LiuGong CLG915E Excavator Service Manual 201701001 PDF Download

Description

LiuGong CLG915E Hydraulic Excavator Service Manual

The LiuGong CLG915E hydraulic excavator service manual is a 1,073-page workshop document identified by publication number 201701001 and dated January 15, 2017 in the manual. Applicability is stated for the CLG915E with Cummins QSB4.5 (EPA Tier 4f / EU Stage IV). Its eight major divisions cover safety, basic service knowledge, structure and function, machine and engine parameters, testing and adjustment, fault diagnosis, removal and installation, and attached system drawings.

Document Identification

• Brand: LiuGong
• Model: CLG915E Hydraulic Excavator
• Engine: Cummins QSB4.5 (EPA Tier 4f / EU Stage IV)
• Manual type: Service / Workshop / Repair
• Document number: 201701001
• Date shown: January 15, 2017
• Language: English
• Pages: 1,073
• Format: PDF

Coverage Built Around the CLG915E Tier 4f Configuration

The cover states the applicable type and model as CLG915E and identifies the Cummins QSB4.5 emissions configuration. The manual explains that it is intended as workshop maintenance reference for both less-experienced and experienced technical service personnel. Its own guidance divides the material into a technical guide—safety, structure/function and maintenance standards, testing/adjusting and fault diagnosis—and a workshop guide containing disassembly/assembly plus electrical, air-conditioning and hydraulic schematics.

Eight Major Manual Divisions

• Safety
  • Safety Precautions
  • Precautions for lifting and matching operations
• Basic knowledge
  • How to Read the Manual
  • Maintenance standards and general service information
• Structural Function and Maintenance
  • Power system
  • Hydraulic system
  • Undercarriage / travel system
  • Swing system
  • Work equipment
  • Electrical system
• Parameters
  • Basic Parameters
  • Performance Parameters of Diesel Engine
  • Performance parameters of complete machine
• Testing and Adjustment
  • Performance Test of Complete Vehicle
  • Other Tests
• Fault Diagnosis
  • Precautions for Fault Diagnosis
  • Basic Fault Detection Before Maintenance
  • Classification of Faults
  • DTC
  • Electrical system fault diagnosis
  • Hydraulic and mechanical system fault diagnosis
• Removal and Installation
  • Overview
  • Power System
  • Undercarriage System
  • Upper structure and work equipment service procedures
  • Hydraulic components and related removal/installation procedures
• Attached Drawing
  • Electrical system schematic drawings
  • Air-conditioning system schematic drawings
  • Hydraulic system schematic drawings

Engine, Hydraulic and Machine Specifications

The parameter chapter provides the data needed to identify the CLG915E configuration and compare test results. The Cummins QSB4.5 is described as turbocharged and air-to-air intercooled with high-pressure common rail, water cooling and a 1-3-4-2 firing order. Bore and stroke are 107 × 124 mm, displacement is 4.5 L and compression ratio is 17.2:1. Rated output is 90 kW (120.7 HP) at 2200 r/min, net power is 84.3 kW (113.0 HP), and maximum torque is 470 N·m (346.6 lbf·ft) at 1500 r/min. Electrical engine equipment includes a 24V-4.8 kW starter and 24V-70A Bosch alternator.

Complete-machine data includes operating weight of 16,500 kg (36,382.5 lb), standard bucket capacity of 0.6 m3 (21.2 cu ft), high/low travel speed of 0~5.4 / 0~3.2 km/h, swing speed of 12.94 r/min, gradeability of 35° (70%) and ground pressure of 34.2 kPa with 700 mm tracks. The standard working equipment is a 4600 mm boom and 2500 mm arm. Working-range figures include 8760 mm maximum digging height, 6310 mm maximum unloading height, 5470 mm maximum digging depth, 8300 mm maximum digging radius and 2470 mm minimum swing radius.

Hydraulic System Data and Testing

The hydraulic system uses a double axial variable plunger main pump with maximum system flow of 2 × 120 L/min. The main relief valve setting is 34.3 MPa (4973.5 psi), while pilot circuit pressure is 3.9 MPa (565.5 psi). The manual provides cylinder dimensions, relief/safety settings and performance checks. Testing and Adjustment includes complete-vehicle performance testing, cylinder settlement, control-lever force and stroke, boom lifting with swing, pilot and secondary pilot pressure, solenoid proportional-valve output, main-relief setting, valve-clearance adjustment, crankcase blow-by, engine-oil pressure, track tension, minus-feedback pressure, hydraulic residual-pressure release, air bleeding, diode inspection, compressor-belt tension and travel-motor/reduction-gear performance.

Fault Diagnosis: DTC, Electrical and Hydraulic/Mechanical

Fault diagnosis is not confined to a short chart. The manual first covers pre-diagnosis inspection and fault classification, then provides detailed DTC procedures with system descriptions, circuit/component information, measurements and step-by-step elimination paths. Extracted text contains 72 distinct six-digit DTC identifiers. Early examples include 101001 for extremely low battery voltage, 101003 for high battery voltage and 101017 for low battery voltage; other listed DTCs cover charging, oil pressure, pilot pressure, air filter, hydraulic-oil temperature, fuel level and water-in-fuel sensing, with identifiers continuing through entries including 261814.

The chapter also separates conventional electrical fault symptoms as E-series items and hydraulic/mechanical symptoms as H-series items. Examples include engine starting or shutdown problems, failed automatic slowdown, display, wiper, travel alarm and air-conditioning faults, while hydraulic/mechanical flowcharts cover weak work-equipment actions and engine speed drop or stalling under hydraulic load. This organization lets a technician enter diagnosis either from a displayed code or from a machine symptom.

Removal, Installation and Attached Drawings

The Removal and Installation chapter starts with general torque specifications and coating materials and then follows major assemblies. Visible contents include removal and installation of the diesel engine assembly, hydraulic oil cooler, intercooler, water radiator, diesel tank, fuel cooler, injector, front and rear engine seals and cylinder head, followed by undercarriage procedures such as track and carrier rollers and track assembly. The attached-drawing division supplies system schematics for electrical, air-conditioning and hydraulic circuits, complementing the diagnostic procedures with circuit-level reference.

Selected CLG915E Reference Data

• Engine model: Cummins QSB4.5
• Engine type: Turbo charged and air-to-air intercooled / high pressure common rail
• Emission: EU Stage IV, EPA Tier4
• Cooling mode: Water cooling
• Ignition order: 1-3-4-2
• Bore × stroke: 107 × 124 mm
• Displacement: 4.5 L
• Compression ratio: 17.2:1
• Rated power: 90 kW (120.7 HP) / 2200 r/min
• Net power: 84.3 kW (113.0 HP)
• Maximum torque: 470 N·m (346.6 lbf·ft) at 1500 r/min
• Engine oil level: 11 L (2.9 US gal)
• Engine net weight: 378 kg (833.5 lb)
• Maximum no-load speed: 2280±50 r/min
• Minimum no-load speed: 800±50 r/min
• Starter motor: 24V-4.8 kW
• Alternator: 24V-70A (Bosch)
• Operating weight: 16500 kg (36382.5 lb)
• Standard bucket capacity: 0.6 m3 (21.2 cu ft)
• Running speed high/low: 0~5.4 / 0~3.2 km/h
• Swing speed: 12.94 r/min
• Gradeability: 35° (70%)
• Ground pressure with 700 mm track: 34.2 kPa (5.0 psi)
• Overall width with 700 mm track: 2690 mm

Keep the Correct CLG915E Procedure Beside the Machine

This manual gives the technician one place to move from a CLG915E symptom to the relevant parameter, test, DTC procedure, hydraulic/electrical drawing and component removal sequence. That is especially useful for jobs such as checking pilot or relief pressure, tracing temperature-sensor faults, testing travel or work-equipment performance, removing engine/cooling components and verifying the Cummins QSB4.5 configuration against the documented values. After payment, the manual is delivered as an instant PDF download with no shipping or waiting; it can be read on phone, tablet, laptop or workshop PC and printed for use at the bench.