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Operation & Maintenance Manual

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LG968 /969Wheel Loader

101

CHAPTER V THE STRUCTURE AND

PRICIPLE OF MAIN COMPONENTS

AND SYSTEM

1 Transmission System

The transmission system includes hydraulic torque converter, transmission box, the oil line system of
hydraulic torque converter of transmission box, transmission axle, front and rear driving axle, wheel
and so on. The transmission system theory is shown in the Figure 5-1.

1. Input gear 2. KR steering gear 3. Intermediate gear 4.4th speed gear 5.K34 gear ring

6. 3rd speed gear 7.Output gear

8. Gear assy 2nd speed large-small gear 9.KR2 gear

10. Working pump gear 11. Steering pump driving gear

12. 1st gear 13.KV1 Gear

14. KV steering gear

Figure 5-1 LG968/969 Transmission System Theory

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Содержание LG968

Страница 1: ...carefully and understand these instructions before use to avoid serious accident For the convenience of relevant people using this manual it should be kept properly Operation Maintenance Manual LG968...

Страница 2: ...1230 mm 16 7 5pieces 3rd Edition in 2008 3 and 1st Print in 2008 4 SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Address Linyi Economic Development Zone 276023 Tel 86 0539 8785688 Fax 86 0539 878569...

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

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

Страница 5: ...g or Cutting 3 8 Notice of Attachment 4 SAFETY STARTING 4 1 Before Starting Engine 5 SAFETY DRIVING 5 1 Warning 5 2 Oneself Safety and Others Safety 5 3 Full Load Transportation 5 4 Never Drive Over S...

Страница 6: ...Waste Materials 9 SAFETY TRANSPORTATION 9 1 Assemble and Disassemble the Machine 9 2 Transportation on the Ground 9 3 Lifting CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE COMPONENTS NAME 2 G...

Страница 7: ...sty Worksite 1 18 Avoid Using Mixed Oil 2 CONTENT OF MAINTENANCE 2 1 Outline of Oil Fuel and Coolant 2 2 Selection of Fuel Coolant and Lubricant 2 3 The Sketch of Lubricating Points 2 4 Outline of Ele...

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

Страница 9: ...nd maintenance and repair of the machine before reading and understanding this manual z The operation specifications and precautions given in the manual only apply to intended uses of the machine If t...

Страница 10: ...manual only apply to those conditions specified by the machine If the uses of the machine are not specified in the manual users should take full responsibility by themselves We will not bear any safe...

Страница 11: ...f this machine please see the following figure Please read the contents of safety label carefully and follow the rules Please keep the labels well if there is any lost broken or unclarity of label ple...

Страница 12: ...g 4 Start for lift Located on the front of the front and rear frames Lock the lift arm cylinder before entering dangerous areas 5 Limit position of lift arm 6 Danger of actuating arm Located on the tw...

Страница 13: ...door of operator cab Located on the steering position of front and rear frames 7 Danger or death during Steering 8 Reference for manual Located on the left operator cab door and mouse of radiator of e...

Страница 14: ...high temperature Located on vent pipe of engine hood 15 Forbidden of flame and fire Located on fuel tank 16 Fuel tank Located on fuel tank Be attention for steam or hot water ejection Located on the t...

Страница 15: ...ood 20 Warning of high voltage Located on the right back pole inner operator cab 21 Warning of seatbelt Located on the right back pole inner the operator cab 22 Warning of avoiding noise Located on th...

Страница 16: ...ader 6 24 Check before starting Located on the right back pole inner the operator cab 25 ROPS FOPS used in anti roll cab Located on the left back pole inner the operator cab 26 Prevent rolling Located...

Страница 17: ...r drinking Those cases could cause your wrong judgments and induce accident z When working with another operator or with a person on worksite traffic duty be sure that all people understand all hand s...

Страница 18: ...ar loose clothing jewelry and loose long hair They can be caught on control levers or control handle or in moving parts and cause serious injury or death z Avoid wearing oily clothes because they are...

Страница 19: ...immediately z Check all the safety items such as the safety protective devices are at the safe status Make sure the tires are not worn and the tire pressure is up to snuff If you don t solve the oil...

Страница 20: ...e body stable z Never hold any control levers when getting on or off the machine z Never get into the operator cab from the ladder at the back of machine or from the tire at the side of operator cab z...

Страница 21: ...f fuel lubricating oil or hydraulic oil If so repair or replace the broken items Clean the repaired items before using z There is explosive air generated near storage battery be sure there is no flame...

Страница 22: ...other parts of your body among movable parts such as between working equipment and oil tank machine and working equipment or joint points between front and rare frame If the working equipment is opera...

Страница 23: ...on Before start working the ground should be planed and pressed firmly If there are big Sand dust sprinkle water first z When working on public roads position flagmen and erect barricades and use the...

Страница 24: ...st the rear view mirror and keep the surface clean to ensure best view from operator s seat Replace with a new one if the mirror has been damaged z Don t leave any tool or part on the operator s seat...

Страница 25: ...s allowed to get close z Check whether the engine runs with abnormal sound or shaking If so it means there may be exceptions report to the manager immediately Operate the machine after the exceptions...

Страница 26: ...z Do not put the arm or foot on the working equipment or extend outside the machine z Driving on the plain ground the lower hinge of arm working equipment should be 400 500mm 16 20in above the ground...

Страница 27: ...Load Transportation z Do not hold full bucket at high position when transport Select proper speed when full load transport The bucket should be at tilt position near the block and relatively a lower...

Страница 28: ...ty is bad or at the narrow crossing z Sand dust big fog or storm may affect visibility Slow the speed when visibility is bad When visibility is not good stop work until good weather z Drive carefully...

Страница 29: ...y overturn and the people may be hurt or even dead z Assemble anti fall or anti turn operator cab when there may stone falls or the machine may turn over at dangerous working place z Be careful when w...

Страница 30: ...t tire or rear tire z Use speed I when driving on ramp with full load Go forward when drive upward the ramp go backward when drive downward the ramp Do not turn z Brake slowly when driving downward th...

Страница 31: ...t of machine There should not be broken wire wring or radius reduction for tightwire z No people is allowed to go between two machine when connect them z Do not stand on the two steel wires or tightwi...

Страница 32: ...irst to make sure the conditions first and then work z Do not break the working equipment when work in narrow area such as tunnel overbridge garage and etc Examine the ground and clean it first z Oper...

Страница 33: ...vironment and the machine z Make sure the bridge or other builds are strong enough to let the machine to pass z Don t use the machine to do unprofessional works Use the head of working equipment as ot...

Страница 34: ...or reach the highest point because the load may go down suddenly and the speed may increase then z When construct dam or unload soil from cliff form one pile first and push the other to push the one b...

Страница 35: ...high voltage condition electric wire is generally supported by fixed insulator To prevent accident please do the following things z The height distance between loader and the electric wire should be...

Страница 36: ...the ground WARNING NEVER get on or off the machine during driving 7 2 Notice for Cold Area z Clear the water snow or dust attached on wires switches power insert or sensor and the covers of these part...

Страница 37: ...or low quality tools z Low the working equipment completely to the ground close the engine push the parking brake switch and wedge the tire during repair to prevent body hurt z Obey the rule of Warnin...

Страница 38: ...when the bucket is lifting 8 2 Working in Close Area Exhaust gas from engine may cause disease or death If it is necessary to work in close area use releaser to relase the exhaust gas in the area If t...

Страница 39: ...ck and dangerous z Stand on the mudguard of the front frame and seize the handrail to clean the front glass of operator cab 8 6 Maintenance during the Engine Working Do not maintain the machine during...

Страница 40: ...parking brake switch and keep it at brake position z Do not let the water inject to the electric part such as sensor wire connector or operator cab If so the operation may be disabled z Wear protect c...

Страница 41: ...e burn may be caused if open the cover of oil tank radiator after welding pour water or oil immediately after finishing welding because the temperature of hydraulic oil fuel and water in engine oil an...

Страница 42: ...aulic system z Never bend or beat the high pressure hydraulic pipe never assemble the hard pipe and soft pipe bended abnormally or broken z Examine the pipe system carefully hard pipe and soft pipe sc...

Страница 43: ...rated Strictly follow the program in user manual to maintain the storage battery z Make sure there is no flammable materials such as blasted grass old paper and etc near the high temperature parts suc...

Страница 44: ...battery Wash with lot of water to clean the vitriol in the eye or on the cloth go to hospital if hurt severely z Keep fire OFF battery during charging because the oxygen and hydrogen may be generated...

Страница 45: ...program and the program in user manual Do as follows z Constant voltage charge Complementary charge charge 16 hours at 16 0 Voltage max current is less than 25A Normal charge charge 24 hours at 16 0...

Страница 46: ...RAMETER z The temperature raising caused by high speed driving may lead to increasing of the pressure of tire which is the normal phenomenon Never try to reduce the pressure but reduce the speed to co...

Страница 47: ...e on the plane ground and use the wedge to forelock it to prevent it fall down once there may be someone touch the tire without permission The quality may reduce if the tire is put use the side becaus...

Страница 48: ...compact materials Clean the dirt of the tire z Never turn on the slope board If it is necessary turn outside the board and then drive back z Lock the direction mechanism after assembly wedge the tire...

Страница 49: ...o one should be at the operator cab Never lift the machine using steel wire connecting the two hook of front frame It is allowed to lift the machine using 4 steel wires with the same length no short t...

Страница 50: ...GENERAL VIEW OF THE MACHINE COMPONENTS NAME Right Left Front Working Light Front Wheel Lift Arm Cylinder Rear Wheel Lift Arm Rocker Arm Bucket Dump Cylinder Cab Engine Cover Rear Balance Weight Accumu...

Страница 51: ...Operation Maintenance Manual LG968 969Wheel Loader 41 2 GEOMETRICAL DIMENSIONS Figure 2 2 Geometrical dimensions of LG968 969 wheel loader mounted with standard lift arms...

Страница 52: ...Operation Maintenance Manual LG968 969Wheel Loader 42 3 PRODUCT TYPE AND ITS MEANING LG 9 6 8 9 Template is 8 9 Load limit is 6 tons Wheel loader Shandong Lingong...

Страница 53: ...erial No production date and manufacturer of the machine The format of nameplate is shown as figure 2 3 figure 2 4 The other configurations please see 8 TECHNICAL PERFORMANCE PARAMETER in this chapter...

Страница 54: ...WARNING The following operations are forbidden for the loader 1 Over load 2 Bias load 3 Dig hard material 4 Lift heavy material using the rope hang directly on the bucket 5 Dig at the place above the...

Страница 55: ...the oil temperature of hydraulic system enhance the service life of whole machine z A double pump with interflow working hydraulic system is used Unloading valve is used in steering system to realize...

Страница 56: ...s 3 6 s Dumping time empty bucket 1 4s 1 4s Travel speed Forward 1st 0 6 5 km h 0 6 5 km h 2nd 0 11 5 km h 0 11 5 km h 3rd 0 23 km h 0 23 km h 4th 0 36 km h 0 36 km h Reverse 1st 0 6 5 km h 0 6 5 km h...

Страница 57: ...m 3210 mm Height 3380 mm 3380 mm Wheel tread 2190 mm 2204 mm Wheel base 3450 mm 3429 mm Min ground clearance 457 mm 457 mm Max dumping height 45 dumping angle 3250 mm 3250 mm Dumping space 45 dumping...

Страница 58: ...1 1 General Views of Controls and Gauges 1 Steering Wheel 2 Panel 3 Gear Control Lever 4 Brake Pedal 5 Seat 6 Accelerator Pedal 7 Rocket Switch at Right Operation Box 8 Air Condition Control Panel 9...

Страница 59: ...p 19 Warning Button Switch Figure 3 2 General view of gauge 1 2 Introduction of Gauges Controls Following are the introduction of gauges controls needed for operating the machine Be sure to understand...

Страница 60: ...ences of inspection and maintenance z Gearbox Oil Pressure Gauge This gauge indicates the pressure of gear shifting system If the pressure index lies in range 15 17 X100kPa or 21 75 24 65 X10PSI the o...

Страница 61: ...The lamp will be on if the oil pressure is below 0 1MPa Charging Indicator Lamp The lamp will be on if start switch is turned on It will be off immediately after the engine is started Otherwise it mea...

Страница 62: ...mp is on means the coarse fuel filter is jammed seriously please clean or replace Turn Indicator Lamp The lamp will be on and shine if turn on the turn switch which means the turn signal has been send...

Страница 63: ...eater Switch if assembled Press bottom side heater works press top side heater stops When the heater or air condition work adjust the air outlet in the front of gauge panel to adjust wind speed so tha...

Страница 64: ...eel and Steering unit are connected When the machine work fine turn the steering wheel clockwise the machine turn right turn the steering wheel counter clockwise the machine turn left The features are...

Страница 65: ...backward right turning light will be on NOTICE All the turning lights will be on at the same time during operating this switch Please put the switch back manually z Speed Control Lever This lever con...

Страница 66: ...ing efficient of whole machine can be improved greatly Lift Limit Function When the control lever is at lift position lever will be locked by electromagnetism when the lift arm moves to the upper most...

Страница 67: ...tside the cab turn 180 clockwise and pull out key pull the handle outside the cab the cab door will be opened Turn the lock bar upward the door will open 1 2 6 Safety Bar WARNING z Be sure to use the...

Страница 68: ...me corroded or the white powder can be seen or the fuse is loose in the fuse holder please replace the fuse z When replacing the fuse please maintain the same capacity 1 2 9 Air Condition Selectable z...

Страница 69: ...ll stop b Warming Turn the temperature adjust switch to O position shut status Open the valves of water pipe of engine start the engine Turn on wind and power switch2 select wind speed to what you nee...

Страница 70: ...t Adjustment Pull the backrest adjust handle C to push the backrest until to the proper angle and then release handle to lock the angle z Height Adjustment There are three weight positions divided by...

Страница 71: ...crease load step by step so that the parts of machine can be fully adjusted to increase life It needs 60 hours to train the new machine please follow the notices below z Run the machine at low speed l...

Страница 72: ...lectrical machine gauge light and lamps and turning signals 9 Open the air storage tank to drain water The following works should be done after training of new machine 1 Clean the filter net at gearbo...

Страница 73: ...p environment temperature and relative temperature go down So please pay attention to the environment conditions and calculate the real power under the current environment condition according to the p...

Страница 74: ...ine z Put the gear control lever at the left bottom of steering wheel to neutral position z Turn the start key clockwise to the ON position connect the power switch sound the horn z Turn the starting...

Страница 75: ...ke sure there is no other person on the machine or around to prevent accident and the machine is under control z Raise the lift arm keep the bucket backwards and keep running status z Put the gear con...

Страница 76: ...elerograph and operate the transmission lever at the same time when change the speed from low to high when change the speed from high to low release the accelerograph first and then change the transmi...

Страница 77: ...ipment on the ground z Stop the machine at plane ground where there should not be danger of stone falls coast or flood If it is necessary to stop the machine on slope wedge the tire to prevent movemen...

Страница 78: ...heck whether there is overheat z Check rim bolts transmission axis bolt and other pins to see whether they are loose z Add antifreeze if temperature is below 0 and drain the water if no antifreeze see...

Страница 79: ...The smaller the loader work angle is the more work efficient is 2 Digging Operation Digging Piled Soil or Blasted Rock When digging piled soil or blasted rock the loader should face the material and...

Страница 80: ...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 dig...

Страница 81: ...never been planed the camion can not be used z The conveying distance is within 500 meter it is not economical to use camion z The conveying driving speed is determined according to the road conditio...

Страница 82: ...ously When operate the lift arm to lift the or lower operate the control lever between lifting and lowering operating Never let the lever at the raising or lowering position to ensure pushing smoothly...

Страница 83: ...chine z Try to use small towing angle of towing rope to ensure the angle between towing rope and the machine towed is within 30 The height of the towing points of the two machines should be close z Co...

Страница 84: ...Battery to disassemble the battery and put it into hothouse or warm water be attention NEVER let water enter the battery warm it to 15 slowly otherwise explosion may happen 3 Please use anti high and...

Страница 85: ...t transmission lever at neutral N position push the parking brake switch put blocks at front and back of tire z Open the side door at right side of engine cover z Pull the dipstick out and wipe it cle...

Страница 86: ...5L from oil inlet of engine Run the engine at idle status check whether the oil filter and oil releasing plug are leaky z 15 minutes after the engine is stopped let the mobile oil flow back to oil pa...

Страница 87: ...min rotate to loose the oil dipstick of oil inlet at the left side of gearbox stretch it out and clean z Dip the oil dipstick into oil pipe and rotate tightly and then take out at least twice z Oil te...

Страница 88: ...en the cover of oil inlet of gearbox add prescriptive hydraulic transmission oil Rotate the cover back z Start the engine and run at idle status add oil until the oil level is between lower scale and...

Страница 89: ...gine put transmission lever at neutral N position push the parking brake switch wedge the front and rear wheels z Rotate to disassemble the oil drain plugs of two wheels near front axle and the oil dr...

Страница 90: ...oil level drops after several minutes add some more until the oil level reach the prescribed position can keep stable NOTICE Check the oil level every month Examine the oil level especially after new...

Страница 91: ...ndicator is lower than 2 scale please add hydraulic oil Selection of oil please see CHAPTER IV 2 2 Selection of Oil Fuel and Coolant The followings are the same Oil Replacing WARNING If it needs any o...

Страница 92: ...ve clothes and operate carefully to prevent self hurt z Disassemble the flange cover of oil box clean the inner part and the oil inlet port and oil recycle elements if the elements are broken please r...

Страница 93: ...down below 0 drain the coolant out except the one added with antifreeze Please see 3 5 3 Operation in Cold Weather in this chapter z Lower the bucket to the ground set all control levers or handles t...

Страница 94: ...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...

Страница 95: ...l of torque converter overheats 1 Over low oil level in gearbox oil tank 2 Over high oil level in gearbox oil tank 3 Over low shifting pressure and clutch slips 4 T Q radiator is clogged 5 T Q operate...

Страница 96: ...rectangular seal ring 3 Pressure in air storage tank drops quickly after shutting down pressure drop is over 0 1 MPa in 30 min 1 Inlet valve of foot brake valve is clogged by dirt even damage 2 Loose...

Страница 97: ...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 a...

Страница 98: ...l circuits 3 Change seals of hydraulic tanks 4 Replace steering unit 5 Change by the specified oil 3 Inflexible or failure of steering system 1 Damaged spring plate of steering unit 2 Cracked broken o...

Страница 99: ...e engine during maintenance 1 3 Spare Parts z Use only parts specified by the manufacturer of the wheel loaders 1 4 Oil and Fuel z Use oil and fuel specified in this manual according to ambient temper...

Страница 100: ...elding near seal rings and bearings z Never weld any pipe or tube containing fuel or oil 1 12 Fire Prevention z Use inflammable cleaner or light oil to clean parts Keep spark or cigarette light away f...

Страница 101: ...Drain the oil from the machine and fill with the new brand oil 2 CONTENT OF MAINTENANCE 2 1 Outline of Oil Fuel and Coolant WARNING z Because of the bad operation conditions and dusty ambient circumst...

Страница 102: ...see CHAPTER III 3 5 3 Operation in Cold Weather and refill before next working if there is no antifreeze in the coolant z Antifreeze is flammable Keep fire off when the antifreeze is added z Never us...

Страница 103: ...may choose specified oils in the following table Kinds of Fluids Recommended Types And Standards Capacity Using places Engine oil Ambient temperature 15 CD 15W 40 GB11122 Ambient temperature 15 CD 5W...

Страница 104: ...TX30 Rotella DX30 Caltex Delo Gold Multigrade 15W 40 Essolube XT 5 z Hydraulic oil Similar Oil Brands Chinese Brands CALTEX SHELL MOBIL CASTROL ESSO Hydraulic oil L HM46 5 40 GB11118 1 Tellus 27 Tell...

Страница 105: ...90 10 50 Gear oil GX 85W 90 Spirax EP Heavyduty HD90 HD80w 90 z Brake fluid Similar Oil Brands Chinese Brands Grade MOBIL ESSO British BP SHELL Motor vehicle brake fluids HZY3 GB12981 SAE 1703C Super...

Страница 106: ...omponents related to the electric system Check the tension and distress of fan belt Check the fluid level of storage battery z Never remove or disassemble any electric components installed in the mach...

Страница 107: ...Assembling bolts of driven spiral gear and right differential carrier in the main transmission M16 1 5 55 40Cr 280 330 6 Assembling bolts of bearing bracket and carrier in the main transmission M22 1...

Страница 108: ...ce 3 2 Every 50 Hours Week Service Carry out the periodic maintenance of every 10 hours with this maintenance operation at the same time z Check oil level of the gearbox hydraulic oil tank and brake b...

Страница 109: ...ystem Clean the filter mesh of oil bowl in the booster pump Clean the air vent and check the brake fluid Add if deficient and replace if necessary 3 4 Every 500 Hours Season Service Carry out the peri...

Страница 110: ...s with this maintenance operation at the same time z Check performances of the torque converter and gearbox and disassemble them for checking if necessary z Check the sealing performance of multi pass...

Страница 111: ...converter of transmission box transmission axle front and rear driving axle wheel and so on The transmission system theory is shown in the Figure 5 1 1 Input gear 2 KR steering gear 3 Intermediate ge...

Страница 112: ...ating lowering median and lifting to achieve the control of loader s working equipment The hydraulic control system employs hydraulic priority control technique which is handy and flexible to control...

Страница 113: ...valve unload valve and will converge with the oil of working equipment hydraulic system to let working equipment hydraulic system achieve large flow with low pressure working When the system working p...

Страница 114: ...and the brake state relieves 3 3 Emergency and Parking Brake System This system employs the electronic control air driving inner expand hoof type brake system During running gently rotate the operati...

Страница 115: ...iority control system buckle auto level system appliance switch lamps air condition circuit and other electric instruments The system of this machine employs D C 24V voltage negative electrode and sin...

Страница 116: ...Operation Maintenance Manual LG968 969Wheel Loader 106...

Страница 117: ...Operation Maintenance Manual LG968 969Wheel Loader 1 Figure5 4 LG968 969 Electric System Theory...

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