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Operation & Maintenance Manual

──

LG918 Wheel Loader

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

2.3 The Sketch of Lubricating Points

2.4 Detailed Rules of Electric System Maintenance

If the wire stays in the wet environment or the insulation of it is damaged, the electric system

may leakage which will cause hazardous accident.

Maintenance of components related to the electric system.

Check the tension and distress of the fan belt.

Check the fluid level of electrolyte in the storage battery.

Never remove or disassemble any electric components installed in the machine.

Never install any electric components other than those specified by the company.

Be sure to keep the electric system dry when washing the machine or working in rain and snow.

Avoid the electric system corroding by seawater when working on the seashore.

2.5 Maintenance Tools

Содержание LG918

Страница 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 Main...

Страница 2: ...30 mm 16 6 25pieces 4th Edition in 2008 9 and 2nd Print in 2009 8 SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone Shandong 276023 Tel 86 0539 8785688 Fax 86 0539...

Страница 3: ...METRICAL DIMENSIONS 45 3 PRODUCT TYPE AND ITS MEANING 46 4 NAMEPLATE 46 5 USE CONDITIONS 47 6 CIRCUMSTANCES REQUIREMENT 48 7 FEATURES 48 8 TECHNICAL PERFORMANCE PARAMETER 49 CHAPTER III OPERATION AND...

Страница 4: ...gine 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 rese...

Страница 5: ...perate 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...

Страница 6: ...d 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 ma...

Страница 7: ...E CONTENTS Figure 1 1 Figure of safety label position Domestic Type 1 1 Safety Label and Its Position The positions of safety labels of this machine are shown in the figure 1 1 and figure 1 2 Please r...

Страница 8: ...ted above the start button 2 Start for lift 5 Danger of injury or death during steering 6 Notice for antifreeze fluid if stuck Located on the front of front and rear frames Lock the lift arm cylinder...

Страница 9: ...igh temperature 12 Notice for fuel oil tank Located on the inner right front glass the operator cab Located on vent pipe of engine hood Located on the inner left front glass of the operator cab Locate...

Страница 10: ...he machine 14 Warning of safety distance Pay attention to the steam or hot water ejection Located on both sides of engine Touch the machine only after all parts stop Located on the both sides of engin...

Страница 11: ...Operation Maintenance Manual LG918 Wheel Loader 5 Figure 1 2 Figure of safety label position Export Type...

Страница 12: ...n the lifting position of the front and rear frames 3 Limit position of lift arm Located on both sides of actuating arm Located on right and left operator cab doors 6 Notice for the door of operator c...

Страница 13: ...and left platform frames Located on the hydraulic oil tank 8 Hydraulic oil tank 9 Warning of high temperature Located on vent pipe of engine hood 10 Fuel tank Located on fuel tank Pay attention to st...

Страница 14: ...has been added If coolant 45 has been added Located on the left operator cab door and mouse of radiator of engine hood 12 Antifreeze fluid if sticking 13 No fire warning Located on fuel tank 14 Warni...

Страница 15: ...onal safety range Located on the left back upright column in inner operator cab Located on the inner left back upright column of the operator cab Located on the inner left back upright column of the o...

Страница 16: ...t back upright column of the operator cab 21 ROPS FOPS used in anti roll cab Located on the inner right back upright column of the operator cab 23 Prevent rolling Located on the inner right front upri...

Страница 17: ...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...

Страница 18: ...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 flammabl...

Страница 19: ...ly z Check all the safety items 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 wa...

Страница 20: ...to the 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 too...

Страница 21: ...lean 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...

Страница 22: ...orking 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 b...

Страница 23: ...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...

Страница 24: ...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 t...

Страница 25: ...d 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 ab...

Страница 26: ...re 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...

Страница 27: ...uld 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 th...

Страница 28: ...e 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...

Страница 29: ...nd 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...

Страница 30: ...s 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 back...

Страница 31: ...t of the towed machine The tightwire with wring or radius reduction can not be used z People are not allowed to go between two machines when the machines are connected z Do not stand on the towing ste...

Страница 32: ...e status of the working area before entering a narrow passageway such as tunnel overbridge and garage Take care with the working devices during operation z Operate down wind in strong windy weather z...

Страница 33: ...ment and the machine frequently z Make sure that every bridge is strong enough to let the machine pass z Don t use the machine for any work other than what the machine is designed for It may damage th...

Страница 34: ...z When constructing a dam or unloading soil from a cliff form one pile first and use the second pile to push the first one 6 3 Ensure Ventilation in Close Environment z Open the window to ensure enoug...

Страница 35: ...distance between loader and the overhead electric wire should be z At least 2m 6 5ft at low voltage condition z At least 4m 13ft at high voltage condition To prevent an accident please do as follows...

Страница 36: ...s method Never jump down to the ground WARNING NEVER get on or off the machine while it is moving 7 2 Notice for Cold Area z Clear the water snow or dust attached to wires switches power insert or sen...

Страница 37: ...repair tools correctly do not use broken or low quality tools z Lower the working equipment completely to the ground stop the engine push the parking brake switch and wedge the tire during repairs to...

Страница 38: ...a close area use releaser to release the exhaust gas in the area If there is no releaser please open the door 8 3 Maintenance of frames during jacking up z When jacking up the frame do not let anyone...

Страница 39: ...rail to clean the front glass of the operator cab 8 6 Maintenance While the Engine is Working Routine maintenance of the machine should never be done while the engine is working When it is necessary p...

Страница 40: ...in the braked position z Do not let water enter an electric part such as sensor wire connector or operator cab If so the operation may be disabled and the electric circuit may be damaged z Wear prote...

Страница 41: ...in the engine the oil and water in the radiator may be still very high after just finishing the work Wait for the temperature falling down and follow the procedures to do the operations above z To av...

Страница 42: ...d soft pipe of the hydraulic system Leakage can cause fire so routine maintenance is critical z Examine the pipe system carefully hard pipe and soft pipe screw down the connectors according to the pro...

Страница 43: ...temperature parts such as the silencer when parking the machine z Check whether there is leakage of fuel mobile oil or hydraulic oil Replace the broken soft pipes Clean before operation and after rep...

Страница 44: ...vent 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 P...

Страница 45: ...th 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...

Страница 46: ...f 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 bubbles Never operate in a low pressure condition z...

Страница 47: ...dump the oil directly onto the ground z Obey the relative rules and laws when dealing with harmful materials such as grease fuel coolant solvent filter and storage battery 9 SAFETY TRANSPORTATION 9 1...

Страница 48: ...heir accredited representative 9 3 Lifting Use the hook of the front and rear frame to transport the machine to ship or train Select proper lifting equipment according to the weight of the loader othe...

Страница 49: ...owed 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 onto the ship train wedge the ti...

Страница 50: ...Operation Maintenance Manual LG918 Wheel Loader 44 CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME Figure 2 1 General view and components name of LG918 wheel loader...

Страница 51: ...Operation Maintenance Manual LG918 Wheel Loader 45 2 GEOMETRICAL DIMENSIONS Figure 2 2 Geometrical dimensions of LG918 wheel loader mounted with standard lift arms...

Страница 52: ...ATE 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...

Страница 53: ...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 pro...

Страница 54: ...new damping system The machine operation is smooth and comfortable z The type of power shifting transmission is fixed axle so the structure is compact and the transmission efficiency is high z The dri...

Страница 55: ...0 9 6 km h 2nd 0 25 km h 0 25 km h Max breakout force 58 kN 56 kN Max traction force supplied by engine 56 kN 56 kN Max tipping load 36 kN 30 kN Max climbing angle 30 30 Min turning radius outside of...

Страница 56: ...n ground clearance 290 mm 290 mm Max dumping height 45 dumping angle 2510 mm 2800 mm Dumping space 45 dumping angle 920 mm 888 mm Dumping angle 45 45 Operating weight 6200kg 6250kg 8 3 Product Standar...

Страница 57: ...rking Brake Control Lever 8 Seat 9 Bucket Control Lever 10 Lift Arm Control Lever 11 Turning Switch 12 Starting Switch 13 Horn Button Figure 3 1 General view of control System 1 Steering Wheel 2 Panel...

Страница 58: ...ing Lamp 13 Left Turn Indicator Lamp Figure 3 3 General view of gauges 1 Gearbox Pressure Gauge 2 Air Pressure Gauge 3 Working Chronometer 4 Left Turn Indicator Lamp 5 Indicator Lamp 6 Revolution Indi...

Страница 59: ...erature 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 in...

Страница 60: ...e 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 Th...

Страница 61: ...wn 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 Parki...

Страница 62: ...ON position automatically z Turning Switch Push this switch forward and the left turning lamp lights Push this switch backward and the right turning lamp lights Refer to 1 1 Control System and the Gau...

Страница 63: ...d Press the lower button and unit heater will work press upper button and unit heater stops working When the unit heater or air condition works adjust the air outlet in the front or profile of gauge p...

Страница 64: ...for low air speed Press 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...

Страница 65: ...l get two front and two rear for a total of four gear levers The working condition of each lever is shown as following Fore and aft gear control lever High low speed control lever Forward Gear Neutral...

Страница 66: ...o back to control the lower float neutral and lift of the lift arm Lift is used for lifting Neutral is used for maintaining the lift arm in the desired position Lower is used for lowering Float is use...

Страница 67: ...n When leveling the ground place the control handle in the floating position and the control handle is locked by the electromagnetic force to realize the lock automatically Take the control handle fro...

Страница 68: ...ight door to 180 and the orientation lock on the door will touch the outside lock of the cab and the door will be locked outside the cab Turn the control bar downward and it will unlock 1 2 6 Frame Lo...

Страница 69: ...ositions O L M and H The speed of evaporating fan increases from left to right to adjust the air volume Open the temperature control switch 3 to the max the indicator lamp 1 will light then the compre...

Страница 70: ...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 and high volume of air b Heating Turn the te...

Страница 71: ...z Adjust the cab s seat before starting operation or replacing the operator z Make sure that you can depress the brake pedal completely when your back is against the seat backrest z Fore and Aft Adjus...

Страница 72: ...n 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 Onc...

Страница 73: ...ng 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 acce...

Страница 74: ...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 lever...

Страница 75: ...y 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 w...

Страница 76: ...on a slope and use the foot brake pedal to slow the speed if the double brake pedals are assembled the left one should not be used 3 3 2 Gearshift Changing between Forward and Backward z Press the ac...

Страница 77: ...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...

Страница 78: ...rter 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 loo...

Страница 79: ...ction of the loader After digging the loader moves backward and turns the designated degree and moves forward to the truck The smaller the loader work angle is the more efficient the work is 2 Digging...

Страница 80: ...shovel edge moves up and down when thrusting material into the bucket or when digging the front tires will leave the ground and slip z If there is too much material loaded into the bucket the bucket m...

Страница 81: ...nnection point of lift arm at the transportation position 400 500mm above the ground 4 Dumping Operation z When dumping material on to trucks or into freight yards raise the lift arm to the position f...

Страница 82: ...ar transmission axle If the machine can not turn disassemble the steering cylinder z The connection hole of the rear frame at the inner side of the rear wheel can only be used for lifting and binding...

Страница 83: ...rest repairing garage If the distance is longer than 10 km or the towing speed faster than 10 km h the front and rear transmission axle must be disassembled or put the loader on towing truck for trans...

Страница 84: ...the machine on the dry and hard ground If that is impossible park the machine on a wooden board which can prevent the tires from freezing on the ground 3 The capacity of storage battery will obviousl...

Страница 85: ...2 Oil Selection Engine Oil Replacement z Park the machine on level ground and put the transmission lever in neutral N position Pull the parking brake switch and put the blocks in the front and back o...

Страница 86: ...lement sealing 3 6 2 Adding Fuel to Fuel Tank Fuel Level Check z Park the machine on level ground and check the fuel level by dipstick on the outside of fuel tank If the fuel level is under 0 please a...

Страница 87: ...and contain it with container Notice Not only the oil in the gear box but also the oil in the radiator of the torque convertor should be drained out WARNING If the temperature of the gearbox oil is r...

Страница 88: ...lever in the neutral position Pull the parking brake switch and wedge the front tire Loosen the oil inlet plug on the shells of the front and rear axles It is proper if the oil level is at the bottom...

Страница 89: ...of the axle shell And then check the oil level again z Tighten the oil drain plugs on the two wheels on the end sides of the front axle and the oil inlet plug at the middle of the axle shell z Replace...

Страница 90: ...drain the oil to the container Open the oil inlet cover at the same time to fasten the draining process z Disassemble the flange cover of the oil box bottom Clean the oil tank inside z Disassemble the...

Страница 91: ...rain the coolant except the one added with antifreeze Please refer to 3 5 3 Operation in Cold Weather in this chapter z Lower the bucket to the ground and set all control levers or handles to the Neut...

Страница 92: ...ting motor does not mesh or keep meshing without rotation Faulty battery charge Charge 7 Starting motor turns feebly 1 Insufficient battery charge 2 Faulty alternator 1 Charge 2 Replace 8 Starting mot...

Страница 93: ...e gearshift control levers and linkages 3 Change the spring of pressure regulator valve 4 Refer to 1 2 3 and 4 of problem 1 5 Insufficient driving force 1 Low shifting pressure 2 High oil temperature...

Страница 94: ...sage valve excessive clearance between valve spool and valve block 3 Oil leakage of oil lines 4 Severe internal leakage of working pump 5 Idle suction of working pump 6 Low set pressure value of safet...

Страница 95: ...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...

Страница 96: ...pecified in this manual according to ambient temperature 1 5 Using the Prescriptive Oil and Fuel Keep containers of oil and fuel clean and use specified oil and fuel 1 6 Keep the Machine Clean Always...

Страница 97: ...machine after complete cooling of the engine z Do not allow water to spray on any electric components 1 16 Checking in Raining and Snowing Circumstances z Clean the machine immediately after working...

Страница 98: ...which is condensed by the moisture in the air from entering the fuel tank z If the engine fails to suck fuel or the filters have been just replaced drain out the air in the circuit 2 1 2 Coolant z Us...

Страница 99: ...n oil quality during long term storage Use the oil with the longest shell life 2 1 5 Filters z Filters are extremely important safety components They can prevent impurities in the fuel from entering i...

Страница 100: ...ight diesel Oil GB252 Ambient temperature 14 20 light diesel Oil GB252 Ambient temperature 29 35 light diesel Oil GB252 120L Fuel tank Brake fluid Motor vehicle brake fluid HZY3 DOT3 GB12981 4L Brake...

Страница 101: ...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 automobile GL 5 85W 90 GB13895 Caltex Thuban...

Страница 102: ...system may leakage which will cause hazardous accident z Maintenance of components related to the electric system 1 Check the tension and distress of the fan belt 2 Check the fluid level of electroly...

Страница 103: ...0 M24 2 120 8 8 250 360 320 480 7 Assembling bolts between teeth and bucket M16 40 M16 70 45 193 257 3 CONTENT OF MAINTENANCE Maintenance content includes the run in period of a new machine and the pe...

Страница 104: ...nth Service Carry out the periodic maintenance of every 10 and 50 hours with this maintenance operation at the same time z Check the storage battery Clean surface and terminals of the battery then coa...

Страница 105: ...ce the filter cartridge in the oil lines of torque converter gearbox Replace the gearbox oil z Change the gear oil in the front and rear axles z Check and clean the filter mesh of the oil bowl in the...

Страница 106: ...uirements The maintenance time should be determined by the closer one between the two the maintenance schedules If the working condition is very severe please shorten the maintenance cycle and increas...

Страница 107: ...system diagram is shown in the Figure 5 1 1 Engine 2 Hydraulic Torque Converter 3 Gear Box 4 Parking Brake 5 Wheel 6 Wheel Side Reducer 7 Differential 8 Driving Axle 9 Main Transmission 10 Transmissi...

Страница 108: ...ctor 10 Redirector cylinder Figure 5 2 LG918 Hydraulic System Diagram mechanical control 1 Multi way valve 2 Lift arm cylinder 3 Steering cylinder 4 Hydraulic oil tank 5 Oil returning filter 6 Respira...

Страница 109: ...ystem and parking brake system as shown in Figure 5 4 and 5 5 1 Air booster pump 2 Air brake valve 3 Air tank 4 Combination valve of oil water Separator 5 Air compressor Figure 5 4 LG918 Single Brake...

Страница 110: ...ushes 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 brak...

Страница 111: ...Operation Maintenance Manual LG918 Wheel Loader 105 Figure5 6 LG918 Electric System Diagram with Yuchai engine Domestic type...

Страница 112: ...Operation Maintenance Manual LG918 Wheel Loader 106 Figure5 7 LG918 Electric System Diagram with Yuchai engine Export type...

Страница 113: ...Operation Maintenance Manual LG918 Wheel Loader 107 Figure5 8 LG918 Electric System Diagram with Yangma engine Export type...

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