. trasmission & torque converter assembly (1)

3. Place shock absorber (23) under bracket (22) 9. Connect hose (17) to connector assembly (8).
and right bracket (24), tighten bolt (3), washer (4)
10. Install connector assembly (19) to the
and spacer (2).
trasmission & torque converter assembly (1)
4. Install bolt (7) and washer (6) to secure
11. Connect tube (18) to connector assembly
trasmission & torque converter assembly (1) to
(19).
flywheel.
12. Connect hose (16) with tube (18).
5. Install bolt (5) and washer (6) to secure torque
111
CLG 856III Wheel Loader Service Manual/Disassembly and Assembly
End by:

a. Install work pump and steering pump. Refer to

Disasembly and Assembly, “Steering
Pump-Install”

b. Install the rear drive shaft. Refer to Disasembly

and Assembly,” Drive Shaft (rear)—Install”

c. Install the center drive shaft. Refer to

Disasembly and Assembly, “Drive Shaft
(rear)—Install”

d.Install the cab assembly, refer to Disasembly

and Assembly, “Cab Assembly –Install “.

112