Volvo SDLG LG936L Operation & Maintenance Manual Download Page 130

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Operation & Maintenance Manual

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LG936L Wheel Loader

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Figure 5-10 Electric System Principle Diagram with Cummins Engine (Export Type)

Summary of Contents for SDLG LG936L

Page 1: ...understand 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 Maintenance Manual LG936L WHEEL LOADER SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD ...

Page 2: ...880 1230 mm 16 7 25pieces 1th Edition and 2nd Print in 2009 2 SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone 276023 Tel 86 0539 8785688 Fax 86 0539 8785698 8785671 Services Tel 8008607999 4006587999 86 0539 8785800 Services Fax 86 0539 8785671 Website www sdlg cn ...

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 Lingong Construction Machinery Co Ltd P R China All rights reserved The contents of this publication may not be reproduced in any form or communicated to a third party without prior written permission of ...

Page 4: ... 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 Shandong Lingong Construction Machinery Co Ltd Linyi Economic Development Zone Linyi 276023 Shandong Province P R China Please quote the title part number and date of the manual This will help us to understa...

Page 5: ...5 SAFETY DRIVING 20 5 1 Warning 20 5 2 Safety of self and Others 20 5 3 Full Load Transportation 22 5 4 Drive at Proper Speeds 22 5 5 Ensure Good Visibility 22 5 6 Pay Attention to Blockages 23 5 7 Driving in Dangerous Conditions 23 5 8 Driving Safely on the Ramp 24 5 9 Towing 25 6 SAFETY OPERATION 26 6 1 Keep Good Operation Habits 26 6 2 Pay Attention to Surroundings 28 6 3 Ensure Ventilation in ...

Page 6: ...49 7 FEATURES 49 8 TECHNICAL PERFORMANCE PARAMETER 50 8 1 Performance of Whole Machine 50 8 2 Principle Dimension and Weight 51 8 3 Product Standard and License 51 CHAPTER III OPERATION AND APPLICATION 52 1 BE FAMILIAR WITH MACHINE 52 1 1 Control Systems and Gauges 52 1 2 Introduction of Gauges Controls 55 2 RUN IN PERIOD OF NEW MACHINE 70 3 OPERATION AND USE OF LOADER 71 3 1 Notices for Usage 71 ...

Page 7: ... of Electric System Maintenance 106 2 5 Maintenance Tools 106 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 108 3 3 Every 250 Hours Month Service 108 3 4 Every 500 Hours Season Service 109 3 5 Every 1000 Hours Half a Year Service 109 3 6 Every 2000 Hours Year Service 110 3 7 Alteration 110 3 8 Replace the Air Sto...

Page 8: ... 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 reserve the right at our sole discretion to change or modify our design but we do not promise to apply the changes to products that are sold We also reserve the right to change the data and machine and...

Page 9: ... 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 the machine is used for any unintended purpose that is not specifically prohibited ensure the safety of yourself and others before using z Any operation and actions which are in conflict with the descri...

Page 10: ...ified 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 machine In any case you should not engage in prohibited operations as described in this manual The following signs are used for identification of safety information in this manual DANGER This word i...

Page 11: ... 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 repair or replace the label If any component attached with safety labels is replaced please make sure the new component has the same safety label When cleaning the safety labels please use cloth soap and wa...

Page 12: ...rting Located above the start button Lock the lift arm cylinder before entering dangerous areas 2 Limit position of lift arm 3 Danger of lift arm Located on both sides of lift arm Located on both sides of lift arms 4 Danger of injury or death during steering Located on the steering position of front and rear frames ...

Page 13: ...ocated on the inner left front glass of the operator cab Located on the left side of operator cab door or mouse of radiator of engine hood Located on the operation tank Located on outside of operator cab left door maintains Sitting allowed only in cab s loading while in operation Located on the left side of operator cab door or mouse of radiator of engine hood act on with a with a with a Located o...

Page 14: ... or hot water ejection Located on both sides of engine Touch the machine only after all parts stop Located on the both sides of engine hood 15 Warning of safety distance Located on vent pipe of engine hood Located on the cover of engine water tank Located on the of fuel oil tank Precaution 16 Warning to touch the machine Located on the front of front and rear frames ...

Page 15: ...Operation Maintenance Manual LG936L Wheel Loader 5 Figure 1 2 Figure of safety label position Export Type ...

Page 16: ...ctuating arm Located on both sides of actuating arm Located on both sides of actuating arm 3 Antifreeze fluid if 45 coolant has been added 4 Antifreeze fluid if 45 coolant has been added Located on the left operator cab door and mouse of radiator of engine hood 35 Located on the left operator cab door and mouse of radiator of engine hood ...

Page 17: ...ip over 9 No passenger warning 6 Notice of required reading manual Located on the left front upright column of operator cab Located on the inner right front upright column of the operator cab Located on the inner left back upright column of the operator cab 8 Check before starting Located on the inner left back upright column of the operator cab ...

Page 18: ...fuel tank Located on the inner left back upright column of the operator cab Located on the inner left back upright column of the operator cab 11 Wearing seat belt warning Located on the left back upright column in inner operator cab 12 Warning of high voltage 14 No fire warning Located on battery tank ...

Page 19: ...both sides of engine hood 16 Warning of machine reversing Located on the lifting position of the front and rear frames 17 Start for lift Located on filler of water tank of engine hood Pay attention to steam or hot water ejection 18 Notice of hot water and oil Located on vent pipe of engine hood 19 Warning of high temperature ...

Page 20: ... Notice for platform frame Located on the hydraulic oil tank 21 Hydraulic oil tank Located on the operation tank 22 Notice for parking brake Located on the steering position of front and rear frames 23 Danger of serious injury during steering 24 Warning for starting Located above the start bottom ...

Page 21: ...g 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 are to be used z Follow all the safety rules 2 2 Safety Devices z Be sure all guards and covers are in their proper positions and repair them when damaged z Use the safety devices properly such as park...

Page 22: ...g 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 are flammable z Compressed air may hurt the body When using compressed air be sure to wear a mask safety cloth and shoes The pressure of compressed air should be lower than 0 3MPa z All the protective items sho...

Page 23: ... 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 deformation loose fittings and abnormal sounds or accidents may occur Check the safety devices routinely 3 2 When Leaving Operator s Seat z Always keep the parking brake switch in the lock position z Level the w...

Page 24: ...operator cab from the ladder at the back of machine or get off from the wheel 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 to the operation flat roof by rope 3 4 Fire Prevention The following fluids are flammable and must be kept away from high heat and fire engine lubricant for loader engine hydraulic oil for hydrauli...

Page 25: ...replace the broken items Clean the repaired items before use z If there is explosive air generated near the storage 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 The fire extinguisher should be ready for use at all times and the user must be knowledgea...

Page 26: ... your body into movable parts 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 working equipment must be locked if people have to work between the moving components z Make sure the supporter and the accessories are correctly set when some one works und...

Page 27: ...spect the area for any unusual conditions that could be 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 firmly If there is a lot of sand and dust sprinkle with water first z When working on public roads there should be a trained person managing the ...

Page 28: ...ipment if assembled are broken The safety belt must be replaced with a new one every three years z Check the gauges for damage and make sure 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 clean to ensure the best view from the operator s seat Replace w...

Page 29: ... the horn for warning z Start the engine Please refer to CHAPTER III 3 2 2 Starting of Engine z Only start the engine in the cab Do not start the engine by short circuit It may destroy the machine if it is started from side short circuit This is very dangerous 4 1 4 Check after Starting the Engine Check after the engine is started to make sure there is no potential danger z When examining the mach...

Page 30: ...forward 5 SAFETY DRIVING 5 1 Warning z The warning light should be turned on to warn the other drivers on the road when the machine is broken down or operating at a low speed 5 2 Safety of self and Others z Develop good driving habits to ensure everyone s safety z Sound the horn to ensure safety before moving z Be sure there are no people or blockage on the left and right side z Check the brakes o...

Page 31: ...ne body z Never use the bucket as a people carrier z Follow the traffic rules 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 immediately and stop when the engine flameouts WARNING z Steering unit does not work when engine stops z Emergency brake could hurt pe...

Page 32: ...he 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 method of machining to let the others know z Keep a low speed so as to maintain control easily at all times z Never drive fast turn to brake suddenly on rugged slippery or oblique ground z Slow down when p...

Page 33: ...own and check whether there are some blockages when 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 when you are unsure about the environment Investigate the condition of the road the strength of the bridge landform of the working area and all geologi...

Page 34: ...e care with the snow shovel 5 8 Driving Safely on the Ramp z Turnover or slippage may occur when driving on an abrupt hill dyke or ramp z The bucket should be 200mm 300mm above the ground when driving on an abrupt hill dyke or ramp Lower the bucket and touch the ground to help brake or prevent turn over in emergency conditions z Do not turn on the ramp Do not drive across the ramp or change direct...

Page 35: ... Follow the direction in CHAPTER III 3 5 2 7 Towing a dangerous contion 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 Construction Machinery Co Ltd or their accredited representative if the engine does not start or the brake system has problems z Please tow t...

Page 36: ...gerous Shandong Lingong Construction Machinery 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 Keep perpendicular during loading and unloading materials If working in a side direction the steering cylinder and differential carriers may be damaged and the m...

Page 37: ... 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 when there is smoke fog sand or dust which affects visibility z When working at night please make sure Proper lighting system is installed Fuction light works normally To carefully estimate the height an...

Page 38: ...d right and move forward and backward all the time Keep people away from all sides of the working equipment z To ensure safety when working at the side of a road or hear a cliff where the land may shift designate a person to watch and direct at all times z Take care with the dumping position when unloading sand or rocks from the high position z When pushing material off a cliff or when the highest...

Page 39: ...se when working in this 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 the flammable materials such as lipin cotton papers dry grass chemicals and oily or oiled rags 6 5 Don t Get Close to High Voltage Wire Do not touch the aerial electric wire Elect...

Page 40: ...part of the machine until the 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 1 Pay Attention to the Safety of Yourself and Others z Park the machine on level ground The working equipment should be put on the ground z Never park on a ramp If parking o...

Page 41: ...ee better reaction and prevent malfunction z Do not charge the storage battery with frozen electrolytes and do not use other power to start the engine It is dangerous and can cause fire Please refer to CHAPTER III 3 5 3 Operation in Cold Weather 8 SAFETY EXAMINATION AND REPAIR 8 1 General Knowledge z Operation and maintenance people should be trained to become the licensed Do not allow anyone to e...

Page 42: ... safe place to prevent lost Put the handrail around and put the No Enter warning label to prevent people from entering without permission z No people are allowed to get close to the machine or accessories without permission z Keep the working area clean and tidy without flammable materials around to prevent fire or slippage z Lock the front and rear frames with a safety bar to prevent rotation bef...

Page 43: ...has no blockage and is clean when working on the top of the machine Follow the rules below NOTICE z Do not allow lubricant or grease to leak z Do not randomly put the tools around the work place z Walk slowly and carefully z Never jump down from the machine When climbing up and down the machine face the machine and keep three points contact two hands one foot or two feet one hand with the handrail...

Page 44: ... 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 such as nuts bolts cotton yarn or tools falls into the inside of the machine If it happens the machine may be disabled Pick out the fallen pieces safely z Do not carry any unnecessary tools or parts in your pockets during examination of the machine...

Page 45: ... the electricity in the terminals for storage to prevent explosion z For loaders with ZF controlling units disconnect the wire nipples on the computer control panel to protect the computer control panel from being burnt out by the impulse current generated in welding After repairing do connect the wire nipples on the computer control panel according to requested or the machine will not work z Clea...

Page 46: ...tor Check the air temperature in front of the radiator to gauge the temperature z To avoid hot oil ejecting from the radiator stop the engine let the hot water cool and open the cover slowly to release the pressure Never touch the radiator Check the air temperature in front of the radiator to gauge the temperature z While the machine is warming up do not touch engine silencer tail pipe or relay to...

Page 47: ...skin and cause death If the liquid splash onto your skin the case of a physician trained for this kind of burn will be immediately required z Make sure all the pipe clamps protective board and anti heat cover are installed properly to prevent vibration and overheating due to friction with other parts z Choose proper container to hold liquid when replacing the hydraulic oil of the hydraulic system ...

Page 48: ...d after repair z Check the wire to see whether it is breakage and voltage leakage if so replace it or repair it z Use inflammable liquid to clean the parts do not use gasoline or other flammable materials z Never weld or flame cut the pipe or tank containing flammable liquid Clean them using inflammable liquid before welding and flame cutting z Check the fire extinguisher before starting repair wo...

Page 49: ...ause an explosion Prevent circuit from shorting z Keep fire away from the crust on the battery because it is flammable z Store the battery under dry clean and well ventilated circumstances with temperatures between 5 25 Prevent sun light irradiation Keep the battery 2m away from a heat source The battery will be affected by high temperature z Never reverse and put horizontally Prevent damage by to...

Page 50: ...urrent is less than 25A Normal charge charge 24 hours at 16 0 Voltage max current is less than 25A z Connect the positive pole of the charging machine with the negative pole of the storage battery and then connect the negative pole of the charging machine with the positive pole of the storage battery Never reverse z Examine the vent of the battery to prevent blockage otherwise it may explode z Low...

Page 51: ...ERS z Driving at high speeds increases the temperature and therefore the pressure Never try to reduce the pressure but reduce the speed to cool the tire Continuous high speed driving can lead to over heating and tire explosion z Stand at the back of the tire and stand as far as possible away from the tire when adjusting the pressure of the tire z Check the tire and rim every day for cracks or bubb...

Page 52: ...The tire should be rotated 90 once per month at least z Please stand aside if a tire starts to fall down Never try to hold a tire since the tires for engineering mechanisms are generally very heavy and you may be seriously hurt 8 20 Waste Materials Do as follows to prevent pollution z Never dump waste oil under ground or into the river z Contain the oil vented from the machine in a container never...

Page 53: ...length prescribed by national and local laws for transporting the machine using a tow truck Obey the traffic rules z Know the weight height width and length of machine regulation before deciding the transport routine z Know the allowed limit of weight bearing when passing bridges or private buildings Obey the relative rules when driving on the public roads z The machine may be unloaded when using ...

Page 54: ...n the front frame It is allowed to lift the machine using 4 steel wires of the same length no shorter than 7m Keep the machine horizontal during lifting Prevent damage to hood operator cab and hydraulic pipes No person or 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 the lock bar after lifting ...

Page 55: ...Operation Maintenance Manual LG936L Wheel Loader 45 CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME Figure 2 1 General view and components name of LG936L wheel loader ...

Page 56: ...Operation Maintenance Manual LG936L Wheel Loader 46 2 GEOMETRICAL DIMENSIONS Figure 2 2 Geometrical dimensions of LG936L wheel loader mounted with standard lift arms ...

Page 57: ...ingong 4 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 3 and Fig 2 4 The other configurations of nameplate refer to CHAPTER II 8 TECHNICAL PERFORMANCE PARAMETERS Figure 2 3 Nameplate of LG936L basic configuration loader ...

Page 58: ...nd ports It can be used for dragging to flatten the ground piling and stacking of bulk soil sand sand stone coal and garbage It can chuck wood fork grass clean snow and chuck box liked material with proper work equipment Please refer to CHAPTER III 3 5 Operations for details WARNING The following operations are forbidden for the loader 1 Over loading 2 Unbalanced 3 Digging hard material 4 Lifting ...

Page 59: ...e vertical stability is high z Provide 5 ton grade LG transmission whose reliability is higher z Power matches suitably Select the work pump with large displacement to improve the working efficient z Employ dustproof design on the position of pins to prolong the using life z Employ hydraulic controlling mechanism with patent right to provide portable operation and high reliability z Articulated fr...

Page 60: ...loading capacity 30000N 27000N Lifting time full load 5 3 s 5 3 s Lowering time empty bucket 2 9 s 2 9 s Forward tilting time empty bucket 1 0 s 1 0 s Travel speed Forward 1st 0 13 km h 0 13 km h 2nd 0 38 km h 0 38 km h Reverse 1st 0 17 km h 0 17 km h Max breakout force 96 kN 92 kN Max traction force supplied by engine 105 kN 105 kN Max tipping load 66 kN 66 kN Max climbing angle 30 30 Min turning...

Page 61: ...m Bucket width 2510 mm 2510 mm Height 3170 mm 3170 mm Wheel track 1865 mm 1865 mm Wheel base 2850 mm 2850 mm Min ground clearance 370 mm 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 Operating weight 10700kg 1070kg 8 3 Product Standard and License Product Standard Q LGJ 001 wheel loader ...

Page 62: ...ure 3 1 General view of control System Double Control Lever Manual Flameout 1 Panel 2 Steering Wheel 3 Turning Switch 4 High and Low Speed Control Lever 5 Brake Pedal 6 Accelerator Pedal 7 Seat 8 Flameout Control Soft Knot 9 Parking Brake Control Switch 10 Bucket Control Lever 11 Lift Arm Control Lever 12 Roker Switch 13 Starting Switch 14 Horn Button ...

Page 63: ...and Low Speed Control Lever 11 Starting Switch 12 Horn Button Figure 3 2 General view of control System Pilot Single Lever Manual Flameout 1 Steering Wheel 2 Panel 3 High and Low Speed Control Lever 4 Brake Pedal On both sides 5 Accelerator Pedal 6 Seat 7 Parking Brake Control Lever 8 Equipment Control Lever 9 Switch Group 10 Starting Switch 11 Horn Button Figure 3 3 General view of control System...

Page 64: ... Lamp 13 Left Turn Indicator Lamp Figure 3 4 General view of gauges 1 Gearbox Oil Pressure Gauge 2 Air Pressure Gauge 3 Working Chronometer 4 Left Turn Indicator Lamp 5 Indicator Lamp 6 Revolution Indicator 7 Right Turn Indicator Lamp 8 Fuel Level Gauge 9 Engine Water Temperature Gauge 10 Torque Converter Oil Temperature Gauge 11 Starting Switch 12 Switch Group 13 Water Spraying Switch 14 Rain Wip...

Page 65: ... for details of stopping the engine z Torque Converter 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 moves past green into the red ranges be sure to stop the machine for inspection z Working Chronometer This indicator shows the total operation hours of the ...

Page 66: ...r inspection if the index moves outside this range This gauge indicates the air pressure of the brake system If the pressure index lies in the green range 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 if assembled This gauge indicates the ratio of remaining fuel level in the fuel tank to t...

Page 67: ...d the lamp will come on if the left braking pedal is stepped down the power will not be cut off and the lamp will go off if the right braking pedal is stepped down z 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 emergency steering pump works z Parking Brake Indicator Lamp The lamp wi...

Page 68: ...when the engine is running START Position This is the engine start position Keep the key at this position during starting After the engine has started immediately pull out the key or it will return to ON position automatically z Radio and CD Player selectable This switch is at the right side of the ceiling cab and for the details please refers to Radio and CD Player Assemble Operation Manual Vehic...

Page 69: ...nd the right turning lamp is lightened when the switch is put backward Notice The turn indicator lamp is lightened when operate the switch After the operation of turning finished please put back the switch by your hand z Rocker Switches The rocker switch includes rocker switch on gauges and the one on right front side of the cab top The switches on the gauges refer to 1 1 Control System and the Ga...

Page 70: ...side and the high beam of the rear headlight will come on If no side is pressed no lamp will come on z Front Headlight Switch if assembled Press bottom side and low beam of the front headlight will come on Press top side and the high beam of the front headlight will come on If no side is pressed no lamp will come on z Front Rear Lighting Lamp Switch Press bottom side and the front rear lighting la...

Page 71: ... the top side for high air speed Press the middle of the button and the fan will stop z Horn Switch Press the button in the middle of the steering wheel and the horn will sound z Power Switch The switch locates in the right battery box The power of the whole vehicle is shut off when the switch turns to the position The power of the whole vehicle is turn on when the switch turns to the position Ple...

Page 72: ...ward to the 1 position can obtain the forward gear Ⅰ and the machine goes forward at low speed When turn it to 2 position the forward gear Ⅱ can be obtained and the machine goes forward at high speed Putting the lever to R position can obtain the reverse gear and the machine goes backward z Equipment Control Handle and Lever 1 Equipment Control Lever Refer to 1 1 General View of Controls and Gauge...

Page 73: ...rm in the desired position Lower is used for lowering Float is used for moving freely under applied force Notice Do not lower the arm at float position Bucket Rear Tilt is used for drawing in the bucket Neutral is used for keeping the bucket in the desired position Forward Tilt is used for dumping The working device control handle also has the following functions Lifting limit location function Wh...

Page 74: ...ion automatically to increase the efficient of the whole vehicle z Brake Pedal The Brake Pedal controls the brake of the vehicle Refer to 1 1 General View of Controls and Gauges Figure3 1 Figure3 2 Figure 3 3 in this chapter Do not use the left brake pedal to avoid the drive from being cut off on ramp if double brake pedal are provided z Accelerator Pedal This pedal controls the acceleration of th...

Page 75: ...ter closing the door Insert key outside the cab Turn 180 clockwise and pull out key Pull the handle outside the cab and the cab door will open Turn the lock bar upward and it will open 1 2 6 Frame Locking Bar WARNING z Be sure to use the front and rear frame locking bar during maintenance or transporting the machine z Be sure to release the frame locking bar during routine travel z The frame locki...

Page 76: ...is used to protect the wiring and cable from burning out If the fuse has become corroded by oxidation or the fuse is loose in the fuse holder please replace the fuse z When replacing the fuse please replace with a fuse of the same specification 1 2 9 Air Conditioning 1 2 9 1 Ⅰcontrol panel and is operation if assembled z The Appearance of Panel The panel of air conditioning is on the right operato...

Page 77: ...ed temperature until the indicator lamp 1 turns off and the compressor stops working Now the setting temperature is the temperature in the cab When the inside temperature is higher than the setting temperature the indicator lamp 1 lightens and the compressor will begin to refrigerate when the inside temperature is lower than the setting temperature the indicator lamp 1 turns off and the compressor...

Page 78: ...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 switch 3 is always in the coolest position and the air volume and power switch 2 is in the fan low gear L position in order to prevent the evaporator from frosting Avoid the sun shining directly in summer Please shut the door an...

Page 79: ...l feel comfortable z Fore and Aft Adjustment This handle is on the left bottom side of the seat Pull the fore and aft handle B and move the seat forward or backward to the desired position it will lock automatically after pushing it down z Backrest Angle Adjustment Put the backrest angle adjust handle C upward to pull the backreat until the angle is comfortable The backrest angle is locked when lo...

Page 80: ...uips two key for every using condition z The key of left and right doors of cab z The starting switch key for engine z The key of left and right doors of engine hood z The key of left and right otter boards of engine hood z The key for adding fuel port of fuel box 2 RUN IN PERIOD OF NEW MACHINE A new machine must have a run in period first to increase the load step by step from free rotating so th...

Page 81: ...e battery electrolyte and its reserves and fasten the connect poles z Check the oil level of the gearbox Please refer to 3 6 3 Adding Oil to Gearbox in this chapter z Check the seal of the hydraulic system and braking system z Check the connection and sensitivity of all control levers z Check the temperature and the connections of the circuit system the power supply of electrical machine gauge lig...

Page 82: ...he mobile temperature of the engine is above 50 But the water temperature of the engine should not be over 95 and the mobile temperature of the engine should not be over 120 otherwise stop the loader to cool it 10 Never lift the bucket to the highest position to transport material The lower hinge of the lift arm should be 400 500mm above the ground to ensure stable driving during the transporting ...

Page 83: ...l levers are in the neutral position before starting make sure the gear control lever is in neutral position and put the switch in its original position z Step on the accelerator slowly when starting to prevent breaking parts z Follow the correct starting steps to start the engine z Refer to Diesel Engine Usage and Maintenance User Manual for other operations of diesel engines Steps of starting en...

Page 84: ...tion to the value of the gauge z Do not let the engine run at high speed or low speed more than 20 minutes in the idle status z If the engine has to run at idle status the machine should be loaded from time to time or the engine should run at the middle speed 3 3 Running 3 3 1 Driving Make sure there is no other person in on or around the machine or around to prevent accident And keep the machine ...

Page 85: ...erator properly when shifting gear to avoid sharp speed increase z It is best to change the running direction from forward to backward or from backward to forward after stopping the machine to get the best driver comfort and prolonging the life of the engine z No need to stop and brake the machine to shift gears while running Release the accelerator and operate the transmission lever at the same t...

Page 86: ...ps to Stop z Release the accelerator and press the brake pedal to stop the machine Put the gear control lever in the neutral position z After safely stopping push the parking brake switch to lock the machine in place z Level the bucket and other equipment to the ground z Stop the machine on the level ground where there is no danger of stone falling coasting or flooding If it is necessary to stop t...

Page 87: ...l is too high or diluted find the reasons and solve them z Check the oil pipes water pipe gas pipe and other parts for leaking conditions z Check the gearbox torque converter steering unit fixing of front and rear frame and sealing conditions And check whether there are overheating conditions z Check whether the rim bolts transmission axis bolts and other pins are loose z Add antifreeze if the tem...

Page 88: ...Operation Maintenance Manual LG936L Wheel Loader 78 ...

Page 89: ...the truck transports and unloads the material There are generally two loading and unloading ways Cross Load The loader faces the material then it moves backward after digging a full load and lets the auto unload truck move into the position between material and the loader This method costs the minimum time and can reduce the cycle time most effectively V Shape Load The auto unload truck is fixed a...

Page 90: ...en loading the blasted rock Notice Do not let the blasted rock go under the bucket which will make the front tires leave from the ground and slip Try to hold the load in the center of the bucket otherwise if the load is on one side of the bucket it will be unbalanced z Raise the lift arm to prevent the bucket from inserting too deeply while thrusting the bucket into the material The tires will bri...

Page 91: ... control lever backward and forward slightly to reduce the resistance NOTICE Keep the two sides of the bucket cutting into the material equally to prevent only a single side working Face the loader forward and never let an angle exist between the front and rear frame 3 Conveying Operation Without Truck The loader must be used without a truck under the following conditions z The ground is too soft ...

Page 92: ... backward to shake down the material z After dumping use the bucket to level equipment if assembled Rear tilt bucket to level position and operate the working equipment control handle to allow the lift arm to lower to prepare for next operation 5 Pushing Operation Level the bucket to the ground and push the accelerator to move forward If there is blockage during moving raise the lift arm a little ...

Page 93: ... towing z If there is no braking system for the towed machine never use soft towing 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 whether the towing rope and towing pin are strong enough to suffer the weight of the towed machine If machine will pa...

Page 94: ...Selection Table of Fuel Coolant and Lubricant for the details of using oil z Attentions for using antifreeze 1 Do not 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 Replace antifreeze with the proper ratio according to the requirements Please refer t...

Page 95: ...water please open the water drain valves located at the bottom of the water tank and the engine Then drain all the coolant water in the evaporators of the cooling system and the air condition system if assembled to prevent cold cracks If antifreeze is added please follow the rules on the nameplate of the antifreeze After cold weather After the weather is warm the relative parts should use the prop...

Page 96: ... is lower than the L line oil should be added by the oil adding port It is a suitable oil level if it is between the L and the H line Dongfeng Cummins 6BT5 9 engine If the oil level is lower than the adding oil graduation line oil should be added by the oil adding port If it is higher than the oil full graduation line FULL check the problem and solve it It is a suitable oil level if it is between ...

Page 97: ...L from oil inlet of engine Run the engine at idle status check whether the oil filter and oil releasing plug are leaky z After the engine was stopped for 15 minutes let the engine oil flow back to the oil pan and check the engine oil level of the engine again Engine oil Filter Replac ement z Clean the area near the engine oil filter Disassemble it with filter elements spanner Assemble z Add diesel...

Page 98: ...re z Start engine and let the engine run in the idle status for minutes Open the checking plug on the right of the gear box If some oil flow out without pressure the oil is of proper volume If the oil level is lower than the plug hydraulic transmission oil should be added The choice of the hydraulic transmission oil can be found in CHAPTER IV 2 2 Selection of Oil Fuel and Coolant New Oil Replac em...

Page 99: ...ich 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 and hold in the idle status for 3 5 minutes Release the oil in the oil pan and add new oil 3 6 4 Adding Oil to Axle Oil Level Check z Park the machine on level ground and put the transmission lever...

Page 100: ...Move the machine slowly with gentle acceleration to let the oil drain plug on the front axle move into the horizontal position and then shut the engine Put the transmission lever in the neutral position Pull the parking brake lever z Add new gear oil from the oil drain port on the two wheels on the end sides of the front axle and the oil inlet port at the middle of the axle shell And then check th...

Page 101: ...ngine and keep in the idle status for 10 minutes Raise and lower the lift arm several times and tilt the bucket forward and backward several times z Raise the lift arm to the highest position tilt the bucket backwards to the extreme position and shut the engine z Push the bucket control lever forward to let the bucket tilt forward freely by its weight Drain out the oil in the bucket cylinder After...

Page 102: ...nd run the engine in the idle status for 5 minutes to release the air in the system z Shut the engine Check the oil level Add oil when it is not enough 3 7 Long Time Storage 3 7 1 Before Storage When putting the machine in storage for a long time be sure to do as follows z After every part is washed and dried house the machine in a dry building Never leave it outdoors If the machine must be outdoo...

Page 103: ...onth so that lubricant can be coated over the surface of the movable parts and other components surfaces The battery in storage can be charged at the same time Wipe off the grease which has coated the hydraulic cylinder rods before work and operation 3 7 3 After Storage Do as follows after long term storage of machine z Wipe off the grease coated on the hydraulic cylinder rods z Add oil and grease...

Page 104: ...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 the tension of fan belt 4 Abnormal noise from alternator Faulty alternator Replace 5 Do not start when starting switch is turned on 1 Faulty cable 2 Insufficient battery charge 1 Check and repair 2 Cha...

Page 105: ... 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 with high load for a continuous long time 6 Radiator is not good 1 Add oil to the specified level 2 Drain oil to the specified level 3 Refer the problems 1 and 2 4 Clean or replace the radiator 5 Shut dow...

Page 106: ...he 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 Loose pipe fitting or broken pipes 3 Poor sealing performance of check valve in combination valve of oil water separator 1 Brake continuously several times to blow the dirt off or change valve 2 Tighten t...

Page 107: ... 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 spool and valve block 3 Low set pressure value of safety valves 4 Overload valve and oil complementary valve is blocked by dirt 1 Change the oil seals 2 Change multi passage valve 3 Change the system press...

Page 108: ...l 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 deformed centre pin and drive shaft 3 Faulty dual overload valve 4 Scuffed rotor and stator scuffed valve spool valve body and sleeve 5 Faulty in steering pump or piloted valve 1 Change the damaged ...

Page 109: ...efore maintenance to prevent someone starting the engine 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 ambient temperature 1 5 Using the Prescriptive Oil and Fuel z Keep containers of oil and fuel clean and use clean oil and fuel 1 6 Keep the Machin...

Page 110: ... remove the battery cables z Keep the distance between the grounding cable line and welding area more than 1m z Avoid welding 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 inflammable cleaner or light oil Keep spark or cigarette light away from them 1 13 Sealing Part z When replacing O ring or gaskets cle...

Page 111: ... and Maintenance Manual of diesel engine for replacing and maintaining air filter 1 18 Avoid Using Mixed Oil z Never 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 Detailed Rules of Using Oil Fuel and Coolant WARNING z Because of bad operating conditi...

Page 112: ...tely z Add coolant to specified level If the level is too low it will cause the overheating of the engine system and the corrosion of the cooling system z Add antifreeze to coolant if ambient temperature is lower than 0 Drain the coolant out after working please refer to CHAPTER III 3 5 3 Operation in Cold Weather and refill oil before next working if there is no antifreeze in the coolant z Antifr...

Page 113: ...onsult the maintenance people z Never open the packs of new filters until they are used z Always use authorized filter parts 2 2 Selection of Fuel Coolant and Lubricant 2 2 1 Selection Table of Fuel Coolant and Lubricant Please choose Shandong Lingong s preferred special oils and choose specified oils from the following table Kinds of Fluids Recommended Types And Standards Capacity Using places Am...

Page 114: ... CALTEX ESSO Diesel Machine Oil Excelled CD and CD 15W 40 GB11122 HEIBAWANG1300 SAE15W 40 15 50 RotellaSX 40 Rotella TX 40 20w 40 Rotella DX 40 Essolube XT 3 Essolube XT 2 Diesel Machine Oil Excelled CD and CD 5W 30 GB11122 HEIBAWANG1300 SAE10W 30 20 40 Delvac super 1 over 40 Rotella SX30 10w 30 Rotella TX30 Rotella DX30 Caltex Delo Gold Multigrade 15W 40 Essolube XT 5 z Hydraulic oil Similar Oil ...

Page 115: ...uban GL5 EP 90 Titan Gear LS90 Mobil Gear oil HD80W 90 20 40 Automobile Gear oil HD85W 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 performance brake fluid DOT3 Brake fluid Brake fluid Disc brake fluid Donax B z Grease Similar Oil Brands Chinese...

Page 116: ...m Check the tension and distress of the fan belt Check the fluid 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 company z Be sure to keep the electric system dry when washing the machine or working in rain and snow z Avoid the electric system corrodi...

Page 117: ...M16 1 5 55 40Cr 280 330 6 Connect bolts between main driving bearing chock and bracket M22 90 40Cr 450 550 7 Lock bolts of main driving input flange M33 1 5 8 320 400 8 Connect bolts between plane frame assembly and rim M18 1 5 10 264 354 9 Connection between the bracket of main driving and axle shell M12 1 25 35 10 9 110 130 10 Rim nuts M18 1 5 35 265 355 11 Connect bolts between brake clip assem...

Page 118: ...k and brake booster pump z Tighten all connection bolts of transmission axles z Check whether all connection bolts of hubs and the brake caliper are loosen z Check all connection 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 first 50 hours as follows z Check and clean the air vent o...

Page 119: ...f every 10 50 and 250 hours with this maintenance operation at the same time z Check and adjust the clearance of hand brake system z Check the wear condition of brake discs and friction discs Replace them if necessary z Clean the silencer of the braking electromagnetic valve In addition do the extra maintenance in the first 500 hours as follows z Check if there is leakage in the hydraulic system C...

Page 120: ...ame time z Check performance of the torque converter and gearbox differentials of front and rear axles and the wheel side reducers Disassemble them for checking if necessary z Check the sealing performance of multi passage valve and hydraulic tank by measuring the natural sedimentation volume of the cylinders fuel oil and then check the system pressure If the natural sedimentation volume is over t...

Page 121: ... the mechanical manual control hydraulic system is composed of a work pump multi way valve lift arm cylinder bucket cylinder steering pump load sensing hydraulic redirector priority valve steering cylinder hydraulic pressure oil tank and pipe attachments DF25 multi way valve includes bucket unit and lift arm unit The bucket unit includes dumping neutral and receiving bucket in three positions The ...

Page 122: ... including floating lowering neutral and lifting to utilize the work control of loader working device The third hydraulic function can be reserves The set pressure of the safety valve is 16MPa 16 5MPa The overload pressure of the rocker cylinder s large cavity is 18MPa 18 5MPa while that of the small cavity is 12MPa 1 Life Arm Cylinder 2 Multi way Valve 3 Steering cylinder 4 Redirector 5 Priority ...

Page 123: ...gram 1 Work and Pilot Pump 2 Oil Tank 3 Pressure Select Valve 4 Hydraulic Oil Radiator 5 Steering and speed changing pump 6 Oil returning filter 7 Priority valve 8 Redirector 9 Steering Cylinder 10 Pilot Filter 11 Pilot Valve 12 Multi way Valve 13 Lift arm Cylinder 14 Bucket Cylinder Figure 5 4 Three Units Valve Pilot Control Hydraulic System Diagram 3 Brake System Brake system is used when the ma...

Page 124: ...5 LG36L Single Brake Pedal Braking Diagram 1 Air Booster Pump 2 Shuttle Valve 3 Air Brake Valve 4 Air Tank 5 Combination Valve of Oil Water Separator 6 Air Compressor 7 Brake Magnetic Valve 8 Parking Brake Air Chamber Figure 5 6 LG936L Double Brake Pedal Braking Diagram 3 1 Driving Brake System Single Brake Pedal As shown in Figure 5 5 this system is the single line air pushing oil four wheels cal...

Page 125: ...e is outputted at the same time to cut off the power of gear box When the right brake pedal is stepped on during driving the brake principle is the same as left brake pedal but the power of transmission box is not cut off Release the brake pedal and the compressed air of the booster pump drains from the brake valve to the atmosphere and the brake is released 3 3 Parking Brake System This system em...

Page 126: ...ing motor charge generator appliance switch lamps and other electric instruments The system of this machine employs D C 24V voltage negative electrode and single wire lines The relation of each electric instrument and their working theories refer to the diagram sketch of the electric system as is shown in figure 5 7 5 8 5 9 5 10 ...

Page 127: ...Operation Maintenance Manual LG936L Wheel Loader 0 117 Figure 5 7 Electric System Principle Diagram Mechanical Operation ...

Page 128: ...Operation Maintenance Manual LG936L Wheel Loader 0 118 Figure 5 8 LG936L Electric System Principle Diagram Pilot Operation Domestic Type ...

Page 129: ...Operation Maintenance Manual LG936L Wheel Loader 0 119 Figure 5 9 LG936L Electric System Principle Diagram with DEUTZ Engine TD226B Export Type ...

Page 130: ...Operation Maintenance Manual LG936L Wheel Loader 0 120 Figure 5 10 Electric System Principle Diagram with Cummins Engine Export Type ...

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