Volvo SDLG LG956L Operation & Maintenance Manual Download

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Operation & Maintenance Manual

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LG956L Wheel Loader

9 SAFETY TRANSPORTATION ....................................................................................................................... 47

9.1 Assemble and Disassemble the Machine............................................................................................... 47
9.2 Transportation on the Ground ............................................................................................................... 48
9.3 Lifting.................................................................................................................................................... 48

CHAPTER II INTRODUCTION................................................................................................................................ 50

1 GENERAL VIEW OF THE MACHINE & COMPONENTS’ NAME............................................................ 50

2 GEOMETRICAL DIMENSIONS.................................................................................................................... 51

3 PRODUCT TYPE AND ITS MEANING ........................................................................................................ 53

4 NAMEPLATE.................................................................................................................................................. 53

5 USE CONDITIONS......................................................................................................................................... 56

6 CIRCUMSTANCES REQUIREMENT ........................................................................................................... 56

7 FEATURES...................................................................................................................................................... 56

8 TECHNICAL PERFORMANCE & PARAMETER ........................................................................................ 58

8.1 Performance of Whole Machine............................................................................................................ 58
8.2 Principle Dimension and Weight........................................................................................................... 58
8.3 Performance of Whole Machine (with Bucket of 3.0m

and Standard Lift Arm) ................................. 59

8.4 Principle Dimension and Weight (with Bucket of 3.0m

and Standard Lift Arm) ................................ 60

8.5 Product Standard and License ............................................................................................................... 60

CHAPTER III OPERATION AND APPLICATION................................................................................................... 61

1 BE FAMILIAR WITH MACHINE.................................................................................................................. 61

1.1 Control Systems and Gauges................................................................................................................. 61
1.2 Introduction of Gauges & Controls....................................................................................................... 63

2 RUN-IN PERIOD OF NEW MACHINE......................................................................................................... 77

3 OPERATION AND USE OF LOADER .......................................................................................................... 78

CHAPTER

Ⅳ

MAINTENANCE ........................................................................................................................... 104

1 MAINTENANCE GUIDE ............................................................................................................................. 104

Summary of Contents for SDLG LG956L

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 LG956L WHEEL LOADER SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD ...

Page 2: ...al 880 1230 mm 16 8 pieces 1st Edition in 2009 12 1st Print SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone Shandong 276023 Tel 86 0539 8785688 Fax 86 0539 8785698 Website www sdlg cn Services Tel 8008607999 4006587999 0539 8785800 Services Fax 86 0539 8785671 ...

Page 3: ... 25 5 2 Safety of self and others 25 5 3 Full Load Transportation 26 5 4 Drive at Proper Speeds 27 5 5 Ensure Good Visibility 27 5 6 Pay Attention to Blockages 28 5 7 Driving in Dangerous Conditions 28 5 8 Driving safely on the Ramp 29 5 9 Towing 30 6 SAFETY OPERATION 31 6 1 Keep Good Operation Habits 31 6 2 Pay Attention to Surroundings 33 6 3 Ensure Ventilation in Close Environment 34 6 4 Don t ...

Page 4: ...1 Performance of Whole Machine 58 8 2 Principle Dimension and Weight 58 8 3 Performance of Whole Machine with Bucket of 3 0m3 and Standard Lift Arm 59 8 4 Principle Dimension and Weight with Bucket of 3 0m3 and Standard Lift Arm 60 8 5 Product Standard and License 60 CHAPTER III OPERATION AND APPLICATION 61 1 BE FAMILIAR WITH MACHINE 61 1 1 Control Systems and Gauges 61 1 2 Introduction of Gauges ...

Page 5: ...ing Torque of Screw 112 3 CONTENT OF MAINTENANCE 112 3 1 Every 10 Hours Days Service 112 3 2 Every 50 Hours Week Service 113 3 3 Every 250 Hours Month Service 113 3 4 Every 500 Hours Season Service 114 3 5 Every 1000 Hours Half a Year Service 114 3 6 Every 2000 Hours Year Service 115 3 7 Alteration 115 3 8 Replace The Air Storage Tank After 3 Years of Service 115 CHAPTER V SYSTEM PRICIPLE DIAGRAM ...

Page 6: ...ngine 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 t...

Page 7: ... 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 8: ...cified 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 ...

Page 9: ... 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 10: ...fting 5 Notice for operation 6 Notice for driving Located on the lifting position of front and rear frames Located on the right front glass inside the operator cab Located on the left front glass inside the operator cab maintains Sitting allowed only in cab s loading while in operation Lock the lift arm cylinder before entering dangerous areas Located on both sides of lift arms Located on both sid...

Page 11: ...for cutting off power 11 Warning for cutting off power 12 Antifreeze fluid Located on the steering position of front and rear frames Located on the left side of operator cab door and inlet port of water tank of engine hood Located on outside of operator cab door Located on the right operation box Located on the right operation box Located on the right operation box ...

Page 12: ...Fuel oil tank 17 Notice of hot water 18 Warning of machine reversing Pay attention to the steam or hot water ejection Located on vent pipe of engine hood Located on the cover of engine water tank Located on the hydraulic oil tank Located on the fuel oil tank Located on right and left platform frames Located on both sides of engine hood ...

Page 13: ...Operation Maintenance Manual LG956L Wheel Loader 8 19 Personal safety range 20 No fire warning Located on both sides of engine hood Located on battery box ...

Page 14: ...Operation Maintenance Manual LG956L Wheel Loader 9 Figure 1 2 Figure of safety label position Export Type ...

Page 15: ...person 3 Antifreeze fluid 4 Antifreeze fluid If coolant 35 has been added If coolant 45 has been added Located on both sides of lift arm Located on both sides of lift arm Located on the left operator cab door and engine hood Located on the left operator cab door and engine hood Located on the left operator cab door and engine hood ...

Page 16: ...g 8 Check before starting 9 No passenger warning Located on the right front upright column inside the operator cab Located on left operator cab door Located on the right front upright column inside operator cab Located on the right back upright column inside the operator cab Located on the right back upright column inside the operator cab ...

Page 17: ...ring seat belt warning 12 Warning of high voltage 13 No fire warning Located on the right back upright column inside the operator cab Located on the right back upright column inside the operator cab Located on the right back upright column inside the operator cab Located on battery box ...

Page 18: ...e 15 Warning of machine reversing 16 Notice of hot water 17 Fuel tank 18 Warning of high temperature Located on both sides of engine hood Located on cover of water tank of engine hood Located on both sides of engine hood Located on fuel tank Located on vent pipe of engine hood ...

Page 19: ...ct switch of cutting power if assemble 23 Warning for cutting off power 24 Parking brake Located on the lifting position of the front and rear frames Located on the hydraulic oil tank Located on right and left platform frames Located on the right operation box Located on the right operation box Located on the right operation box ...

Page 20: ...ration Maintenance Manual LG956L Wheel Loader 15 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 button ...

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: ...ng 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 sh...

Page 23: ...afety 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 brake valve manual control lever or the parking brake switch in the lock posi...

Page 24: ...r 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 hydraulic system hydraulic pressure shafting oil and gear oil for transmission system brake fluid and antifreeze fluid f...

Page 25: ...age 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 knowledgeable about its use and function Check and maintain it as referenced in users manual z Never operate machine near ...

Page 26: ...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 under the machine Do not use the hydraulic tan...

Page 27: ...d 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 traffic Erect the barricades and use the sign of DON T ENTER to ensure safety of passing traffic and pedes...

Page 28: ...n 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 with a new one if the mirror has been damaged z Don t leave any tool or part around the operator s seat They may fall because of the vibration during moving and working which could break the control leve...

Page 29: ...gine 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 engine runs with an abnormal sound or shaking If so there may be some malfunctions report to the manager immediately Operate the machine after the malfunctions are eliminated z Test the control of the engine ...

Page 30: ...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 outside the machine z When driving on the level ground adjust the lower hinge of the arm working equipment to 400 500mm 16 20in above the ground z Always warn people near the machine in all direction by sounding the horn z Th...

Page 31: ...ould hurt people z It is dangerous to shift from forward to backward gear at high speed Never do this 5 3 Full Load Transportation z Do not keep a full bucket in the high position when moving Select the proper speed with a full load during transport Lower the bucket to contact the tilt block and run with proper height 400 500mm above the ground so that the center of gravity can be lowered to insur...

Page 32: ...g the steering wheel Loader may turn over if operated in the wrong way z Let the engine run smoothly never drive at high speed 5 5 Ensure Good Visibility z Slow the speed and sound the horn if necessary to let others know and determine the proper direction when the visibility is bad or at a narrow crossing z Sand dust fog or storm may affect the visibility Slow down when visibility is poor When vi...

Page 33: ...Slow down after passing through water or during rain Step on the brake pedal gently and alternately to let the skid device dry after working in water or in rain z The clay piled on the ground or near the canal is usually soft Never allow a turn over caused by the weight or vibration of the loader z Never drive the machine near hanging things or close to a deep ravine The machine weight or vibratio...

Page 34: ... ramp rather than drive through alleyway or footpath z Choose proper gears before going down the slope and never change the speed during going down the slopes z Do not suddenly brake on the ramp because the center of gravity is on the front tire or rear tire z Use gear I when driving on the ramp with a full load Go forward when driving up the ramp go backward when driving down the ramp Never turn ...

Page 35: ...g Construction Machinery Co Ltd or their accredited representative if the engine does not start or the brake system has problems z Please tow the machine on level ground it is dangerous to tow on a ramp z If a disabled machine is towed by an other machine the tightwire should be strong enough to pull the weight of the towed machine The tightwire with wring or radius reduction can not be used z Peo...

Page 36: ...ion 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 machine may be unbalanced z Confir...

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: ...ondition 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 Electroshock may result in eve...

Page 40: ...e 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 on a ramp is necessary the ra...

Page 41: ...event 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 enter the working area exc...

Page 42: ...lace 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 before exa...

Page 43: ...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 handrails and p...

Page 44: ...ess 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 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 ...

Page 45: ... is allowed to weld without a license Escaped gas and damaged electric wires are potential problems during welding Obey the following z Switch off the electricity in the terminals for storage to prevent explosion z Clean the paint at the welding site to prevent the production of harmful gas z Avoid welding on the hydraulic equipment or pipe or places nearby Flammable steam and sparks may be genera...

Page 46: ...ool 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 prevent burn z While the machine is warming up do not disassemble the water heat sensor of the engine oil heat sensor of the torque converter or the water pipe ...

Page 47: ...rd 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 and when cleaning the parts Please refer to 8 20 Waste Materials in this chapter for the methods to deal with waste liquid 8 13 Preventing Fire z Stop the engine before adding fuel Do no...

Page 48: ...id before welding and flame cutting z Check the fire extinguisher before starting repair work Know the location of fire extinguishers and first aid bag and know how to use them z Never use fire match or lighter to check dark areas 8 14 Air Storage Tank z Open the drain valve of the air storage tank to drain every day This is especially important in cold weather Make sure the drain valve is closed ...

Page 49: ...ase charge before use z Pay attention to the labels on equipment before installation to prevent accidents z Spread vaseline on the poles to prevent erosion The wire connections should be firm and credible Never hammer the wire pole which may cause the leak of vitriol z Connect the positive pole of the storage battery with the negative pole of the machine first and then connect the negative pole of...

Page 50: ...se or charging to prevent early invalidation due to water loss grid increasing and diachylon dropping 8 18 Starting to Use Voltage Raising Method The wrong connection of voltage raising cable may lead to fire so please do as follows z Two operators are needed to start voltage raising start one sits on the operator seat z Two machines are not allowed to touch when one is starting z Turn off all the...

Page 51: ... or the rear of the rolling direction of the tire Check the tire from the side If disassembling one tire lock the other tires z Take care when welding near a tire which can cause explosion of the tire z Only a trained person with a professional license can repair a tire and rim using specific tools and following the proper steps z Use the uniform tire with the same standard and same flower pattern...

Page 52: ...e machine So keep the engine speed low during loading and unloading the machine z Load and unload machine on level ground and remain at a safe distance off the road z Secure the tires well during loading and unloading the machine to make sure it will not move Put a cushion under the gangway z Slope boards should be strong enough with sufficient length and width to form a safe slope The angle with ...

Page 53: ... train Select proper lifting equipment according to the weight of the loader otherwise it is dangerous to surpass the weight limit z Notices for lifting Make sure the loader is in the transporting state The front and rear frame should be in the middle position Lock the machine using the lock bar to prevent rotation of the front and rear frame during lifting All the control levers or handles should...

Page 54: ...Maintenance Manual LG956L Wheel Loader 49 z Connect the turning equipment using the lock bar after lifting onto the ship train wedge the tire and bind the machine tightly to prevent movement during transportation ...

Page 55: ...Operation Maintenance Manual LG956L Wheel Loader 50 CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME Figure 2 1 General view and components name of LG956L wheel loader ...

Page 56: ...Operation Maintenance Manual LG956L Wheel Loader 51 2 GEOMETRICAL DIMENSIONS Figure 2 2 Geometrical dimensions of LG956L wheel loader mounted with standard lift arms with the bucket of 2 7m3 ...

Page 57: ...Operation Maintenance Manual LG956L Wheel Loader 52 Figure 2 3 Geometrical dimensions of LG956L wheel loader mounted with standard lift arms with the bucket of 3 0m3 ...

Page 58: ...te 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 2 5 2 6 2 7 and 2 8 The other configurations of nameplate refer to CHAPTER II 8 TECHNICAL PERFORMANCE PARAMETERS Figure 2 4 Nameplate of LG956L loader mounted with Weichai engine and standard lift arm with bucket of 2 7m3 ...

Page 59: ...6L Wheel Loader 54 Figure 2 5 Nameplate of LG956L loader mounted with Weichai engine and long lift arm with bucket of 2 7m3 Figure 2 6 Nameplate of LG956L loader mounted with Weichai engine and super long lift arm with bucket of 2 7m3 ...

Page 60: ...el Loader 55 Figure 2 7 Nameplate of LG956L loader mounted with Weichai engine and standard lift arm with bucket of 3 0m3 Figure 2 8 Nameplate of LG956L standard lift arm loader mounted with Shangchai and Cummins engine with bucket of 3 0m3 ...

Page 61: ...ing 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 machine as follows 1 Altitude 3000m 2 Temperature 15 40 3 Water depth 500mm The loader is a general construction machine and can be used under the conditions listed in this manual Please follow the rules and utilize relative specific purpose eq...

Page 62: ...voltage small flow and low voltage big flow so the power of hydraulic system increases obviously and the oil consumption and noise reduces to improve the tracing property of whole machine further The other is full hydraulic load sensing steering hydraulic system and single pump large flow working device hydraulic system turn stably and lift quickly to improve the productivity z The optimized and i...

Page 63: ...Shangchai and Cummins engine 0 38 km h 0 38 km h 0 38 km h Reverse gear 0 16 1 km h 0 16 1 km h 0 16 1 km h Max breakout force 180 kN 161 kN 172 kN Max traction force supplied by engine 160 kN 160 kN 160 kN Tipping load 110 kN 98 Kn 94 kN Max climbing angle 30 30 30 Min turning radius outside of rear wheel 6036 mm 6036 mm 6036 mm Level passing radius outside of bucket 6746 mm 6936 mm 6983 mm Max t...

Page 64: ...ifting time full load 6 4 s 6 4 s 6 4 s Lowering time empty bucket 3 6 s 3 6 s 3 6 s Dumping time empty bucket 1 3 s 1 3 s 1 3 s Travel speed Forward 1st 0 12 3 km h 0 13 5km h 0 13 5km h 2nd 0 40 5 km h 0 38km h 0 38km h Reverse gear 0 16 1 km h 0 16 1 km h 0 16 1 km h Max breakout force 180 kN 180 kN 180 kN Max traction force supplied by engine 160 kN 150 kN 150 kN Tipping load 110 kN 110 Kn 110...

Page 65: ...cket width 3024 mm 3024 mm 3024 mm Height 3382 mm 3382 mm 3382 mm Wheel track 2190 mm 2190 mm 2190 mm Wheel base 3200 mm 3200 mm 3200 mm Min ground clearance 457 mm 457 mm 457 mm Max dumping height 45 dumping angle 3120 mm 3120 mm 3120 mm Dumping space 45 dumping angle 1130 mm 1130 mm 1130 mm Dumping angle 45 45 45 Operating weight 16900kg 16900kg 16900kg 8 5 Product Standard and License Product S...

Page 66: ...meout Control Flexible Shaft 10 Equipment Control Lever 11 Speed Change Control Lever 12 Starting Switch 13 Horn Button Figure 3 1 General view of control System pilot single handle and select switch for cutting off power 1 Steering Wheel 2 Gauge Panel 3 Speed Change Control Lever 4 Brake Pedal on both sides 5 Accelerator Pedal 6 Seat 7 Parking Brake Switch 8 Equipment Control Lever 9 Switch Group...

Page 67: ...ing Lamp 13 Left Turn Indicator Lamp Figure 3 3 General view of gauges 1 Gearbox Pressure Gauge 2 Brake 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 Rai...

Page 68: ...mperature 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 machine its value can be used as a reference for inspection a...

Page 69: ... 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 if assembled This gauge indicates the ratio of remaining fuel level in the fuel tank to the volume of tank z Revolution Indicator if assembled This gauge indicates the rotating speed of engine z Indicator Lamp The in...

Page 70: ...ncy steering function is selected to install When the wheel loader is steered emergently the lamp will come on if the emergency steering pump works Parking Brake Indicator Lamp If the brake air pressure is normal the lamp will come on when the brake valve manual control handle is pulled up or the parking brake switch is pushed down The lamp will go off when the brake valve manual control handle is...

Page 71: ... engine has started immediately pull out the key or it will return to ON position automatically z Radio and CD Player Control Panel if assembled 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 If the radio is not assembled the connecting line of radio is reserved please assemble it according to the electric prin...

Page 72: ...ightened when operate the switch After the operation of turning finished please put back the switch by your hand z Rocker switch The rocker switch includes gauge panel rocker switch and rocker switch at the right side of seat The gauge panel rocker switch can be referred to 1 1 Control System and the Gauge Figure 3 4 in this chapter When the start switch is at ON position the water sprayer rain wi...

Page 73: ...witch if assembled Press bottom side the back light head light and tail light will come on together Press top side no lamp will come on z Warning Lamp Switch if assembled Press bottom side all the turning lamps will blink for an emergency circumstance sending light to warn the other vehicles and passersby Press top side all the turning lamps will stop blinking z Warning Button Switch if assembled ...

Page 74: ...urns left The features are listed below z The rotation angles of the steering wheel and the machine are not equal If the steering wheel is continuously turned the machine rotation angle will increase until at the needed position z The faster the steering wheel turns the faster the machine turns z The steering wheel will not automatically come back after turning the turning angle of the machine wil...

Page 75: ...for drawing in the bucket Neutral is used for keeping the bucket in the desired position Forward Tilt is used for dumping Lifting limit location function When place the control handle in the lifting position the electromagnetic force from lifting limit location locked magnet coil of pilot valve can lock the control level in the lifting position When the lift arm lifts to the highest position the l...

Page 76: ...if assembled The handle is located on the right operator box at the right side of the seat Step on the brake pedal to carry out the driving brake When the switch valve handle locates in the power cutting off position the power outputted by transmission box is cut off while braking when the switch valve handle locates in the power connecting position the power outputted by transmission box is not c...

Page 77: ...cally after 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 fra...

Page 78: ...nel The panel of air conditioning is at the right side of cab s seat 1 2 9 1 Ⅰcontrol panel and is operation if assembled z Operating methods a Refrigeration Start the engine Open the air volume and power switch 2 which have three gears fan low gear fan middle gear and fan high gear and four positions O L M and H The speed of evaporating fan increases from left to right to adjust the air volume Op...

Page 79: ...e air volume and power switch 2 to choose the position of gear and adjust to the desired air volume 1 2 9 2 Ⅱcontrol panel and is operation if assembled z The Appearance of Panel z Operating methods a Refrigeration First time use turn the air volume and power switch to high gear after the engine started turn the temperature control switch to refrigeration Turn the air volume to obtain low middle a...

Page 80: ...ater but not using hot water or steam Run the compressor once a week when the refrigeration isn t used in winner for 1min to maintain the air conditioning in normal state 1 2 10 Adjustment of Cab s Seat WARNING z When adjusting the cab s seat park the machine in a safe place and stop the engine z Adjust the cab s seat before starting operation or replacing the operator z Make sure that you can dep...

Page 81: ... tie it when operating the machine Before using safety belt please check the degree of wear and firm Replace it if it is necessary Adjust the length of safety belt before using to make sure the safety belt can be used for safety guarantee and comfort Move the position of lock on the safety belt to adjust the length of safety belt The clamper of the safety belt is at the right side of seat and put ...

Page 82: ...ion to the lubricating condition routinely add and change the lubricant according to rules z Pay attention to the temperatures of the gearbox torque converter front and rear frame rim and brake drum Once they are overheating find the reason and repair it z Check the fastening conditions of the bolts and nuts Do the following maintenance after 10 hours of run in time on the new loader z Check the f...

Page 83: ...e or step on the brake pedal in changing the forward levers during driving When changing the speed from low to high release the accelerator a little and operate the Gear Control Lever at the same time and step on the accelerator when changing the speed from high to low release the accelerator first and then change the transmission slowly 7 After the lift arm and bucket are moving to the required p...

Page 84: ...l in the oil bowl of the brake booster pump 6 Check the seal ability of the oil pipe water pipe air pipe and other parts 7 Check the seal ability of the hydraulic pipes and the surrounding pipes 8 Check the wire connection of the storage battery 9 Check the pressure of the tire to see whether it is normal Please refer to CHAPTER II 8 1 Performance 10 Check the control levers or handles to see whet...

Page 85: ...if engine oil pressure gauge is not in the normal position in more than 10 seconds After that start again otherwise there may be some problem z When the engine oil pressure does not reach the designated value the high running speed of the engine will induce a high temperature and the turbo charger may be broken z Use the working equipment control levers to let the preheated hydraulic oil circle in...

Page 86: ... on a slope or uneven ground z Select the proper transmission gears when go down a slope and never change the gears during that time z Never run over speed while driving on a slope and use the foot brake pedal to slow the speed 3 3 2 Gearshift Changing between Forward and Backward z Press the accelerator properly when shifting gear to avoid sharp speed increase z It is best to change the running d...

Page 87: ...try to stop the engine and put speed change control level in the neutral position while driving down sloping ground z Never using left brake pedal if assemble the double brake pedals when driving on a slope to prevent power from cutting off WARNING Never use the brake valve manual control handle or parking brake switch to brake or slow the speed of the machine while running unless in an emergency ...

Page 88: ...eck whether there are particle likes materials on the engine If so clean them immediately to prevent fire z Clean all the flammable materials around the machine to prevent fire z Lock the door and window and draw the key 3 4 4 Do the Followings after Work Everyday z Check the fuel reserves z Check the oil level of the engine oil pan and its cleanness If the oil level is too high or diluted find th...

Page 89: ... There are generally two loading and unloading ways z 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 z V Shape Load The auto unload truck is fixed and forms almost a 60 angle with the backw...

Page 90: ...the bucket from inserting too deeply while thrusting the bucket into the material The tires will bring ample traction by raising the lift arm z If enough material is loaded into the bucket operate the working equipment control lever to take back the bucket in order to load it fully Remark If the shovel edge moves up and down when thrusting material into the bucket or when digging the front tires w...

Page 91: ...transportation distance is within 500 meters it is not economical to use a truck z The transportation driving speed is determined by the road condition z In order to get good visibility and stability the bucket should be turned to its upper limit location bucket lift arm touch the upper limited block and keep the lower pin connection point of lift arm at the transportation position 400 500mm above...

Page 92: ...rd ground put the lift arm control lever in the float position for soft ground put the lift arm control lever in the neutral position Use reverse gear to strike the ground with blade 7 Towing Operation WARNING Before towing the tires must be blocked by the parking brake to prevent the machine from rolling During towing be careful to prevent severe and fatal injury z If possible the engine of the t...

Page 93: ...going up and down a slope z When towing the machine down a slope the machine should have sufficient traction power and braking power Another towing machine should be used to pull at the back side to prevent the towed machine from losing control or turning over z Start to tow and brake gently at the low speed and turn on the warning flash lamp z The speed for towing the loader should be within 10 k...

Page 94: ...der to prevent the materials from freezing on the machine which may affect it working the next day please do as follows 1 Completely clean the silt and water on the machine to prevent silt water or snow entering the sealed parts which may freeze or break the sealed parts 2 Park the machine on the dry and hard ground If that is impossible park the machine on a wooden board which can prevent the tir...

Page 95: ... front and back of tires z Open the side door on the right side of the engine cover z Pull the dipstick out and wipe it clean with a cloth Insert the dipstick back and pull it out again to check the oil level at least twice Weichai WD10G220E13 engine The oil level is normal if the oil level is between H and L limit If the level is lower than the L limit oil should be added by the oil adding port S...

Page 96: ...the dipstick If the level is lower than the ADD limit oil should be added by the oil adding port z Put back the oil dipstick and close the profile door of the engine For choosing the appropriate oil please refer to CHAPTER IV 2 2 Oil Selection Engine Oil Replacement z Park the machine on level ground and put the transmission lever in neutral N position Pull the brake valve manual control handle or...

Page 97: ... open the left door of the engine hood z 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 Replacement Disassemble z Clean the area near the engine oil filter Disassemble it with filter elements span...

Page 98: ... of the tire z Start engine and let the engine run in the idle status for several minutes Open the oil checking plug at the side of the transmission box the oil level is normal if there is oil flowing but not form pressure if there is not oil flowing 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 Cool...

Page 99: ...ch 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: ...lly to prevent injury z Drain out all the old oil and screw tight the oil drain plugs at the center bottom of the axle shell z Start engine Press the brake valve manual control handle or rotate the parking brake switch until it rebounds to release the brake Move the machine slowly with gentle acceleration to let the oil draining port at the end of wheel side move into the horizontal position and t...

Page 101: ...E 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 level ground and put the transmission lever in the neutral position Pull the brake valve manual control handle or press the braking control lever to carry out braking Start the engine and keep in the idle status for 10 minutes Rais...

Page 102: ...art engine and raise and lower lift arm Tilt the bucket forward and backward the bucket to the extreme position 2 3 times to let the hydraulic oil fill the cylinders and pipes sufficiently And 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 th...

Page 103: ...pen 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 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...

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: ...e 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 do...

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: ...l 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 pres...

Page 108: ...il 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: ...meone 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 specified oil and fuel 1 6 Keep the Machine Clean z Always keep the m...

Page 110: ...ing 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 clean the clamp faces first and make sure the O ring and gaskets are in the correct assembly position 1 14 Checking the Frame...

Page 111: ...ne 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 conditions high temperature and high load and dusty ambient circumstances oil easily deteriorates Change oil as soon as the oil deteriorates or is mixed with many impurities z Add the specified volume o...

Page 112: ...ature 35 use 45 2 1 3 Lubricant z Lubricant is used to reduce noise and prevent wear on the joint surfaces z Joints not included in the manual connectors jointing sleeves are treated during overhaul So they do not need be lubricated When some parts become inflexible because of long term operation it is necessary to add lubricant z Remember to wipe off the overflow lubricant when adding it 2 1 4 Th...

Page 113: ... HM46 hydraulic oil GB11118 1 Ambient temperature 10 L HM32 hydraulic oil GB11118 1 Ambient temperature 30 L HV46 hydraulic oil GB11118 1 210L Hydraulic oil tank Domestic Type Hydraulic oil CALTEX superfine wind ring of temperature anti grinding hydraulic oil 46 210L Hydraulic oil tank Export Type Fuel Ambient temperature 4 0 light diesel Oil GB252 Ambient temperature 5 10 light diesel Oil GB252 A...

Page 114: ...transmission oil Similar Oil Brands Chinese Brands CALTEX MOBIL FUCHS ESSO SHELL 8 Hydrostatic transmission oil Q SH303 064 Caltex Delo Gold Multigrade15W 40 Mobile HEIBAWANG1300 SAE 15W 40 Titan universal HD15W 40 Standard Torque Fluid G7 Rotella 10W z Gear oil Axle oil Similar Oil Brands classified by API standard GL 5 Chinese Brands CALTEX FUCHS MOBIL ESSO SHELL Heavy duty gear oil for automobi...

Page 115: ...er 110 z Grease Similar Oil Brands Chinese Brands MOBIL CALTEX CASTROL ESSO British BP SHELL ZG 2 or ZG 3 Lithium based lubricant grease GB7324 Mobile grease XHP222 Marfak multi Purpose LM grease Ronex MP Beacon EP 2 Energrease L Retinax A Alvania ...

Page 116: ...1 Check the tension and distress of the fan belt 2 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 corro...

Page 117: ...nnect bolts between main driving bearing chock and bracket M22 100 10 9 500 600 8 Lock bolts of main driving input flange M33 1 5 8 320 400 9 Connect bolts between plane frame assembly and rim M20 1 5 10 500 580 10 Connection between the bracket of main driving and axle shell M16 1 5 45 8 8 193 257 11 Rim nuts M20 1 5 8 480 580 12 Connect bolts between brake clip assembly and stent M20 1 5 56 10 9...

Page 118: ...50 hours as follows z Check and clean the air vent of the gearbox Check the filter cartridge of the oil line 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 the hydraulic reservoir z Check if there is leakage in the brake system Clean the filter mesh...

Page 119: ...rtridge and pilot filter of hydraulic reservoir Check the quantity and cleanness of hydraulic oil Filter the 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 replace the brake fluid 3 5 Every 1000 Hours Half a Year Service Carry out the periodic mainte...

Page 120: ...ar 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 z Check the welded seams of rim and other stress parts and adjust the deformation 3 7 Alteration The maintenance principles listed above ar...

Page 121: ...ont and rear driving axle wheel and others The transmission system diagram is shown in the Figure 5 1 Figure 5 1 Transmission System Principle Diagram 2 HYDRAULIC SYSTEM 2 1 Pilot Control and Load Sensing Hydraulic System As shown in Figure 5 2 the hydraulic system includes the working equipment hydraulic system and steering hydraulic system The pilot control hydraulic system is composed of a work...

Page 122: ...r Figure 5 2 Pilot Control and Load Sensing Hydraulic System Principle Diagram 2 2 Pilot Control and Flow Enlarge Hydraulic System As shown in Figure 5 3 the pilot control hydraulic system is composed of a work pump pilot valve multi way valve load select valve lift arm cylinder bucket cylinder hydraulic pressure oil tank and pipe attachments which is mobile and flexible The bucket unit includes d...

Page 123: ...f working device hydraulic system is more than 16Mpa the unload valve unloads the pressure and supply oil to the working device by working pump only to utilize high pressure small flow working 1 Work Pump 2 Hydraulic Oil Tank 3 Pressure Select Valve 4 Double Units Pump 5 Flow Enlarge Pump 6 Steering Cylinder 7 Redirector 8 Priority Valve 9 Multi way Directional Valve 10 Lift Arm Cylinder 11 Bucket...

Page 124: ...Shuttle Valve 3 Air Brake Valve 4 Air Storage Tank 5 Combination Valve of Oil Water Separator 6 Air Compressor 7 Brake Magnetic Valve 8 Parking Brake Air Chamber Figure 5 5 Double Brake Pedals Braking Principle Diagram 3 1 Driving Brake System Single Brake Pedal As shown in Figure 5 4 this system is the single line air pushing oil four wheels caliper disk brake system using four brake calipers for...

Page 125: ...es the piston of the booster pump to change the oil pressure the max oil pressure is about 14MPa Brake fluid pushes the piston of the caliper disk brake and makes the friction disk contact the brake plate to achieve the purpose of slowing and braking At the same time output the signal of air pressure and cut off the power of transmission box When the right brake pedal is stepped on during driving ...

Page 126: ... air draining port of brake electromagnetic valve to aerospace Then the brake is pulled up under the spring to arrive to brake The parking brake indicator lamp controlled by output air pressure is lightened at the same time and cut off the power of transmission box When the system air pressure is lower than 0 4Mpa the brake electromagnetic valve will cut off automatically to control the compress a...

Page 127: ...Operation Maintenance Manual LG956L Wheel Loader 122 Figure5 6 Engine Electric System Diagram with Weichai Engine Domestic Type ...

Page 128: ...Operation Maintenance Manual LG956L Wheel Loader 123 Figure5 7 Engine Electric System Diagram with Weichai Engine Export Type ...

Page 129: ...Operation Maintenance Manual LG956L Wheel Loader 124 Figure5 8 Engine Electric System Diagram with Shangchai Engine ...

Page 130: ...Operation Maintenance Manual LG956L Wheel Loader 125 Figure5 9 Engine Electric System Diagram with Cummins Engine ...

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