SDLG LG958L, Operation & Maintenance Manual

Page 1: ...rstand these instructions before use to avoid serious accident For the convenience of relevant people using this manual it should be easily accessable and kept in readable condition Operation Maintena...

Page 2: ...anual 880 1230 mm 16 6 5pieces 1st Edition in 2009 12 and 1st Print SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone Shandong 276023 Tel 86 0539 8785688 Fax 86 05...

Page 3: ...2 5 2 Safety of self and others 22 5 3 Full Load Transportation 24 5 4 Drive at Proper Speeds 24 5 5 Ensure Good Visibility 24 5 6 Pay Attention to Blockages 25 5 7 Driving in Dangerous Conditions 25...

Page 4: ...2 7 FEATURES 52 8 TECHNICAL PERFORMANCE PARAMETER 53 8 1 Performance of Whole Machine 53 8 2 Principle Dimension and Weight 54 8 3 Product Standard and License 55 CHAPTER III OPERATION AND APPLICATION...

Page 5: ...lectric System Maintenance 107 2 5 Maintenance Tools 107 2 6 Tightening Torque of Screw 107 3 CONTENT OF MAINTENANCE 108 3 1 Every 10 Hours Days Service 108 3 2 Every 50 Hours Week Service 109 3 3 Eve...

Page 6: ...engine and other functioning parts about operation use and maintenance We are continually striving to improve the quality of our products to produce more advanced and a safer engineering machine We r...

Page 7: ...to operate maintain or repair the machine before reading and understanding this manual z The operation specifications and precautions given in the manual only apply to intended uses of the machine If...

Page 8: ...fied by the machine If the uses of the machine are not specified in the manual users should assume full responsibility for their actions We will not bear any safety responsibility for the operators or...

Page 9: ...re shown in the figure 1 1 and figure 1 2 Please read carefully and follow the contents of all the safety labels Please maintain the labels when a label becomes lost broken or unclear immediately repa...

Page 10: ...Warning for starting Located above the start button 2 Limit position of lift arm Located on the lifting position of front and rear frames Lock the lift arm cylinder before entering dangerous areas 3...

Page 11: ...or the operator during steering brake cab door Located on the steering position of front and rear frames Located on the outside of Operator cab left door maintains Sitting allowed only in cab s loadin...

Page 12: ...luid 14 Notice for Hydraulic oil tank 13 Notice for platform frame Located on the left side of operator cab door and mouse of radiator of engine hood Located on the hydraulic oil tank act on with a wi...

Page 13: ...nk Located on vent pipe of engine hood Located on the fuel oil tank 17 Notice of hot water Pay attention to the steam or hot water ejection Located on the cover of engine water tank 18 Warning of mach...

Page 14: ...Operation Maintenance Manual LG958L LG959 Wheel Loader 6 20 No fire warning Figure 1 2 Figure of safety label position Export Type Located on fuel tank...

Page 15: ...f lift arm 3 Antifreeze fluid 4 Antifreeze fluid 1 Limit position of lift arm Located on both sides of lift arm Located on both sides of lift arm Located on the left operator cab door and engine hood...

Page 16: ...event rolling 8 Check before starting 9 No passenger warning Located on the left of operator cab door Located on the right front upright column of operator cab Located on the right front upright colum...

Page 17: ...ning 12 Warning of high voltage 13 No fire warning 14 Personal safety range Located on both sides of engine hood Located on the right rear upright column of operator cab Located on the right rear upri...

Page 18: ...18 Warning of high temperature 19 Start for lift 20 Hydraulic oil tank Located on both sides of engine hood Located on the cover of water tank of engine hood Located on fuel tank Located on the cover...

Page 19: ...me 22 Select switch of cutting 23 Warning for cutting off power power 24 Parking brake Located on the right and left platform frames Located on the right operation box Located on the right operation b...

Page 20: ...on Maintenance Manual LG958L LG959 Wheel Loader 12 25 Danger of serious injury during steering 26 Warning for starting Located on the steering position of front and rear frames Located above the start...

Page 21: ...ing drugs or drinking alcohol when your judgment may be impaised z When working with another operator or with a person on worksite traffic duty be sure that all people understand all hand signals that...

Page 22: ...clothing jewelry and loose long hair They can be caught by control levers or control handles or moving parts which may cause serious injury and even death z Avoid wearing oily clothes because they ar...

Page 23: ...ms for example the safety protective devices should be at the safe status Make sure the tires are not worn and the tire pressure is normal Routinely check for oil leaks water leaks air leaks deformati...

Page 24: ...any tools or other items when climbing up and down the loader lift the tools needed to the operation flat roof by rope 3 4 Fire Prevention The following fluids are flammable and must be kept away fro...

Page 25: ...orage battery be sure there is no flame or fire nearby Repair maintain and use the storage battery as referenced in users manual z Do not use flame or fire match or lighter to check in a dark place z...

Page 26: ...of equipment If the working equipment is in operation the clearance will change and this may lead to serious damage or personal injury when standing too close The engine must be turned off and the wor...

Page 27: ...dangerous z Examine the condition of the ground and the quality of the soil in the work area and determine the proper method of operation Before starting work the ground should be planed and pressed...

Page 28: ...re the control lever or control handle is in the braking position z Clean the dirt on the cab window and all the lamps to ensure better visibility z Adjust the rear view mirror and keep the surface cl...

Page 29: ...he engine is started to make sure there is no potential danger z When examining the machine park the machine in a spacious place and do not let unauthorized people to get close z Check whether the eng...

Page 30: ...afety before moving z Be sure there are no people or blockage on the left and right side z Check the brakes on dry and firm level ground z Do not put an arm or foot on the working equipment or extend...

Page 31: ...les on the common roads Pass the crossing road quickly and do not block the road z Drive on the side of the road and let the other vehicles go first Keep a proper distance from others z Brake immediat...

Page 32: ...the loader to turn over 5 4 Drive at Proper Speeds z Know the characteristics of the loader and follow the actual conditions in the working area Drive at the proper speed Select path of drive and met...

Page 33: ...turning or going through a narrow passageway z Operate carefully to prevent unstable loads when the ground is uneven and the load is not stable 5 7 Driving in Dangerous Conditions z Do not operate whe...

Page 34: ...when driving on an abrupt hill dyke or ramp So take care z The bucket should be 200 300mm above the ground when driving on an abrupt hill dyke or ramp Lower the bucket and touch the ground to help bra...

Page 35: ...n may be caused by using the wrong method z Wear gloves to deal with a tightwire z Before preparation for the towing confirm the signals with other people z Please contact Shandong Lingong Constructio...

Page 36: ...achinery Co Ltd assumes no resposibility for the injury or damage induced by overload z It is dangerous to hit any object at a high speed Damage may be done to the loaders the goods and the operator z...

Page 37: ...d under the bucket or to let the bucket go over the cab of the truck z When driving backwards ensure visibility of what is behind you z Install lighting systems during dark conditions And stop work wh...

Page 38: ...ward and backward all the time Keep people away from all sides below front rear inside right and left sides of the working equipment z To ensure safety when working at the side of a road or hear a cli...

Page 39: ...condition 6 4 Don t Get Close to Dangerous Environment z If the ejected gas from the silencer hits flammable material or the vent pipe is close to the flammable material fire may occur Be aware of th...

Page 40: ...he people who are on the ground cut off the electricity once the machine touches the wire z When operating near high voltage cables make sure other persons are far from the machine 7 SAFETY PARKING 7...

Page 41: ...oil tank to preheat the hydraulic oil so as to guarantee better reaction and prevent malfunction z Do not charge the storage battery with frozen electrolytes and do not use other power to start the e...

Page 42: ...or flame Do not pile oily cloths anywhere because it may self ignite z Never smoke when adding fuel or examining the storage battery z Put the accessories in a safe place to prevent lost Put the hand...

Page 43: ...s to work under the machine only using the working equipment to support the machine z Never work under the machine without good support 8 5 Working on the Machine z Make sure the top of the machine ha...

Page 44: ...unless fully trained to do so 8 7 Do Not Let Anything Fall into the Inner Part of the Machine z When opening the examination window and the oil filling port of the oil tank make sure that nothing suc...

Page 45: ...g Connect the heads after repair Otherwise the machine can not start and drive by itself z Clean the paint at the welding site to prevent the production of harmful gas z Avoid welding on the hydraulic...

Page 46: ...e coolant system touch your skin or eyes z Choose a proper container to hold the liquid when replacing the coolant mobile oil of the engine oil of the transmission box and cleaning the parts Please re...

Page 47: ...ubstances on the machine such as fuel grease oily cloth or other flammable materials z Keep fire away from the storage battery because explosive gas may be generated Strictly follow the program in thi...

Page 48: ...of the air storage tank frequently because of high pressure air Examine the anti erosion layer and welding line to ensure safety 8 15 Electric System z The electric system must be maintained by a pro...

Page 49: ...or downside fixing method to prevent destruction caused by loosening z There is an indicator on the cover of the battery The green light means it can be used the black light means it should be charge...

Page 50: ...negative or ground cable first when the voltage raising cable is removed z Connect the ground cable to the frame of the broken machine Connection should be as far as possible away from the storage bat...

Page 51: ...a fence around and hang a No Enter sign if the tires are stored outside the warehouse z Store the tires in a dry and clean place Water can oxidize a tire and dirt and oil can erode a tire No light he...

Page 52: ...the board is uniform to ensure firm orientation z Keep the board surface clean free of lubricant oil ice and loose materials Clean the dirt off the tires z Never turn around on the slope board If it i...

Page 53: ...handles should be in the middle position Stop the engine lock all the equipment using keys and then remove No one is allowed to stay in the operator cab Never lift the machine using steel wire connect...

Page 54: ...Operation Maintenance Manual LG958L LG959 Wheel Loader 46 CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME Figure 2 1 General view and components name...

Page 55: ...Operation Maintenance Manual LG958L LG959 Wheel Loader 47 2 GEOMETRICAL DIMENSIONS Figure 2 2 Geometrical dimensions of LG958L wheel loader mounted with standard lift arms...

Page 56: ...Operation Maintenance Manual LG958L LG959 Wheel Loader 48 Figure 2 3 Geometrical dimensions of LG959 wheel loader mounted with standard lift arms...

Page 57: ...NAMEPLATE The nameplate is fixed on the left rear side of the front frame describing the model serial No production date and manufacturer of the machine The type of nameplate is shown in Fig 2 4 Fig...

Page 58: ...Manual LG958L LG959 Wheel Loader 50 Figure 2 5 Nameplate of LG958L prevention rollover configuration loader The engine is made in Weichai or Shangchai Figure 2 6 Nameplate of LG958L wheel loader mount...

Page 59: ...Maintenance Manual LG958L LG959 Wheel Loader 51 Figure 2 7 Nameplate of LG958L prevention rollover configuration loader with the engine made in Cummins Figure 2 8 Nameplate of LG959 basic configurati...

Page 60: ...g 2 Unbalanced 3 Digging hard material 4 Lifting heavy material using a rope hung directly on the bucket 5 Dig with the bucket above the machine level 6 CIRCUMSTANCES REQUIREMENT Requirements for this...

Page 61: ...eatly z The optimized fuel oil tank enlarged the volume and added the rear protection steel plate The optimized hydraulic fluid tank guaranteed the cleanliness of the hydraulic system effectively and...

Page 62: ...of rear wheel 4546 mm 4546 mm Level passing radius outside of bucket 5082 mm 5150 mm Max turning angle 30 30 Min turning radius Outside of Rear wheels 6036 mm 6036 mm Min through radius Outside of buc...

Page 63: ...4 mm Wheel base LG958L 3200 mm 3200 mm Wheel base LG959 3179 mm Min ground clearance 457 mm 457 mm Max dumping height 45 dumping angle 3120 mm 3500 mm Dumping space 45 dumping angle 1120 mm 1164 mm Du...

Page 64: ...anel 3 Gear Control Lever 4 Brake Pedal 5 Accelerator Pedal 6 Seat 7 Parking Brake Switch 8 Equipment Control Lever 9 Switch Group 10 Starting Switch 11 Horn Button Figure 3 2 General View of Control...

Page 65: ...ont Headlight Switch 17 Rear Light Lamp Switch 18 Warning Lamp Switch Figure 3 3 General View of Gauges 1 Gearbox Pressure Gauge 2 Brake Air Pressure Gauge 3 Working Chronometer 4 Left Turn Indicator...

Page 66: ...verter Oil Temperature Gauge This gauge shows the torque converter oil temperature When the temperature index lies in the green range 60 120 the oil temperature is normal If the temperature index move...

Page 67: ...the pressure index lies in the range of 4 8 100kPa or 5 8 11 6 10PSI the oil pressure is normal Be sure to stop the machine for inspection if the index moves outside this range z Fuel Level Gauge This...

Page 68: ...f if the power is not cut off Emergency Steering Indicator Lamp The emergency steering function is selected to install When the wheel loader is steered emergently the lamp will come on if the emergenc...

Page 69: ...e user can select to install OFF Position Insert or remove the key in this position Turn the key to this position to cut off the electric power ON Position This position is used to turn on the electri...

Page 70: ...ting the switch After the operation of turning finished please put back the switch by your hand z Rocker Switch Rocker switch includes panel rocker switch and the right side rocker switch of driver s...

Page 71: ...cles and passersby Press the top side all the turning lamps will stop blinking z Unit Heater Switch if assembled Press bottom side the unit heater will work press top side it stops working When the un...

Page 72: ...le of the machine will be kept After finishing turning the machine turn the steering wheel in the reverse direction to keep the machine moving in a straight direction 1 2 4 Control Levers and Pedals z...

Page 73: ...Notice Never put the lift arm down when it is in the floating position Bucket Control Handle Move the control handle from left to right to control the front tilt neutral and rear tilt of the bucket R...

Page 74: ...ely regulated between idle and full speed z Parking Brake Switch This switch is on the right operator box and it is used for the parking brake Pull this switch to engage the parking brake Rotate the s...

Page 75: ...to the counterweight 2 1 2 8 Fuse NOTICE z Always be sure to close the startup switch before replacing the fuse The fuse is used to protect the wiring and cable from burning out If the fuse has become...

Page 76: ...temperature control switch anticlockwise slowly to obtain the desired temperature until the indicator lamp 1 turns off and the compressor stops working Now the setting temperature is the temperature...

Page 77: ...s normal the power indicator lamp will come on If the refrigeration indicator lamp comes on the compressor starts working for the refrigeration of air conditioning Notice Avoid the temperature control...

Page 78: ...upward to pull the backrest until the angle is comfortable The backrest angle is locked when loose the handle z Height Adjustment There are three positions for the height of seat and the operator can...

Page 79: ...ting so that each part of the machine can be have full run in period for increasing the life of the machine It needs 60 hours to train the new machine and operate follows z Run the machine in neutral...

Page 80: ...turning signals z Open the air storage tank to drain water The following maintenance should be done after the run in period of new machine z Clean the filter at the bottom of the gearbox and the oil f...

Page 81: ...re and relative temperature goes up So please pay attention to the environmental conditions and calculate the real power under the current environmental condition according to the power correcting tab...

Page 82: ...utral position z Turn the start key clockwise to the ON position Connect the power switch and ring the horn z Press the accelerator slowly then turn the start key clockwise to the START position After...

Page 83: ...r around to prevent accident And keep the machine under control z Raise the lift arm Keep the bucket backwards and keep the motor running z Put the gear control lever at forward I or reverse I positio...

Page 84: ...shift gears while running Release the accelerator and operate the transmission lever at the same time when changing the speed from low to high and when changing the speed from high to low release the...

Page 85: ...e parking brake switch to lock the machine in parking state z Level the bucket and other work equipment to the ground z Stop the machine on the level ground where there is no danger of stone falling c...

Page 86: ...bolts transmission axis bolts and other pins are loose z Check whether the work equipment is in good working order z Check the appearance and the pressure of the tire to see whether it is normal z Ad...

Page 87: ...loader should face the material and do as follows z If the bucket must be lowered while driving the machine forward stop the machine when the bucket is about 30cm above from the ground and then lower...

Page 88: ...ortation Digging and Shoveling Material on Flat Ground Lightly set the bucket edge leaning on the ground see picture when digging and shoveling material on flat ground Be careful not to fasten the loa...

Page 89: ...material can be dumped by the lever control Act slowly and gently during dumping to prevent the bucket from striking the ground z If the material sticks onto the bucket move the working equipment cont...

Page 90: ...but use fixed towing or use towing bar Connect the towing bar to the towing pin at the back of the loader z If there is no braking system on the towed machine no one is allowed to stay on it z Check w...

Page 91: ...ot use antifreeze containing formaldehyde ethanol or propanol 2 Never use any waterproofing agent independently or together with antifreeze 3 Never use antifreeze with different trademarks together 4...

Page 92: ...d weather After the weather is warm the relative parts should use the proper engine oil fuel and hydraulic oil that are appropriate for the temperature 3 6 Oil and Fuel Supply 3 6 1 Fuel Supply of Eng...

Page 93: ...the oil adding port Notice Check the other side of the dipstick when the machine under the idle speed It is a suitable oil level if it is between the adding oil graduation line and the oil motion full...

Page 94: ...Pull the parking brake switch and put the blocks in the front and back of the tires Start the engine and run at idle status until the oil temperature reaches 20 40 then stop the engine z Rotate the o...

Page 95: ...ear the engine oil filter Disassemble it with filter elements spanner Assemble z Add diesel oil full in the filter element and smear engine oil on the rubber seal ring z Tighten 3 4 1 cycles after the...

Page 96: ...when the oil temperature is about 40 z The oil level should be between the upper limit and middle limit when the oil temperature is about 80 If the oil level is not in the regular range hydraulic tran...

Page 97: ...h is in profile and clean all the parts If there are any metal powders or fragments please contact the maintenance man z Assemble the parts and add a little new hydraulic transmission oil Start engine...

Page 98: ...all the old oil and screw tight the oil drain plugs at the center bottom of the axle shell z Start engine Press the hand braking control valve Move the machine slowly with gentle acceleration to let...

Page 99: ...the maintained axle to work Oil Replacement z Replace oil after the first 500 hours and then do it every 1000 hours The oil should be replaced at least one time a year Brake oil z Refer to CHAPTER IV...

Page 100: ...ay attention to safety NOTICE Pay attention to the clarity of the oil while replacing it never let other materials enter the hydraulic system directly z Clean out the in bucket Park the machine on lev...

Page 101: ...oil tank without oil filter elements z Start engine raise and lower lift arm tilt the bucket forward and backward and turn left and right to the extreme position 2 3 times to let the hydraulic oil fi...

Page 102: ...ng Storage WARNING Open doors and windows to ensure ventilation and exhaust to allow of poisonous gas if the antirust is used in the building Start the machine once a month so that lubricant can be co...

Page 103: ...hen engine is running 1 Faulty alternator 2 Faulty cable 3 Improper adjustment of belt tension 1 Replace 2 Check and repair 3 Refer to Operation and Maintenance Manual of diesel engine for adjusting t...

Page 104: ...ge 3 The oil of torque converter overheats 1 Low oil level in gearbox oil tank 2 High oil level in gearbox oil tank 3 Low shifting pressure and clutch slips 4 T Q radiator is clogged 5 T Q operates wi...

Page 105: ...the rectangular seal ring 3 Pressure in air storage tank drops quickly after shutting down pressure drop is over 0 1 MPa in 30 min 1 Inlet valve of foot brake valve is clogged by dirt as damaged 2 Lo...

Page 106: ...il 2 Insufficient force of the bucket the bucket tend to lower down or float up 1 Damaged seal ring of steering cylinder piston 2 Over worn of multi passage valve excessive clearance between valve spo...

Page 107: ...oil circuits 3 Change seals of hydraulic tanks 4 Replace steering unit 5 Change by the specified oil 3 Inflexible or failure of steering system 1 Damaged spring plate of steering unit 2 Cracked broken...

Page 108: ...ine during maintenance 1 3 Fitting preparation z Use only parts specified by the manufacturer of the loaders wheel 1 4 Oil and Fuel preparation z Use oil and fuel specified in this manual according to...

Page 109: ...ding near the seal rings and bearings z Never weld any pipe or tube while has fuel as or oil in them 1 12 Fire Prevention z Clean the parts with nonflammable cleaner or light oil Keep spark or cigaret...

Page 110: ...er use oil mixed from different brands If only a different kind of oil from the one previously used drain the oil from the machine and fill with the new brand oil 2 DETAILED RULES OF MAINTENANCE 2 1 D...

Page 111: ...recommend range If the ambient temperature 15 use 25 If the ambient temperature 25 use 35 If the ambient temperature 35 use 45 2 1 3 Lubricant z Lubricant is used to reduce noise and prevent wear on t...

Page 112: ...oil Caltexoils caltex Delo Gold 15W 40 35L Torque converter and gearbox Heavy duty gear oil for automobile GL 5 85W 90 GB13895 32 2 L LG Axle main transmission and hub reduction Gear oil Caltexoils e...

Page 113: ...DX30 HEIBAWANG1300 SAE10W 30 20 40 Delvac super 1 over 40 Essolube XT 5 z Hydraulic oil Similar Oil Brands Chinese Brands CALTEX MOBIL SHELL CASTROL ESSO Hydraulic oil L HM46 5 40 GB11118 1 DTE25 10...

Page 114: ...W 90 10 50 Gear oil GX 85W 90 Spirax EP Heavyduty HD90 HD80w 90 z Brake fluid Similar Oil Brands Chinese Brands CALTEX MOBIL ESSO British BP SHELL Motor vehicle brake fluids HZY3 GB12981 RANDO HDZ46 S...

Page 115: ...id level of electrolyte in the storage battery z Never remove or disassemble any electric components installed in the machine z Never install any electric components other than those specified by the...

Page 116: ...9 Connection between the bracket of main driving and axle shell M16 1 5 45 8 8 193 257 10 Rim nuts M20 1 5 35 480 580 11 Connect bolts between brake clip assembly and stent M20 1 5 56 40Cr 376 502 12...

Page 117: ...system of the torque converter gearbox z Check if there is leakage in the hydraulic system Check and clean the air vent of the hydraulic reservoir Check and clean the oil return filter cartridge of t...

Page 118: ...e oil if possible Add them if deficient and replace them if necessary z Check if there is leakage in the brake system Clean the filter mesh of the oil bowl in the booster pump Clean the air vent and r...

Page 119: ...d hydraulic tank by measuring the natural sedimentation volume of the cylinders fuel oil and then check the system pressure z Check the welded seams of rim and other stress parts and adjust the deform...

Page 120: ...transmission box transmission axle front and rear driving axle wheel and others The transmission system diagram is shown in the Figure 5 1 1 Input Gear 2 KR Reversing Gear 3 Mid Axle Gear 4 4th Gear 5...

Page 121: ...g The set pressure of the safety valve is 18 18 5MPa The overload pressure of the rocker cylinder s large cavity is 20 5MPa while that of the small cavity is 12MPa 1 Work Pump 2 Hydraulic Oil Tank 3 P...

Page 122: ...ystem and parking brake system 1 Air Booster Pump 2 Air Brake Valve 3 Air Tank 4 Combination Valve of Oil Water Separator 5 Air Compressor 6 Brake Magnetic Valve 7 Parking Brake Air Chamber Figure 5 3...

Page 123: ...rake system using two brake calipers for front and back to increase the safety of whole vehicle When the left brake pedal is stepped on during driving the compressed air in air tank 4 flows through ai...

Page 124: ...the compress air in the parking brake air chamber 8 to drain into the aerospace by hand so that the emergency brake is utilized to protect the safety of vehicle and people 4 ELECTRIC SYSTEM The elect...

Page 125: ...Operation Maintenance Manual LG958L LG968 Wheel Loader 104 Figure5 5 LG958L Electric System Principle Diagram with Weichai Engine Domestic Type...

Page 126: ...Operation Maintenance Manual LG958L LG968 Wheel Loader 204 Figure5 6 LG958L Electric System Principle Diagram with Weichai Engine Export Type...

Page 127: ...Operation Maintenance Manual LG958L LG968 Wheel Loader 304 Figure5 7 Electric System Principle Diagram with Cummins Engine...

Page 128: ...Operation Maintenance Manual LG958L LG968 Wheel Loader 404 Figure 5 8 LG958L Electric System Principle Diagram with Shangchai Engine...