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Operation & Maintenance Manual

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LG936 Wheel Loader

CHAPTER II INTRODUCTION

1 GENERAL VIEW OF THE MACHINE & COMPONENTS’ NAME

Figure 2-1 General view and components’ name of LG936 wheel loader

Bucket

Lift arm

Front Wheel

Working light

Rear Wheel

Tilt lever

Dump Cylinder

Front Frame

Driving Cab

Front

Rear

Right

Left

Summary of Contents for LG936

Page 1: ...al carefully and understand these instructions before use to avoid serious accident For the convenience of relevant people using this manual it should be kept properly Operation Maintenance Manual LG9...

Page 2: ...80 1230 mm 16 18pieces 3rd Edition and 1st Print in 2008 4 SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone 276023 Tel 86 0539 8785688 Fax 86 0539 8785698 8785671...

Page 3: ...as commitment by Shandong Lingong construction machinery Co Ltd Shandong Lingong construction machinery Co Ltd accepts no responsibility for any errors that may appear in this document R Shandong Ling...

Page 4: ...to comment on any aspect of this manual or our products in general please send email to TechCenter sdlg cn Alternatively send a fax to 86 539 8785698 or write to Manual Feedback Technical Center Shan...

Page 5: ...5 SAFETY DRIVING 16 5 1 Warning 16 5 2 Oneself Safety and Others Safety 17 5 3 Full Load Transportation 18 5 4 Never Drive Over Speed 18 5 5 Ensure Good Visibility 19 5 6 Pay Attention to Blocks 19 5...

Page 6: ...NT 45 7 FEATURES 45 8 TECHNICAL PERFORMANCE PARAMETER 46 8 1 The Performance and Parameters of whole machine 46 8 3 Product Standard and License 47 CHAPTER III OPERATION AND APPLICATION 48 1 BE FAMILI...

Page 7: ...rque of Threads 100 3 RULES OF MAINTENANCE 100 3 1 Every 10 Hours Days Service 101 3 2 Every 50 Hours Week Service 101 3 3 Every 250 Hours Month Service 101 3 4 Every 500 Hours Season Service 102 3 5...

Page 8: ...er function parts about the operation usage and maintenance We are continually striving to improve the quality of our products to produce more advanced and safer engineering machine We reserve the rig...

Page 9: ...maintenance and repair of 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 the...

Page 10: ...must be sure safety of the operator and machine Otherwise consult us or the dealers The safety precautions for operation and maintenance in this manual only apply to those conditions specified by the...

Page 11: ...e figure above Please read the contents of safety label carefully and follow the rules Please keep the labels well if there is any lost broken or unclarity of label please add new one or repair in tim...

Page 12: ...er and oil 5 Start for lift 6 Label of Fuel Tank 7 Warning of high temperature Located on the mouse of radiator of engine hood Located on the cover of radiator of engine hood Located on the side of en...

Page 13: ...g 11 Warning for start 12 Notice for operation 13 Notice for driving Located above the start switch Located on the top of the fuel tank Located on the inner side of operator cab door Located on the st...

Page 14: ...Operation Maintenance Manual LG936 Wheel Loader 4 14 Danger of actuating arm Figure 1 2 Figure of safety label position Export Type Located on the two sides of actuating arm...

Page 15: ...ence for manual 5 Checks before Start 6 Driver only Lock the lift arm cylinder before entering dangerous areas Located on the two sides of actuating arm Located on the two sides of actuating arm Locat...

Page 16: ...Notice of warm oil and hot water 12 Start for lift Located on the left back pole inner operator cab Located on the left operator cab door and water inlet port of engine hood Located on the two sides o...

Page 17: ...ring 17 Forbidden of flame and fire 18 Fuel tank 19 Warning for starting switch Located on vent pipe of engine hood Located on the top of hydraulic oil tank Located on right and left sides of platform...

Page 18: ...ng Those cases could cause your wrong judgments and induce accident z When working with another operator or with a person on worksite traffic duty be sure that all people understand all hand signals t...

Page 19: ...thing jewelry and loose long hair They can be caught on control levers or control handles or in moving parts and cause serious injury or death z Avoid wearing oily clothes because they are flammable z...

Page 20: ...eck all the safety items such as the safety protective devices are at the safe status Make sure the tires are not worn and the tire pressure is up to snuff If you don t solve the oil leak water leak a...

Page 21: ...ladder at the back of machine or from the tire at the side of operator cab z Never hold any tools or other items when climbing up and down the loader lift the tools needed using rope to the operation...

Page 22: ...lame or fire nearby Repair and maintain the storage battery as referenced in users manual z Flame or fire match or lighter is not allowed to be used to check dark place z Fire extinguisher should be p...

Page 23: ...ipment or joint points between front and rare frame If the working equipment is operated the clearance will change and this may lead to serious damage or personal injury when stand too close The engin...

Page 24: ...working on public roads position flagmen and erect barricades and use the mark of DON T ENTER to ensure safe passing traffic and pedestrians z In places when there are buried objects such as water pip...

Page 25: ...s seat Replace with a new one if the mirror has been damaged z Don t leave any tool or part on the operator s seat These things may fall induced by moving and shake during working and so this could b...

Page 26: ...n extensive place no other people is allowed to get close z Check whether the engine runs with abnormal sound or shaking If so it means there may be exceptions report to the manager immediately Operat...

Page 27: ...xtend outside the machine z Driving on the plain ground the lower hinge of arm working equipment should be 400 500mm 16 20in above the ground z Pay attention to the people around and in front sound th...

Page 28: ...position near the block and relatively a lower position 400 500mm above the ground so that the center of gravity could be low to insure driving smoothly z Make sure the limit lifting weight of the loa...

Page 29: ...speed Never let the people get into the working space or find specific director z Keep the light on and drive at proper speed during night which may produce illusion for height of ground z Keep the fr...

Page 30: ...ller when driving on snowy ground to prevent slip z Take care when shovel snow because the road shoulder or other things can not be seen under the snow 5 8 Safety Drive on the Ramp z Pay attention to...

Page 31: ...NING Injury even death could result if a disable machine is towed incorrectly z Follow the direction in CHAPTER III 3 5 2 7 Towing danger may be cause by wrong method z Wear gloves to dell with tightw...

Page 32: ...rking state z Make sure do not overload otherwise it is dangerous Shandong Lingong construction machinery Co Ltd houlds no resposibilities duce to overload z It is dangerous and wrong method to run in...

Page 33: ...o not hit the truck or tipper It is not allowed to stand under backel and let the backel go over the operator cab of truck z Take care of the cars backside when drive backward z Assemble lighting syst...

Page 34: ...ed to enter near down front back in side the working equipment z Use safety method to work at the side of road or cliff where the landslip may happen There should be people watching and directing all...

Page 35: ...cer toward flammable material or the vent pipe is close to the flammable material may cause fire Pay attention to lipin cotton papers fade grass chemical materials and etc or flammable place 6 5 Don t...

Page 36: ...re z When operating near High Voltage cables make sure other persons are far from the machine 7 SAFETY PARKING 7 1 Pay Attention to the Safety of Yourself and Others z Park the machine at plain ground...

Page 37: ...the engine It is dangerous and can cause the fire Please refer to CHAPTER III 3 5 3 Operation in Cold Weather 8 SAFETY EXAMINE AND REPAIR 8 1 General Knowledge z Operation and maintenance people shoul...

Page 38: ...the handrail around and put the No Enter warning lable to prevent the people from entering without permission z No people is allowed to get close to the machine or accessories with out permission z K...

Page 39: ...e is no block and clean when work on the top of machine Follow the disciplines below NOTICE z Do not leak the lubricant or grease z Do not put the tools around z Walk placidly z Never jump down from t...

Page 40: ...ut bolt cotton yarn or tool fall into the inner part If such things happen the machine may be broken miss operation may be caused and other failures also z Do not carry any tool or part in your pocket...

Page 41: ...revent the pulse current burn the control board for the machine with ZF control unit Connect the polar of electric control board otherwise the machine may not be started and move z Clean the oil paint...

Page 42: ...the pressure to prevent hot oil jet Use the arm to feel the temperature of air near the hydraulic oil radiator torque converter oil radiator to check whether the temperature comes down z During machi...

Page 43: ...event vibration and overheat due to friction with other part z Choose proper container to hold liquid when replacing the hydraulic oil of hydraulic system and cleaning the parts Dealing of waste liqui...

Page 44: ...ame cut the pipe or tank containing flammable liquid Clean them use inflammable liquid before z Examine the fire extinguisher is well before repair Make sure the place where the fire extinguisher is a...

Page 45: ...he temperature is too high z Never reverse and put horizontal Prevent hammer by machine or press heavily z Storage life is 6 months under room temperature without charge If overtime please charge befo...

Page 46: ...e or current if the electrolyte overpass 45 to prevent spurt out of electrolyte due to high temperature z Never overcharge during using or charging to prevent early invalidation due to water lost grid...

Page 47: ...from the tire when adjust the pressure of tire z Check the tire rim every day whether the tire is crack or bubble Never operate at low pressure condition z Check the bolt and nut of rim whether there...

Page 48: ...er dump the waste oil to places such as cloacae river and etc z Contain the oil vented from the machine in a container never dump the oil directly onto the ground z Obey the relative rules and laws wh...

Page 49: ...the public roads z The machine may be disassembled when using other transportations Please contact with Shandong Lingong construction machinery Co Ltd or their accredited representative 9 3 Lifting U...

Page 50: ...ipes No person and car is allowed to pass under the machine during lifting Draw back the lock bar to turn the machine after lifting z Connect the turning equipment using lock bar after lifting onto th...

Page 51: ...TER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME Figure 2 1 General view and components name of LG936 wheel loader Bucket Lift arm Front Wheel Working light Rear Wheel Tilt lever Dump...

Page 52: ...Operation Maintenance Manual LG936 Wheel Loader 42 2 GEOMETRICAL DIMENSIONS Figure 2 2 Geometrical dimensions of LG936 wheel loader mounted with standard lift arms...

Page 53: ...ate is fixed on the left back side of front carriage describing the model serial No production date and manufacturer of the machine The format of nameplate is shown as figure 2 3 figure 2 4 The other...

Page 54: ...ises freight yards and ports etc It can be used for dragging flat the ground piling and Stacking of bulk soil sand sand stone coal garbage It can chuck wood fork grass clean snow chuck box liked mater...

Page 55: ...lity z New style steel structure cab damping and seal better visibility good inside decoration safe and comfortable operation environment with cool and hot temperature air condition z Reasonable power...

Page 56: ...0 17 km h Max breakout force 96 kN 92 kN Max tractive force supplied by engine 105 kN 105 kN Max tipping load fully turning 66 kN 0kN Max climbing angle 30 30 Min turning radius outside of the rear wh...

Page 57: ...m 370 mm Max dumping height 45 dumping angle 2950 mm 3278 mm Dumping space 45 dumping angle 1050 mm 1020 mm Dumping angle 45 45 Operate weight 10700kg 10700kg 8 3 Product Standard and License Product...

Page 58: ...Gauges 1 Panel 2 Steering Wheel 3 Steering Switch 4 Gearshift Control Lever 5 Brake Pedal 6 Accelerator Pedal 7 Seat 8 Flameout control soft shaft 9 Rocket Switch 10 Parking Brake Switch 11 Lift Arm C...

Page 59: ...Combined Switch figure 3 2 General view of control System front oriented one handle three pedals 1 Working Chronometer 2 Engine Water Temperature Gauge 3 Gearbox Oil Pressure Gauge 4 Torque Converter...

Page 60: ...Gauge Fuel level Gauge Socket switch 1 2 Introduction of Gauges Controls Following are the introduction of gauges controls needed for operating the machine Be sure to understand their functions and me...

Page 61: ...oil pressure is normal Be sure to stop the machine for inspection if the index lies in other areas If the pressure index lies in range 11 15 100kPa or 15 95 21 75 10PSI the oil pressure is normal Be...

Page 62: ...Lamp The lamp will be on immediately if the start switch is turned on It will be off immediately after the engine is started Otherwise it means the level of lubricant is too low or there is some prob...

Page 63: ...not on please check to eliminate exceptions Fuel Coarse Filter Indicator Lamp If this lamp is on means the coarse fuel filter is jammed seriously please clean or replace Turn indicator lamp The lamp w...

Page 64: ...switch is at ON position when the combined switch is turned to position Low Beam Headlight will be on push down the switch High Beam Headlight will be on Turning Light Push this switch forward left t...

Page 65: ...er vehicles and passersby When the button springs back all the turning light will blink z Warning Button Switch if assembled Push this button down all the turning lamps will blink used for emergency c...

Page 66: ...tion work adjust the air outlet in the front of gauge panel to adjust wind speed so that the frost can be cleaned or warm cool wind will be blown z Top Lamp Switch It is at the back of the top lamp in...

Page 67: ...g angle of machine will be kept After finishing turning of machine turn the steering wheel reversely to keep the machine move in straight direction 1 2 4 Control Levers and Pedals z Speed Control Leve...

Page 68: ...applied force Control Bucket Push the working equipment control handle left and right can control the bucket Forward Tilt Neutral and Rear Tilt Rear Tilt is used for drawn in bucket Neutral is used f...

Page 69: ...en assembled two brake pedals Never use left brake pedal during driving on ramp to prevent the power being cut off to induce danger z Accelerator Pedal This pedal controls the accelerograph of the eng...

Page 70: ...tomatically after close the door Insert key outside the cab turn 180 clockwise and pull out key pull the handle outside the cab the cab door will be opened Turn the lock bar upward the door will open...

Page 71: ...tion Selectable z Appearance of Control Panel The control panel of air condition is at the right side of operator seat NOTICE z Always be sure to close the startup switch before replacing a fuse The f...

Page 72: ...When the temperature drops to the desired degree turn the temperature switch counter clockwise slowly until the indication lamp1 is off The lamp1 will be on if the cab temperature is higher than this...

Page 73: ...ng the operator z Make sure that you can depress the brake pedal completely when your back is against the seat backrest z Weight Adjustment Weight adjust handle is at the middle bottom of the seat Tur...

Page 74: ...k tongue into the locker the locker will block the lock tongue Press the red button at the side of locker placket to release the lock tongue from locker Check whether the locker can block and release...

Page 75: ...astening status of bolts and nuts of all parts Especially the bolts of diesel engine cylinder cover vent pipe bolts front and rear frame bolts rim bolts transmission axle bolts and connection bolts on...

Page 76: ...ipment control lever back to the middle position after operating the lift ram and bucket to the required position 8 Stop to change the forward or backward driving direction 9 Full load working is allo...

Page 77: ...l levers to see whether they are sensitive and in the middle 11 Adjust the seat position to sit comfortably Please see 1 2 10 Adjustment of Cab s Seat 12 Check the safety belt there be sometimes and o...

Page 78: ...temperature and the turbo charger may be broken z Use the working equipment control levers or handle periodically to let the hydraulic oil fluid in hydraulic tank and pipes to fast warm the hydraulic...

Page 79: ...edal to slow the speed 3 3 2 Gearshift Changing between Forward and Backward z Press the accelerograph a little bit during change transmission to prevent too much impulsion z It is best the change the...

Page 80: ...tral position during going down the slope z Never use left brake pedal during driving on ramp to prevent the power being cut off to induce danger WARNING Never use control lever of manual brake valve...

Page 81: ...k whether there are particle liked materials piled on engine if so clean immediately to prevent fire z Clean all the possible flammable materials around the machine to prevent fire z Lock the door and...

Page 82: ...cially for long distance transportation z When work together there are two ways to cooperate if loader dig the material and the camion transport and unload the material Cross Load Loader face material...

Page 83: ...neously z Keep the bucket horizontal when loading the stockpil while make it a dumping angle down when loading the blasted rock Notice Forbid getting the blasted rock under the bucket which will make...

Page 84: ...be carried out carefully with1st gear z Set the bucket edge facing down slightly z When driving the machine forward operate the working equipment control levers or handle to let the lift arm tilt forw...

Page 85: ...lever control Act slowly and gently during dumping to prevent striking z If the material sticks onto bucket move the working equipment control levers or handle cyclically to let the bucket tilt forwar...

Page 86: ...wheel can only be used for lifting and binding but not for towing z If there is no braking system for machine towed never use soft towing but use fixing towing or use towing bar Connect the towing bar...

Page 87: ...rademark of oil please see CHAPTER IV 2 2 1 Selection Table of Fuel Coolant and Lubricant z Attentions for using antifreeze 1 Do not use antifreeze containing formaldehyde ethanol or propanol 2 Never...

Page 88: ...ature is below 0 and there is no antifreeze in coolant please open the water drain valves located at the bottom of water tank and all the drain valves of engine to drain all the coolant water in cooli...

Page 89: ...oil level is between scale H and L of dipstick Weifang TD226B Engine If the oil level is below scale L it needs to add some mobile oil from oil inlet The oil is proper if the oil level is between sca...

Page 90: ...minutes after the engine is stopped let the mobile oil flow back to oil pan and check the mobile oil level of engine again Mobile Oil Filter Replacing Disassembly z Clean the area near the mobile oil...

Page 91: ...re is oil flowing out but the indication pointer of oil pressure gauge is still at the proper position if there is no oil flowing out please add oil to the gearbox Oil selection of gearbox please see...

Page 92: ...mble the coarse filter clean all the parts If there is any metal power or particles please contact with maintenance man z Assemble the parts orderly add new transmit oil a little bit start engine at i...

Page 93: ...arking brake switch gently until it rebounds use small accelerograph to move the machine slowly to let the oil drain plug of front axle at horizontal position and then shut the engine put speed contro...

Page 94: ...g brake switch start the engine at idle status for 10 minutes raise and lower the lift arm several times tilt forward and backward the bucket several times z Raise the lift arm to the upper most posit...

Page 95: ...status for 5 minutes to release the air of system z Shut the engine check the oil level if there is not enough oil add some more 3 7 Long Time Storage 3 7 1 Before Storage When putting the machine in...

Page 96: ...month so that lubricant can be coated over the surface of movable parts and other components surfaces storage battery can be charged at the same time Wipe off the grease coated the hydraulic cylinder...

Page 97: ...s 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 the tension o...

Page 98: ...of torque converter overheats 1 Over low oil level in gearbox oil tank 2 Over high oil level in gearbox oil tank 3 Over low shifting pressure and clutch slips 4 T Q radiator is clogged 5 T Q operates...

Page 99: ...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 even damage 2 Loose...

Page 100: ...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 spool an...

Page 101: ...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 or...

Page 102: ...ting the engine during maintenance 1 3 Spare Parts z Use only parts specified by the manufacturer of the wheel loaders 1 4 Oil and Fuel z Use oil and fuel specified in this manual according to ambient...

Page 103: ...ding near seal rings and bearings z Never weld any pipe or tube containing fuel or oil 1 12 Fire Prevention z Use inflammable cleaner or light oil to clean parts Keep spark or cigarette light away fro...

Page 104: ...ain the oil from the machine and fill with the new brand oil 2 CONTENT OF MAINTENANCE 2 1 Outline of Oil Fuel and Coolant WARNING z Because of the bad operation conditions and dusty ambient circumstan...

Page 105: ...see CHAPTER III 3 5 3 Operation in Cold Weather and refill before next working if there is no antifreeze in the coolant z Antifreeze is flammable Keep fire off when the antifreeze is added z Never use...

Page 106: ...eifang diesel engine Ambient temperature 15 CD 15W 40 GB11122 Ambient temperature 15 CD 5W 30 GB11122 13L YC6108G diesel engine Engine oil CALTEX Delo Gold Multigrade 15W 40 or Mobile HEIBAWANG1300 SA...

Page 107: ...TX30 Rotella DX30 Caltex Delo Gold Multigrade 15W 40 Essolube XT 5 z Hydraulic oil Similar Oil Brands Chinese Brands CALTEX SHELL MOBIL CASTROL ESSO Hydraulic oil L HM46 5 40 GB11118 1 Tellus 27 Tellu...

Page 108: ...90 10 50 Gear oil GX 85W 90 Spirax EP Heavyduty HD90 HD80w 90 z Brake fluid Similar Oil Brands Chinese Brands Grade MOBIL ESSO British BP SHELL Motor vehicle brake fluids HZY3 GB12981 SAE 1703C Super...

Page 109: ...ension and distress of fan belt Check the fluid level of storage battery z Never remove or disassemble any electric components installed in the machine z Never install any electric components other th...

Page 110: ...sion M16 1 5 55 40Cr 280 330 7 Assembling bolts of bearing bracket and carrier in the main transmission M22 90 40Cr 450 550 8 Lock nuts of input flange in the main transmission M33 1 5 8 320 400 9 Ass...

Page 111: ...are loosened z Check all assembling bolts of teeth for tightening z Check and lubricate the accelerator control parking brake and gearshift control system In addition do the extra maintenance in the f...

Page 112: ...he extra maintenance in the first 500 hours as follow z Check if there is leakage in the hydraulic system Check and clean the air vent of hydraulic reservoir Replace the oil return filter cartridge of...

Page 113: ...l sedimentation volume of the cylinders fuel oil and then check the system pressure If the natural sedimentation volume is over than its specified value replace the multi passage valve or hydraulic ta...

Page 114: ...rear driving axle wheel and so on The transmission system theory is shown in the Figure 5 1 Figure 5 1 LG936 Transmission System Theory 2 Hydraulic System As shown in figure 5 2 The machinery control...

Page 115: ...s triple expansion valve this bucket valve of rocket cylinder controls three actions including dumping forward tilt median and taking bucket back rear tilt multiway valve of lift arms cylinder control...

Page 116: ...c System Theory 3 Brake System Brake system is used when the machine decelerates even stops or the long term parks on the level ground or incline as is shown in figure 5 4 figure 5 5 The brake system...

Page 117: ...decelerating or parking Release brake pedal the compressed air in booster pump will be drained to the atmosphere and the brake state will be terminated 3 2 Driving Brake System Double Brake Pedal Brak...

Page 118: ...outlet of brake electromagnetic valve the brake unit will be pulled up due to the spring force to brake the machine and at the meanwhile air pressure signal will be send and the break indicator lamp...

Page 119: ...m Theory 5 Electric System Electric system is composed of storage battery starting motor charge generator appliance switch lamps and other electric instruments The system of this machine employs d c 2...

Page 120: ...110 Figure5 7 Electric System Theory Using YC6108G and TD226B Engine Machinery Control...

Page 121: ...111 Figure5 8 Electric System Theory Using Weifang TD226B Engine Pilot Control Combined Switch...

Page 122: ...112 Figure5 9 Electric System Theory Using Dongfeng CUMMINS 6BT5 9 Engine Pilot Control Combined Switch...

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