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Operation & Maintenance Manual

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LG918 Wheel Loader

103

3 BRAKE SYSTEM

Brake system is used when the machine decelerates, stops or for long-term parking on the level

ground or slight incline. The brake system of this machine is composed of a driving brake system 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 Pedal Braking Diagram

1-Air

booster pump

2-Shuttle valve 3- Air brake valve

4-Air tank

5-Combination valve of oil water Separator

6-Air compressor

7-Brake electromagnetic valve

8-Parking brake air chamber

Figure 5-5 Double Brake Pedals Braking Diagram

Содержание SDLG 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 Maintenance Manual LG918 WHEEL LOADER SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD ...

Страница 2: ...230 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 8785698 Website www sdlg cn Services Tel 8008607999 4006587999 0539 8785800 Services Fax 86 0539 8785671 ...

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 APPLICATION 51 1 BE FAMILIAR WITH MACHINE 51 2 RUN IN PERIOD OF NEW MACHINE 66 3 OPERATION AND USE OF LOADER 67 CHAPTER Ⅳ MAINTENANCE 90 1 MAINTENANCE GUIDE 90 2 DETAILED RULES OF MAINTENANCE 91 3 CON...

Страница 4: ...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...

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 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 descrip...

Страница 6: ...ed 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 is u...

Страница 7: ...HE 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 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...

Страница 8: ...ated 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 before entering dangerous areas 3 Limit position of lift arm 4 Danger of lift arm Located on both sides of lift arm Located on both sides of lift arms Located on the steering position of front and re...

Страница 9: ...high 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 Located on the hydraulic oil tank Located on outside of operator cab left door Located on the fuel oil tank maintains Sitting allowed only in cab s loading while in operation Precaution ...

Страница 10: ...the 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 engine hood 15 Notice of hot water Located on the cover of engine water tank ...

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

Страница 12: ...on 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 cab Located on the steering position of front and rear frames 5 Danger of serious injury during steering Located on both sides of actuating arm Lock the lift arm cylinder before it enter dangerous zon...

Страница 13: ...t 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 steam or hot water ejection 11 Notice of hot water Located on cover of water tank of engine hood ...

Страница 14: ...5 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 Warning of machine reversing Located on both sides of engine hood 35 ...

Страница 15: ...sonal 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 operator cab 16 Warning of high voltage 17 Wearing seat belt warning 18 Warning to avoid noise ...

Страница 16: ...ft 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 upright column of the operator cab 22 Notice of required reading manual 19 No passenger warning Located on the inner left back upright column of the operator cab ...

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 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 parki...

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 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 shou...

Страница 19: ...ely 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 water leaks air leaks deformation loose fittings and abnormal sounds or accidents may occur Check the safety devices routinely 3 2 When Leaving Operator s Seat z Always keep the parking brake switch in...

Страница 20: ...nto 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 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 ...

Страница 21: ...Clean the repaired items before use z If there is explosive air generated near the storage battery be sure there is no flame or fire nearby Repair maintain and use the storage battery as referenced in users manual z Do not use flame or fire match or lighter to check in a dark place z The fire extinguisher should be ready for use at all times and the user must be knowledgeable about its use and fun...

Страница 22: ...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 tank as su...

Страница 23: ...e 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 pedestrians z In the places where objects are buried such as water pipes gas pipes or high voltage...

Страница 24: ...y 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 lever or control handle or switch or move the control lever or control handle which c...

Страница 25: ...ed 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 speed in the ...

Страница 26: ...ure 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 The...

Страница 27: ...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...

Страница 28: ...he 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 visibility is not good stop working until the weather cleans z The loader is a s...

Страница 29: ...und 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 vibration may cause the ground to collapse and result in the machine turning over z Assemble anti fall and anti turn operator cab when working in an area where there is danger of falling stone and...

Страница 30: ...es 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 around z Brake slowly when driving down the ramp do not set the gearshift control lever in the position of the neutral gear z Go down the ramp slowly never ...

Страница 31: ...ht 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 steel wires or tightwires z Keep the hook of the towing machine and the towing parts in a horizontal line 6 SAFETY OPERATION 6 1 Keep Good Operation Habits z Always be seated with the safety belt locked...

Страница 32: ...he 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 Be careful when the lift arm reaches the upper limit Loading in the upper limit position may cause destabilization of loader So the driving speed should be slow and the bucket should tilt forward slo...

Страница 33: ...nment 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 the parts or cause an accident when using the head of the working equipment for other fuctions such as hook grasp draw push or tow 6 2 Pay Attention to Surroundings z No unauthorized person is allowed ...

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 enough air when operating dealing with fuel cleaning parts or painting in close or badly ventilated environments to prevent bodily injury If this can not satisfy the need please assemble aerator z Prepare...

Страница 35: ...l 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 z First ask the electricity company for the voltage Check the validity of action according to the relevent rules when the machine may touch the electric cables z Wear rubber shoes and rubber gloves L...

Страница 36: ...ts 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 sensor and the covers of these parts Otherwise the water in these parts may be frozen and an unpredictable accident may be caused z Before operation preheat sufficiently The machine won t start if do no...

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 prevent bodily injury z Obey the rules of warning labels Pay attention to the important notices on the label on the machine and obey the rules Add a new one or clean the label if it is lost or dirty ...

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 enter the other side of the frame z Before jacking up lock the front and rear frames with a safety bar and put all the levers or handles in the middle and wedge the tire from the opposite side Put th...

Страница 39: ...drail 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 please follow the rules below z Assign an operator to sit on the seat to ensure all the maintenance people can have contact with him so he can prepare to shut the engine when requested z Never touch a...

Страница 40: ...t 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 protect clothes and glasses when using compressed air to clean the filter mesh 8 9 Heavy Materials z Wear protect clothes safety glasses and safety helmet and put a copper bar between the hammer and the p...

Страница 41: ...r 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 avoid hot water ejecting from the radiator stop the engine let the hot water cool and open the cover slowly to release the pressure Never touch the radiator Check the air temperature in front of the ra...

Страница 42: ...nd 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 proper torque Do not examine a leak using your hand rather use a board or paper board The leaking hydraulic liquid may penetrate your skin and cause death If the liquid splash onto your skin the case of...

Страница 43: ...h 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 repair z Check the wire to see whether it is breakage and voltage leakage if so replace it or repair it z Use inflammable liquid to clean the parts do not use gasoline or other flammable materials z Nev...

Страница 44: ...event circuit from shorting z Keep fire away from the crust on the battery because it is flammable z Store the battery under dry clean and well ventilated circumstances with temperatures between 5 25 Prevent sun light irradiation Keep the battery 2m away from a heat source The battery will be affected by high temperature z Never reverse and put horizontally Prevent damage by too much pressure z Th...

Страница 45: ...ith the negative pole of the storage battery and then connect the negative pole of the charging machine with the positive pole of the storage battery Never reverse z Examine the vent of the battery to prevent blockage otherwise it may explode z Lower the charging voltage or current if the electrolytes are over 45 to prevent spurt out of electrolytes due to high temperatures z Never overcharge duri...

Страница 46: ...of the tire and stand as far as possible away from the tire when adjusting the pressure of the tire z Check the tire and rim every day for cracks or bubbles Never operate in a low pressure condition z Check that the bolt and nut of the rim are in place Check whether the torque of the nut satisfies the suggested value of the factory z Never stand in the front or the rear of the rolling direction of...

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 Assemble and Disassemble the Machine z 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...

Страница 48: ...their 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 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 us...

Страница 49: ...lowed 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 tire and bind the machine tightly to prevent movement during transportation ...

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: ...LATE The nameplate is fixed on the left rear side of the front frame describing the model serial No production date and manufacturer of the machine The type of nameplate is shown in Fig 2 3 and Fig 2 4 The other configurations of nameplate refer to CHAPTER II 8 TECHNICAL PERFORMANCE PARAMETERS Figure 2 3 Nameplate of LG918 basic configuration loader ...

Страница 53: ...d ports It can be used for dragging to flatten the ground piling and stacking of bulk soil sand sand stone coal and garbage It can chuck wood fork grass clean snow and chuck box liked material with proper work equipment Please refer to CHAPTER III 3 5 Operations for details WARNING The following operations are forbidden for the loader 1 Over loading 2 Unbalanced 3 Digging hard material 4 Lifting h...

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 driving axle uses mature technology and has good performance big loading power long use life and high reliability z The single stage three element torque convertors can utilize the power of the engine f...

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 rear wheel 4546 mm 4546 mm Level passing radius outside of bucket 5082 mm 5150 mm Max turning angle 35 35 Tire charge pressure Front wheel 0 33 0 35 MPa 0 33 0 35 MPa Rear wheel 0 27 0 29 MPa 0 27 0 ...

Страница 56: ...in 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 Standard and License Product Standard Q LGJ 001 wheel loader ...

Страница 57: ...arking 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 3 Speed Change Control Lever 4 Brake Pedal one for left and right side 5 Accelerator Pedal 6 Seat 7 Parking Brake switch 8 Equipment Control Lever 9 Switch Group 10 Starting Switch 11 Horn Button Fi...

Страница 58: ...ning 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 Indicator 7 Right Turn Indicator Lamp 8 Fuel Level Gauge 9 Engine Water Temperature Gauge 10 Torque Converter Oil Temperature Gauge 11 Starting Switch 12 Switch Group 13 Water Spraying Switch 14 Rain wip...

Страница 59: ...perature 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 an...

Страница 60: ...re 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 ...

Страница 61: ...own 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 Parking Brake Indicator Lamp If the brake air pressure is normal the lamp will come on when the parking brake switch is pushed down The lamp will go off when the parking brake switch springs back the lamp...

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 Gauge Figure 3 1 in this chapter z Switch Group if assembled Refer to 1 1 Control System and the Gauge Figure 3 2 in this chapter The switch controls lighting high and low beam and steering light Lighti...

Страница 63: ...ed 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 panel Adjust wind outlet to clean the frost and blow the warm cool wind z Rain wiper Switch Press bottom side rain wiper will work press top side the rain wiper will stop z Front Headlight Switch Pres...

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 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 Assembly Operation Manual 1 2 3 Steering ...

Страница 65: ...et 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 Reverse gear Low speed Forward Gear Ⅰ Neutral Reverse Gear Ⅰ Neutral Neutral Neutral Neutral High speed Forward Gear Ⅱ Neutral Reverse Gear Ⅱ z Working Device Control Lever or Handle 1 Working device co...

Страница 66: ...to 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 used for moving freely under applied force Notice Never put the lift arm down when it is in the floating position Bucket Control Handle Move the control handle from left to right to control the front ti...

Страница 67: ...on 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 from the floating position it returns to the neutral position automatically to increase the efficient of the whole vehicle z Parking Brake Control Lever This switch is on the left side of the seat in th...

Страница 68: ...right 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 Locking Bar WARNING z Be sure to use the front and rear frame locking bar during maintenance or transporting the machine z Be sure to release the frame locking bar during routine travel z The frame loc...

Страница 69: ... positions 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 compressor starts working for the refrigeration of air conditioning Turn the air volume and power switch 2 to select different gear to obtain three different volume of air Turn the temperature control swi...

Страница 70: ...r 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 temperature control switch to the state of off open the hot water valve the air volume and power switch warm air blow constantly Turn the air volume and power switch to obtain low middle and high volu...

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 Adjustment This handle is on the left bottom side of the seat Pull the fore and aft handle and move the seat forward or backward to the desired position it will lock automatically after pushing it down z ...

Страница 72: ...on 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 fa...

Страница 73: ...ing 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 z After the lift arm and bucket are moving to the required position release the control valve lever to the middle position z Change the forward o...

Страница 74: ...e 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 whether they are sensitive and in the neutral position 11 Adjust the seat position to sit comfortably Please refer to 1 2 10 Adjustment of Cab s Seat in this chapter 12 Check the ...

Страница 75: ...ay 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 hydraulic tank and pipes so that way the hydraulic parts can warm quickly z Keep the engine at an idle speed for several m...

Страница 76: ...g 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 accelerator properly when shifting gear to avoid sharp speed increase z It is best to change the running direction from forward to backward or from backward to forward after stopping the machine to get...

Страница 77: ...eps to Stop z Release the accelerator and press the brake pedal to stop the machine Put the gear control lever in the neutral position z After safely stopping push the parking brake switch to lock the machine in place z Level the bucket and other work equipment to the ground z Stop the machine on the level ground where there is no danger of stone falling coasting or flooding If it is necessary to ...

Страница 78: ...erter steering unit fixing of front and rear frame and sealing conditions And check whether there are overheating conditions z Check whether the rim bolts transmission axis bolts and other pins are loose z Add antifreeze if the temperature is below 0 drain the water out if there is no antifreeze Refer to 3 5 3 Operation in Cold Weather in this chapter z Check whether the work equipment is in good ...

Страница 79: ...ection 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 Operation Digging Piled Soil or Blasted Rock When digging piled soil or blasted rock the loader should face the material and do as follows z If the bucket must be lowered while driving the machine f...

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 must be dumped and titled quickly to remove the excessive load so as to prevent the material from dispersing during transportation Digging and Shoveling Material on Flat Ground Lightly set the bucket e...

Страница 81: ...onnection 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 forward tilt to the maximum position where the bucket does not touch the carriage or material pole And operate working equipment control lever to tilt the bucket forward to dump Part or all of the mat...

Страница 82: ...ear 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 but not for towing z If there is no braking system for the towed machine never use soft towing but use fixed towing or use towing bar Connect the towing bar to the towing pin at the back of the loade...

Страница 83: ...arest 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 transportation 3 5 3 Operation in Cold Weather Attention for cold weather If the temperature is very low the engine will be difficult to start And the radiator may be frozen so please do as follows z Use ...

Страница 84: ...k 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 obviously go down in cold weather So cover it or move the storage battery to a warm place and install it the next day 4 When the temperature is below 0 and there is no antifreeze in coolant water please open...

Страница 85: ...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 parking brake switch and put the blocks in the front and back of the tires Start the engine and run at idle status until the oil temperature reaches 20 40 then stop the engine z Rotate the oil drain plug and let the oil flow out and hold it in a container Change...

Страница 86: ...element 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 add fuel from inlet on the fuel tank For fuel selection please refer to CHAPTER IV 2 2 Selection of Oil Fuel and Coolant 3 6 3 Adding Oil to Gearbox Oil Level Check z Park the machine on level ground ...

Страница 87: ...l 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 relatively high please wear protective clothes and operate carefully to prevent injury z Drain all the oil out and clean the oil on the draining plug the sealing surface of the shell and the gearbox F...

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 side of the oil inlet otherwise please add axle oil Please watch for 5 minutes after adding oil If the oil level keeps stable please assemble the plug For selections of axle oil please refer to CHAPT...

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 the rear axle gear oil according to the procedures above 3 6 5 Adding Oil to Hydraulic Oil Box Oil Level Check z Park the machine on level ground and lower the bucket to the ground Check whether the...

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 flange cover of the oil box top and clean the oil inlet port the oil recycle port and the oil recycle elements If the elements are broken please replace with a new one z Tighten the flange cover and...

Страница 91: ...drain 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 Neutral position Press the parking brake switch and lock the cab door 3 7 2 During Storage WARNING Open doors and windows to ensure ventilation and exhaust to allow of poisonous gas if the antirust is us...

Страница 92: ...rting 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 motor disengages before engine starts 1 Faulty cable 2 Insufficient battery charge 1 Check and repair 2 Charge 3 8 2 Transmission System No Problems Possible Causes Remedy 1 Shifting pressure of every g...

Страница 93: ...he 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 of T Q 3 Damaged T Q blades 4 Damaged overrunning clutch 5 Insufficient driving force of engine 1 Refer to problems 1 and 2 2 Refer to problems 3 3 Disassemble and check the torque converter change b...

Страница 94: ...ssage 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 safety valves 7 Clogged suction tube and filter 1 Change the oil seals of cylinder 2 Change the distribution valve 3 Find out the leaking points and repair 4 Change the oil pump 5 Check oil lines and reme...

Страница 95: ...l circuits 3 Change seals of hydraulic tanks 4 Replace steering unit 5 Change by the specified oil 3 Inflexible or failure of steering system 1 Damaged spring plate of steering unit 2 Cracked broken or deformed centre pin and drive shaft 3 Faulty dual overload valve 4 Scuffed rotor and stator scuffed valve spool valve body and sleeve 5 Faulty in steering pump or piloted valve 1 Change the damaged ...

Страница 96: ... 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...

Страница 97: ...h 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 in rain and snow Lubricate and coat anti rust oil to other parts 1 17 Dusty Circumstances Do the following when the machine works in dusty circumstances z Inspect and clean air filter frequently to a...

Страница 98: ...r 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 Use clean and soft water rain or tap water as coolant Well water and spring water can be used as coolant after soft processing and precipitation to avoid causing scale which can influence the performan...

Страница 99: ...in 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 important equipment and causing problems Replace all filters periodically For the maintenance cycle refer to 3 CONTENT OF MAINTENANCE in this chapter Replace filters at shorter intervals when the mach...

Страница 100: ...light 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 oil cup Grease 2 or 3 lithium based grease GB7324 2 8kg Pins in every joint points of the work equipment Antifreeze Engine coolant of glycol type SH0521 Radiator 2 2 2 Reference Table of Foreign and ...

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 GL5 EP 90 Titan Gear LS90 Mobil Gear oil HD80W 90 20 40 Automobile Gear oil HD85W 90 10 50 Gear oil GX 85W 90 Spirax EP Heavyduty HD90 HD80w 90 z Brake fluid Similar Oil Brands Chinese Brands Grade M...

Страница 102: ...c 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 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...

Страница 103: ...60 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 periodic maintenance of every 10 50 250 500 1000 and 2000 hours 3 1 Every 10 Hours Days Service z Check the sealing performance of work equipment systems such as hydraulic steering and brake system z C...

Страница 104: ...onth 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 coat Vaseline lamina z Check whether assembling bolts of frames are loose and welding seams are cracked z Check whether the front and rear axles engine and gearbox and frame are loose z Check the tire p...

Страница 105: ...ace 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 booster pump Clean the air vent and replace the brake fluid z Check if there is leakage in the hydraulic system Check and clean the air vent of hydraulic reservoir Clean the hydraulic reservoir Repla...

Страница 106: ...quirements 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 increase the maintenance times according to the real conditions 3 8 Replace the air storage tank after 3 years of service ...

Страница 107: ...n 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 Transmission Shaft Figure 5 1 LG918 Transmission System Diagram 2 HYDRAULIC SYSTEM As shown in Figure 5 2 Figure 5 3 the hydraulic system includes the working equipment hydraulic system and steering hydraulic ...

Страница 108: ...ector 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 Respirator 7 Pressure option valve 8 Steering and speed changing pump 9 Pilot filter 10 Priority Valve 11 Redirector 12 Redirector cylinder 13 Pilot valve Figure 5 3 LG918 Hydraulic System Diagram pilot con...

Страница 109: ...system 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 Pedal Braking Diagram 1 Air booster pump 2 Shuttle valve 3 Air brake valve 4 Air tank 5 Combination valve of oil water Separator 6 Air compressor 7 Brake electromagnetic valve 8 Parking brake air cha...

Страница 110: ...pushes 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 driv...

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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