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Operation & Maintenance Manual

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LG946L Wheel Loader

CHAPTER

MAINTENANCE

Ⅳ

1 MAINTENANCE GUIDE

Read following information carefully before carrying out maintenance and inspection.

1.1 Attention to Maintenance and Inspection

Perform the maintenance on hard and level ground.

Lower the work equipment near the ground and level the bucket.

Set all control levers to the

Neutral

position.

Draw up the parking brake handle to set the loader in the parking brake state.

Put blocks in the front and back of wheels.

Lock the front and rear frames with frame locking bars.

1.2 Hanging Warning Tag

Attach the warning tag near the starting switch before maintenance to prevent someone

starting the engine during maintenance.

1.3 Fitting preparation

Use only parts specified by the manufacturer of the loaders wheel.

1.4 Oil and Fuel preparation

Use oil and fuel specified 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 keep the machine clean. Keep grease fittings, pipe joints and oil level gauges clean

and prevent foreign materials entering.

1.7 Pay Attention to the Refrigerant Water and Oil in High Temperature

It is very dangerous to drain hot oil and refrigerant water or remove the filters immediately

after the engine stops. Make sure the engine is cool. The temperature of the oil drained is

appropriately about 20 to 40 If it is lower than this temperature, be sure to war

℃

m it up to this

temperature before draining it.

1.8 Check the Oil and Filters

After the oil is changed or filters are replaced, check the oil and filters. If large amounts of

metallic particles or impurities are found, consult the maintenance people.

1.9 Fuel Strainer

Do not remove the fuel strainer while fueling.

1.10 Oil Changing

Содержание LG946L

Страница 1: ...nderstand 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 Maint...

Страница 2: ...880 1230 mm 16 7 25pieces 2nd Edition in 2012 01 1st Print SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone Shandong 276023 Tel 86 0539 8785688 Fax 86 0539 87856...

Страница 3: ...OF THE MACHINE COMPONENTS NAME 42 2 GEOMETRICAL DIMENSIONS 43 3 PRODUCT TYPE AND ITS MEANING 45 4 NAMEPLATE 45 5 USE CONDITIONS 46 6 CIRCUMSTANCES REQUIREMENT 47 7 FEATURES 47 8 TECHNICAL PERFORMANCE...

Страница 4: ...for the diesel 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 engineeri...

Страница 5: ...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...

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: ...ne are 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...

Страница 8: ...arm 5 Danger of lift arm 6 Start lifting 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 loadi...

Страница 9: ...11 Notice for fuel oil tank 12 Notice for hot water Located on the hydraulic oil tank Located on the left side of operator cab door and inlet port of water tank of engine hood Located on outside of op...

Страница 10: ...n Located on the right and left platform frames Located on the Air Storage Tank s body 18 Air Storage Tank to drain 19 Battery explosion ban of any fires Located on the Air Storage Tank s body Located...

Страница 11: ...er 8 20 Pilot single handle control if assembly 21 Notice for adding antifreeze fluid Located on right control box Located on cover of water tank of engine hood 22 installs position of fire extinguish...

Страница 12: ...be disturbed 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 S...

Страница 13: ...Never wear loose clothing jewelry and loose long hair They can be caught by control levers or control handles or moving parts which may cause serious injury and even death z Avoid wearing oily clothes...

Страница 14: ...e 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 water leaks air lea...

Страница 15: ...led tow doors on the left and right in order to prevent to mistake operation please insure to make the door on the control lever side as urgent exit and please don t get on or off the machine from it...

Страница 16: ...er z Check whether there is the leakage of fuel lubricating oil or hydraulic oil If so repair or replace the broken items Clean the repaired items before use z If there is explosive air generated near...

Страница 17: ...hand arm or other parts of 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 stan...

Страница 18: ...Protective Structuresabd and Roll Over Protection Structure Optioal Installing FOPS ROPS is to protect the workmen in order to prevent the falling objects and the roll over of the machine ROPS can no...

Страница 19: ...depth of water for passage z Be sure there are good ventilation conditions when working in a closed environment 4 1 2 Check before Starting the Engine z Check the machine carefully before starting wo...

Страница 20: ...tires are worn or broken the bolts and nuts are loose Especially pay attention to the loose hub nut and repair or replace for any abnormal situations 4 1 3 When Starting the Engine z Before boarding o...

Страница 21: ...orking range z Operate the control mechanism for the gears Make sure the front middle and rear gears are in the correct positions Make sure all the control levers are easy to use z Examine the foot br...

Страница 22: ...ople near the machine in all direction by sounding the horn z The door of the cab should be locked when driving Do not open the door while driving z It is dangerous to pick up other people No one shou...

Страница 23: ...sumes no responsibility for overload injury or damage to equipment z Do not drive turn or brake suddenly and do not detour z Never suddenly stop or lower the working equipment which may throw out the...

Страница 24: ...5 6 Pay Attention to Blockages z If there are blockages roof of buildings or the door frame keep the loader away from the blockages when turning or passing z Notice the environment Slow down and chec...

Страница 25: ...an not be seen under the snow so take 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 200 3...

Страница 26: ...2 7 Towing Operation 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 Ple...

Страница 27: ...ong 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 th...

Страница 28: ...allow anyone to stand 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 conditi...

Страница 29: ...n left and 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 lan...

Страница 30: ...vironments and know where they are stored and how to use 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 t...

Страница 31: ...les z Never leave the operator cab never move and do not touch any 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...

Страница 32: ...oil flow back to the hydraulic oil tank to preheat the hydraulic oil so as to guarantee better reaction and prevent malfunction z Do not charge the storage battery with frozen electrolytes and do not...

Страница 33: ...rom fire or flame Do not pile oily cloths anywhere because it may self ignite z Never smoke when adding fuel or examining the storage battery z Put the accessories in a safe place to prevent lost Put...

Страница 34: ...thout good support 8 5 Working on the Machine z Make sure the top of the machine has no blockage and is clean when working on the top of the machine Follow the rules below NOTICE z Do not allow lubric...

Страница 35: ...ss 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...

Страница 36: ...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...

Страница 37: ...harmful alkaline materials in the coolant system touch your skin or eyes z Choose a proper container to hold the liquid when replacing the coolant mobile oil of the engine oil of the transmission box...

Страница 38: ...engine before adding fuel Do not smoke and keep fire away while adding fuel z Keep fire away from the storage place of fuel grease or other flammable materials z Clean the flammable substances on the...

Страница 39: ...mportant in cold weather Make sure the drain valve is closed before starting the engine At bottle the body surface stick a related safety marking Please do it according to the content of safety markin...

Страница 40: ...l z Connect the positive pole of the storage battery with the negative pole of the machine first and then connect the negative pole of the storage battery with the positive pole of the machine z Put t...

Страница 41: ...allowed to touch when one is starting z Turn off all the starting switches of the normal machine and the broken machine when connecting the voltage raising cable z Connect the positive cable first whe...

Страница 42: ...ard and same flower pattern for replacement 8 19 2 Storage of Tires z It is the basic rule that tires should be stored in a warehouse No one can enter without permission Put a fence around and hang a...

Страница 43: ...d should not be larger than 15 Keep a safe distance between slope board and board board and machine z Make sure the height of the two sides of the board is uniform to ensure firm orientation z Keep th...

Страница 44: ...ng lifting All the control levers or handles should be in the middle position Stop the engine lock all the equipment using keys and then remove No one is allowed to stay in the operator cab Never lift...

Страница 45: ...Operation Maintenance Manual LG946L Wheel Loader 42 CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME Figure 2 1 General view and components name of LG946L wheel loader...

Страница 46: ...Operation Maintenance Manual LG946L Wheel Loader 43 2 GEOMETRICAL DIMENSIONS...

Страница 47: ...Operation Maintenance Manual LG946L Wheel Loader 44 Figure 2 2 Geometrical dimensions of LG946L wheel loader mounted with standard lift arms...

Страница 48: ...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 2 4 The ot...

Страница 49: ...yards and 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...

Страница 50: ...ation work device is used and it is easy to steer and operate the performance is permanent and reliable z Jingled frame structure large steering angle 38 and small turning radius so it is mobile and f...

Страница 51: ...s Travel speed Forward 1st 0 13 km h 0 13km h 2nd 0 38 km h 0 38km h Reverse gear 1st 0 17km h 0 17km h Max breakout force 125 kN 125 kN Max traction force supplied by engine 120 kN 120 kN Tipping loa...

Страница 52: ...Wheel base 2880mm 2880 mm Min ground clearance 440 5 mm 440 5 mm Max dumping height 45 dumping angle 2950 mm 3235 mm Dumping space 45 dumping angle 1055 mm 1165 mm Dumping angle 45 45 Operating weigh...

Страница 53: ...ver 12 rocker switch 13 Starting Switch Figure 3 1 General view of control System double control lever and manual for cutting off power 1 Working Chronometer 2 Engine Water Temperature Gauge 3 Torque...

Страница 54: ...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 n...

Страница 55: ...start switch is turned on It will go off immediately after the engine is started Otherwise it means there is some problem with storage battery Please examine and repair it High Beam Indicator Lamp The...

Страница 56: ...Operation Manual If the radio is not assembled the connecting line of radio is reserved please assemble it according to the electric principle diagram by authorized person of vehicle or construction m...

Страница 57: ...ight lamp on the front frame will come on If no side is pressed the lamp will go off z Front Rear Headlight Switch Press bottom side the front headlight and rear headlight on the top of cab will come...

Страница 58: ...switch turns to the position The power of the whole vehicle is turn on when the switch turns to the position Please shut the power switch if park the vehicle for a long time 1 2 3 Steering Wheel The...

Страница 59: ...trols and Gauges Figure 3 1 and 3 2 in this chapter Bucket Control Lever Move the control handle from left to right to control the front tilt neutral and rear tilt of the bucket Rear Tilt is used for...

Страница 60: ...d 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 buck...

Страница 61: ...icle Refer to 1 1 General View of Controls and Gauges Figure3 1 and 3 2 in this chapter z Accelerator Pedal This pedal controls the acceleration of the engine Refer to 1 1 General View of Controls and...

Страница 62: ...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...

Страница 63: ...ethods a Refrigeration NOTICE z Always be sure to close the startup switch before replacing the fuse The fuse is used to protect the wiring and cable from burning out If the fuse has become corroded b...

Страница 64: ...he 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 indicato...

Страница 65: ...otice Avoid the temperature control switch 3 is always in the coldest position and the air volume and power switch 2 is in the fan low gear position of L in order to prevent the evaporator from frosti...

Страница 66: ...t the base under the seat by two hands and draw up forcibly and stably When the cracking sound is sounded please loose your hands then the seat will fix in this position Adjust the position of seat to...

Страница 67: ...run in period first to increase the load step by step from free rotating so that each part of the machine can be have full run in period for increasing the life of the machine It needs 60 hours to tr...

Страница 68: ...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 light and lamps and turning signals...

Страница 69: ...table driving during the transporting process z A diesel engine is used in the machine The power of the diesel engine will go down as the altitude environmental temperature and relative temperature go...

Страница 70: ...fter completing 3 2 2 Engine Starting Points for attention of starting engine z Make sure all the control levers are in the neutral position before starting make sure the gear control lever is in neut...

Страница 71: ...warm quickly z Keep the engine at an idle speed for several minutes after starting Increase the speed to 1000 1200r min gradually and then enter the partial load running status Pay attention to the va...

Страница 72: ...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 be...

Страница 73: ...e 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 3 4 S...

Страница 74: ...el reserves z Check the oil level of the engine oil pan and its cleanness If the oil level is too high or diluted find the reasons and solve them z Check the oil pipes water pipe gas pipe and other pa...

Страница 75: ...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...

Страница 76: ...arm to prevent 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 buc...

Страница 77: ...e following conditions z The ground is too soft and not level and the truck can not be used z When the transportation distance is within 500 meters it is not economical to use a truck z The transporta...

Страница 78: ...te the control lever between lifting and lowering operation Never use the lever at the raising or lowering position to ensure pushing the bucket smoothly 6 Striking Operation Tilt the bucket to let th...

Страница 79: ...e z The connection between the towing equipment and the machine should be strong z The weight of the towing machine should be heavier than the towed one and have enough traction power and braking powe...

Страница 80: ...water NEVER let water enter the battery Warm it to 15 slowly otherwise an explosion may occur 3 Please use an anti alpine storage battery in an anti alpine area z Follow up after every working day In...

Страница 81: ...in 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 th...

Страница 82: ...e oil on the rubber seal ring z Tighten 3 4 1 cycles after the seal ring connects with the base z Start the engine and check whether the seal ring is seal If not disassemble the filter element and che...

Страница 83: ...handle or press the parking brake switch to carry out braking and wedge the front and back of the tire z Start the engine and run in the idle status for several minutes Loosen the oil drain plug on t...

Страница 84: ...e front and rear axles It is proper if the oil level is at the bottom side of the oil adding port otherwise please add axle oil Please watch for about 5 minutes after adding oil If the oil level keeps...

Страница 85: ...ar oil from the oil drain port at the end of two wheels sides of the front axle and the oil inlet port at the middle of the axle shell about 32L And then check the oil level again z Tighten the oil dr...

Страница 86: ...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...

Страница 87: ...e it outdoors If the machine must be outdoors park it on well drained concrete and cover it with canvas z Add lubricant grease and change hydraulic oil before storage z Apply a thin coat of grease to...

Страница 88: ...3 A meter does not work when 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 dies...

Страница 89: ...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...

Страница 90: ...e 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...

Страница 91: ...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...

Страница 92: ...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 93: ...el preparation Use oil and fuel specified 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...

Страница 94: ...ose or damaged between bolts and nuts 1 15 Attention to Washing Machine z Wash machine after complete cooling of the engine z Do not allow water to spray on any electric components 1 16 Checking in Ra...

Страница 95: ...icularly temperatures lower than 15 So it is necessary to change the kind of fuel according to the ambient temperature z Always fill the fuel tank full after operating to prevent the water which is co...

Страница 96: ...peration it is necessary to add lubricant z Remember to wipe off the overflow lubricant when adding it 2 1 5 The Storage of Oil and Fuel z Prevent water dirt or other impurities from mixing with the o...

Страница 97: ...l tank Domestic Type Hydraulic oil CALTEX superfine wind ring of temperature anti grinding hydraulic oil 46 140L Hydraulic oil tank Export Type Fuel Ambient temperature 4 0 light diesel Oil GB252 Ambi...

Страница 98: ...ostatic 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 Bra...

Страница 99: ...ance z 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 z Maintenance of components related to the electr...

Страница 100: ...lts of main driving left and right differential cover M14 1 5 400 40Cr 180 210 6 Connect bolts between main driven move helical gear and right cover of differential M16 1 5 55 40Cr 280 330 7 Connect b...

Страница 101: ...intenance operation at the same time z Check oil level of the gearbox hydraulic oil tank and brake booster pump z Tighten all connection bolts of transmission axles z Check whether all connection bolt...

Страница 102: ...e in the brake system Clean the filter mesh of the oil bowl in the booster pump Clean the air vent and check the brake fluid Add them if deficient and replace them if necessary 3 5 Every 500 Hours Sea...

Страница 103: ...oil z Check the clearance and wear condition of the pins and the bushes in every articulated point 3 7 Every 2000 Hours Year Service Carry out the periodic maintenance of every 10 50 100 250 500 and...

Страница 104: ...Operation Maintenance Manual LG946L Wheel Loader 101...

Страница 105: ...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...

Страница 106: ...s 18 18 5MPa while that of the small cavity is 12MPa 1 Boom cylinder 2 Multi way valve 3 Steering cylinder 4 Steering gear 5 Priority valve 6 Steering and transiting twin pumps 7 Working pump 8 Hydrau...

Страница 107: ...sed air of the booster pump drains from the brake valve to the atmosphere and the brake is released 3 2 Driving Brake System This system contains two models electrical and pneumatical caliper disk bra...

Страница 108: ...e emergency brake which can ensure the safety of vehicles and personnel 4 ELECTRIC SYSTEM The electric system is composed of a storage battery starting motor charge generator appliance switch lamps ai...

Страница 109: ...Operation Maintenance Manual LG946L Wheel Loader 106 Figure5 4 Electrical Principle Diagram Engine of LG946L Mechanical operation...

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