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5. Torque Converter Oil Engine Water Gearbox 0i1 Middle Relay Lift Arm Middle Relay Bucket Vorking Chronometer Revolution Indicator 7 ture 6 o o Rear Headlight Switch high low Front Lighting Lamp Switch Rear Lighting Lamp Switch Front Rain Wiper Switch Water S
6. Fuel Level Gauge Vorking Chronometer Revolution Indicator Torque Converter Oil Engine Water Brake Air Pressure Gauge Temperature Gauge Pressure Gauge Gearbox 0il ec Middle Relay Lift Arm Middle Relay Bucket Panel Viring Gro n
7. 0 Quick Changing Buzzer 27 Rear Headlight Switch high low Front Lighting Lamp Switch Rear Lighting Lamp Switch Front Rain Wiper Switch Water Spraying Switch Ressetable Warning Lamp Switch Switch Group l ing Swi h 1 1 Pos 115 Starting Switch reri a dua nel B 8 que i 1 T o Plug n 3 o d m ERA 0 in mpm o d dj da tU 42 Floating Magnetic Valve Die Oo Lo 6 o 63 a START 9 d o o 7 42 O N Bucket Magnetic Valve als ie A eB E 43 Hed af a e 62 zmX 5 19 pt Lift Arm Magnetic Valve i j i E Overtaking Light o o 80 Emergency i Bngine 0i O Steering Del l Comphbor Box Front Headlight low Fro
8. Working Timi i Revolution Vil Temperature Gauge Engine Water Oil Pressure Gauge of m z Rear Headlight high low Front Lighting Rear Lighting IM Sprayer Rocker Fuel Gauge a mig Taing Drake UC NOH US EE of Turque Converter Nepote Gauge Cearbor Dashboard Disk Wiring Assembly Middle Relay Lift Arm Middle Relay Bucket Switch Switch Switch Front Rain Wiper Switch Switch Resettable Varning Lamp Switch Combination Switch auge Cauge d Starting Switch Toy White ey D bois 1 3 7 2 4 8 br a s 2 6 bee i 5 2 6 pos 1 3 5 7 2 4 6 8 Pee 1 52 6 Pree a slale poo ale G tt I follo oFF o o o ol o Reset oto ele orr o o or o o DRE g B 3 Tyr Off P i HEELS DUE EE PE 0 latin Solenoid OFF le a I e eto I ete eie L lolo ote I e oo I ete ete og ojo Left Turningo 9 ol 4 a 4 4 2 4 d De Qe I eje ojo wo Ze I ere yo yo ON Oo o Right Turning o o Fo o e iet Solenoid T cket Solenoi dl Oe uA a pM uA pu Qu 2 9 Rear Lamp o o e os lt O4 o TOA daga sl dida se NA didAi sa data ss a i sl el T Es La g Vf in as sae cp 45 252 33 53 s d o o 80 i i i i Solenoid Valve 1 3 1 t Overtakidgo 7 0 Front Headlight lo
9. 86 85 les le 1 e 2 29 o Quick Changin Magnetic he p gg 172 1275 vehicle type are DC24V NN OD 0 81 3 3 Start Machine n OO o4 yop uick Changing Buzzer 97 Figure5 8 LG918 Electric System Diagram with Yangma engine Export type 107
10. COMPONENTS NAME Cab Engine Hood Scoop Cylinder Lift Arm Rock Arm F B B REAR su A RIGHT Front Wheel Bucket Rear Wheel Figure 2 1 General view and components name of LG918 wheel loader 44 Operation amp Maintenance Manual LG918 Wheel Loader 2 GEOMETRICAL DIMENSIONS 4144 3199 UE s EL LLLI Figure 2 2 Geometrical dimensions of LG918 wheel loader mounted with standard lift arms 45 Operation amp Maintenance Manual LG918 Wheel Loader 3 PRODUCT TYPE AND ITS MEANING LG 9 18 Load limit is 1 8 ton Wheel loader Shandong Lingong 4 NAMEPLATE 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 1s shown in Fig 2 3 and Fig 2 4 The other configurations of nameplate refer to CHAPTER II 8 TECHNICAL PERFORMANCE amp PARAMETERS E 2 A P n ae LOY is IA SDLG MRE EE 18000 N lhe 6200 kg RATED LOAD OPERATING WEIGH KH LAS VELIS WB RS HUE S YCA108G AHORA o K NGINE MODEI RATED POWER AE R H Ky ey E Bp do E PR RX BT98x2140x2920 mm ES 26 5 km h JIMENSIONS LxWxH HIGHEST SPEED NO DATE Kk O c UR LLER RAR AD SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD PENA IMA 0 6 76 Fe Bl LL ECONOMIC DEVELOPMENT PARK LINYI SHANDONG P R CHINA
11. fo Figure 2 3 Nameplate of LG918 basic configuration loader 46 Operation amp Maintenance Manual LG918 Wheel Loader LOIL HARAN LG918 WHEEL LOADER 16000 N Lethe 6250 kg OPERATING WEIGHT AAA AGREE AA RATED POWER REFER TO ENGINE REFER TO ENGINE 6068x2140x2920 m mm 26 5 km h HIGHEST SPEED WPR 0 j Uk i LL wh ak ag SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD PE ARAM EUR lah 257671 Ax KT T Id ECONOMIC DEVELOPMENT PARK LINY SHANDONG P R CHINA Figure 2 4 Nameplate of LG918 wheel loader mounted with long lift arms 5 USE CONDITIONS This loader is a multi purpose large construction machine mainly used for bulk materials It is widely used in mineral yards construction roads freight 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 with proper work equipment Please refer to CHAPTER III 3 5 Operations for details The following operations are forbidden for the loader 1 Over loading Unbalanced Digging hard material Lifting heavy material using a rope hung directly on the bucket Dig with the bucket above the machine level 47 Operation amp Maintenance Manual LG918 Wheel Loader 6 CIRCUMSTANCES REQUIREMENT Requirements for this machine as follows l Altitude 500m 2 Tem
12. rope and the towed machine 1s within 30 The height of the towing points of the two machines should be close The connection between the towing equipment and the machine should be strong The weight of the towing machine should be heavier than the towed one and have enough traction power and braking power to be able to pull or brake two vehicles going up and down a slope When towing the machine down a slope the machine should have sufficient traction power and braking power Another towing machine should be used to pull at the back side to prevent the towed machine from losing control or turning over Start to tow and brake gently at the low speed and turn on the warning flash lamp The speed for towing the loader should be within 10 km h Try to tow the machine to the nearest repairing garage If the distance 1s 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 1s very low the engine will be difficult to start And the radiator may be frozen so please do as follows Use fuel with low viscosity and add antifreeze into the hydraulic oil and lubricant and coolant Refer to CHAPTER IV 2 2 1 Selection Table of Fuel Coolant and Lubricant for the details of using oil Attentions for using antifreeze l
13. 0 33 0 35 MPa 0 27 0 29 MPa 5798 mm 2040 mm 2140 mm 2920 mm 1630 mm 2260 mm Long lift arm 1 0 m 1600 kg lt 4 8 s lt 3 2 s lt 1 1s 0 10 km h 0 26 5 km h 0 9 6 km h 0 25 km h 56 kN 56 kN 30 kN 30 4546 mm 5150 mm 359 0 33 0 35 MPa 0 27 0 29 MPa 6068 mm 2040 mm 2140 mm 2920 mm 1630 mm 2260 mm Operation amp Maintenance Manual LG918 Wheel Loader Min 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 50 Operation amp Maintenance Manual LG918 Wheel Loader CHAPTER III OPERATION AND APPLICATION 1 BE FAMILIAR WITH MACHINE 1 1 Control Systems and Gauges A Ig 1 Panel 2 High and Low Speed Control Lever 3 Fore and aft Gear Control Lever 4 Steering Wheel 5 Brake Pedal 6 Accelerator Pedal 7 Parking 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 E mua i i a a 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 Figure 3 2 General
14. 15 Personal safety range Located on both sides of engine hood AR DANGER e Hazardous moving amp rotating parts e Can cause severe personal injury e DO NOT enter working range with machine in operation 7 S 16 Warning of high voltage Located on the left back upright column in inner operator cab BEWARE verhead wires Underground service equipment 17 Wearing seat belt warning 18 Warning to avoid noise Located on the inner left back upright Located on the inner left back column of the operator cab upright column of the operator cab Ay WARNING Seatbelts AD WARNING Implements may Increase noise must be level Hearing protection must Worn be worn Operation amp Maintenance Manual LG918 Wheel Loader 19 No passenger warning Located on the inner left back upright column of the operator cab WARNING 20 Check before starting Located on the inner left back upright column of the operator cab C N a B WARNING IT I THE RESPONSIBILITY DRIVER ONLY strictly NO passengers OF THE OPERATOR TO HECK AIR PRESSURE mm CHECK OIL LEVELS DAILY GREASE DAILY CHECK FUEL DAILY 21 ROPS amp FOPS anti roll cab used in Located on the inner right back upright column of the operator cab in Shandong Lingong Construction Machinery C
15. 79 Operation amp Maintenance Manual LG918 Wheel Loader 3 Engine oil Filter Replacement Disassemble O Clean the area near the engine oil filter Disassemble it with filter elements spanner Assemble Refer to the explanation on the filter for fitting method After changing the filter elements the engine must run in the idle status at least 1 minute to ensure the engine is lubricated sufficiently before working Over tight mechanical rotation could damage the screw thread or filter element sealing 3 6 2 Adding Fuel to Fuel Tank Fuel Level Check O 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 D Oil Level Check O Park the machine on level ground and put the transmission lever in the neutral N position Pull the parking brake switch and wedge the front tire Start engine and let the engine run in the idle status for 5 minutes Loosen the oil checking plug to check the oil level The oil level should not be lower the oil checking 80 Operation amp Maintenance Manual LG918 Wheel Loader plug If the oil level 1s lower than the oil checking plug hydraulic transmission oil should be added The choice of the hydraulic tr
16. SHANDONG LINGONG GLG Member of Volvo s Group Operation amp Maintenance Manual LG918 WHEEL LOADER N WARNING Operators and maintenance persons should read this manual carefully and 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 SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Operation amp Maintenance Manual LG918 Wheel Loader LG918 WHEEL LOADER Operation amp Maintenance Manual 880x1230 mm 167 6 25pieces 4th Edition in 2008 9 and 2nd Printin 2009 8 SHANDONG LINGONG CONSTRUCTION MACHINERY CO LID 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 Table of Contents PREPACE tal sia I SAFE FY INFORMATION utm i aa ee ED E ee IH GHAPTER ES ARETES l SAFETY LABELPOSITONSAND THE CONTENT Dia a a eeednceion tes l A A ree Peer nma Eam DE a M e M dM Uren e UE 11 SAFETY OPERATION A teta 13 POLARNO AA aa 17 JOA EY DRIVING iorra dE di 20 ivy Und OP ERAN ondas 2 do ALLI PARKIN G s iet sce ree tesis nete aeuo taste racio dh that ish NEA Seder veau deben dde 30 S SAFETY EXAMINATION ANDO REPARA 3l DP SARE TY TRANS POR TATION IE UE A at ect ME 41 CHAPTERITTINTRODUC TION tn A A A A E a aE 44 1 GENER
17. This is the engine start position Keep the key at this position during starting After the engine has started immediately pull out the key or 1t will return to ON position automatically 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 o 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 Lighting When the starting switch is in the ON position the high beam of front headlight is lightened if the switch group turns to OFF and put it up the head lamp tail light and back light is lightened if the switch group turns to the position of D gt or ED Control of high and low light When the starting switch 1s in the ON position the low beam of front headlight 1s lightened 1f the switch group turns to the position of v The high beam of front headlight is lightened when the switch is put down Control of turning lamp The left turning lamp is lightened when the switch is put forward and the right turning lamp is 56 Operation amp Maintenance Manual LG918 Wheel Loader lightened when the switch 1s put backward Notice The turn indicator lamp is lightened when operate the switch After the operation of turning finished please put back
18. 5 iie 4 i fnm Svitch Start Chain 0 0 0 91 19 t o 31130 60 Brown Right Lamp Group CN14 151 3 H 6 34 ken bd o1 10 10 1 lo 3 go 1 1 i 11 10 10 0 Connected With Storage Battery Cathode O 2 20 O 4 40 11 11 8 Energency Turning Valve are peg f A Wo eta i 04 40 o 5 6 1 X te 1019 no LOTT TOS 5o 30 o 7 70 30 30 e we 96 69 oy port 1o i 3 Fuel Level Sensor 2 ly yo 2 Reverse Switch 19 4 64 83 AE 10 10 65 oL 65 n wem MN CNL3 85 11 11 85 2 Fuel Prefiltration Indicator Switch o o Left Lamp Group T 86 12 12 MET t 2 t Lo 20 11 14 14 O Fuel Feed Pump BT l 0 Q0 t 93 i Tu 1 0 Bm Off Val m a imer ine 0i i o4 4013 EUN 2 W alve 0 Brine Engine Oil Pressure Switch O5 5o se C0108 15 MV 31 tH 63 es t sl R a pus Ms 60 E 6a 4 A 0 61 Proximity Switch Lift Arm EE Pose 15 B AN Parking Brake Indicator Switch o Red 0 1 2 E 2c o do S p 13 z s Heater Relay 29 D 0 E lt gt N gite S 304 amp 4 Lo 4 od Heater 2 d Mellow 42 lo 4 jo 42 T 29 Y AN 7 64 64 Bos i h 8 Rid b Proximity Switch Bucket O3 J 3 se Red fio 4 4018 ___ Storage Battery AS 403 Y Si psc BS Cy af Lo 1 A ot Yellow T h o R 3 604 B 57 o 73 2 EC n 1 Ca equ 1 f ement S Power Switch Storage Battery Relay 24 Start Relay 85 m A 1 B DA Quick Changing Magnetic Valve N Ni o o r o d d TAN ML A i All the electric appliances of this ips M AO
19. Located on the inner right front Located on the inner left front glass glass the operator cab of the operator cab NOTICE O Driver musthaveformal driving license and uses and maintains the machine according to the user manuale O Inspect and prepare everything before starting maching eLook around to be sure whether there is any person or barrier O The temperature of engine water should be above 55 C oil temperature should be N NOTICE O Mever get on or off the machine during driving Sitting allowed only in cab Buckles or other working equipments should hold the material in balance never lean to one side too much e Mever run at high speed after loading e Decrease the speed before steering Never turn or brake suddenly e ever drive at high speed when it snows or above 45 C and air pressure should be above 0 45MPa otherwise the machine will not be able to run at speed or full load However the temperature of engine water should not be above 95 C and oil temperature should not be above 120 rains Never steer on slope O Pay attention to the gauges never drive closeto fire Pull the parking brake handle and block the wheels with wedges e Hever inspect or maintain while in operation 12 Notice for fuel oil tank Located on the fuel oil tank 11 Notice for high temperature Located on vent pipe of engine hood Warning High temperature Precaution FUEL TANK Rec
20. amp Maintenance Manual LG918 Wheel Loader WARNING The wrong operation maintenance and repair could result in injury or death An operator should read this manual carefully before operation or maintenance Never attempt to operate maintain or repair the machine before reading and understanding this manual The operation specifications and precautions given in the manual only apply to intended uses of the machine If the machine 1s used for any unintended purpose that is not specifically prohibited ensure the safety of yourself and others before using Any operation and actions which are in conflict with the description in this manual are prohibited II Operation amp Maintenance Manual LG918 Wheel Loader SAFETY INFORMATION Operators should know and obey the safety criteria described in national and local laws If there is no such national or local criteria please follow the rules described in this manual Most accidents are caused by the failure to follow fundamental safety regulations for the operation and maintenance of machines To avoid accidents please read understand and follow all precautions and warnings in this manual about the machine before performing any operation or maintenance Safety precautions are specified in SAFETY of Chapter I Safety information described in this manual cannot include safety precautions for every circumstance that might involve a potential hazard in operation and maintenance
21. and then connect the negative pole of the storage battery with the positive pole of the machine Put the battery on the shaft using the upside fixing method or downside fixing method to prevent destruction caused by loosening There 1s an indicator on the cover of the battery The green light means it can be used the black 38 Operation amp Maintenance Manual LG918 Wheel Loader light means 1t should be charged and the white light means 1t should be replaced Replace with a new battery after the white light indicator Routinely recharge the battery 1f the battery lacks electric power during use to prevent the capability of battery sulfate going down If the battery is installed disassemble it and put it in a dry and well ventilated place if it is not used for long time generally more than 15 days Recharge the battery every 3 6 months based on whether the indicator 1s black or not 8 17 Charging of Storage Battery Explosion may occur if the storage batteries are charged in the wrong way So follow the storage battery instructions in this user manual Do as follows Charge with constant voltage is recommended gt Complementary charge charge 16 hours at 16 0 Voltage max current is less than 25A gt Normal charge charge 24 hours at 16 0 Voltage max current is less than 25A Connect the positive pole of the charging machine with the negative pole of the storage battery and then connect the negative pole of the c
22. 49 49 Defroster ailsli Top Lamp 4 9 5 4 4 olo 148 35 35 I EIE Quick Changing Switch l 4 4 50 50 y olo 1 ale II 65 65 65 al 1 BNS Replaceable O 6 6 O L Dr 41 31 31 64 64 64 EA Radio or CD Q 24 24 4 60 60 nd pom ESEGNN 3 151 025 16 16 76 as o FS z UN a xA Sprayer Machine jo o 10 19 0 26 18 38 38 4 3 lo q got 5 n n ida 3 Frist Rain Wi on no t 4 4 4 o1 130 5 85 85 85 i co M i oM J Mo s 86 m 2 87 87 87 81 d Buttons land 2 10 10 10 ey 11 11 11 1N4007 3 13 8 40 t t ol o 31 Gearbox Pressure Sensor 8 40 ol 20 17 Horn Button M Parking Brake Switch 13 ay T Lol E Brake Air Pressure Sensor nx no T i 18 G ae 1 arnes mesure rele asg summus sss lo o o 4 o N3 oo 6005656656065 66 12 3 4 5 6 7 8 9 10 11 12 13 M cNi CN 1 1 CHS 123 4 5 6 7 8 9 10 11 12 13 M 12345678 902 12 13 14 4 4 Rear Headlight Rear Headlight License Lam Tail Li t Tail L werse Buzzi 12345 678 9 1011 12 13 14 Horn Group 0990909909009 0900 0 D OH Mado V7 oo 00000000000 sje SRASVssasisissia e ze wo ese S S oe ES eS El CN16 N17 N23 CN18 uy H N21 z SI aaa S 2 S lt S S Engine Water Temperature Sensor H 66 0 600 o 0600000 660000 6 14 M Te 123 123 12 123456 1234546 12 AR aL eran ID 0113 13 3 12 113456 113456 11 s Converter Oil Temperature Sensor N15 9 9 o0 9 9 000000 999990 o 0 2 Isi d dd da esas Sees Ja T p 3 Q2 4
23. Good Visibility 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 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 The loader is a special vehicle Drive carefully when taking long parts which may block the visibility Carefully lift go forward and backward and shift gears Never let unauthorized people go into the working area or give specific directions There may be some illusion about the height of the ground and the distance at night so keep the light on and drive at proper speed Keep the front and rear head light and working light on when working in dark areas 5 6 Pay Attention to Blockages If there are blockages roof of buildings or the door frame keep the loader away from the blockages when turning or passing 22 Operation amp Maintenance Manual LG918 Wheel Loader 5 7 Driving in Dangerous Conditions Notice the environment Slow down and check whether there are some blockages when turning or going through a narrow passageway Operate carefully to prevent unstable loads when the ground is uneven and the load is not stable Do not operate when you are unsure about the environment Investigate the condition of the road the strength of the bridge landform of the working area and all geologic
24. LG918 Wheel Loader Brake Air Pressure Gauge This gauge indicates the air pressure of the brake system lt gt Ifthe pressure index lies in the green range 0 4MPa 0 8MPa the oil pressure is normal Be sure to stop the machine for inspection if the index moves outside this range lt gt Ifthe pressure index lies in the range of 4 8 x100kPa or 5 8 11 6 x 10PSI the oil pressure is normal Be sure to stop the machine for inspection if the index moves outside this range Fuel Level Gauge if assembled This gauge indicates the ratio of remaining fuel level in the fuel tank to the volume of tank Revolution Indicator if assembled This gauge indicates the rotating speed of engine Indicator Lamp The indicator lamp is located on the gauge panel Refer to 1 1 Control Systems and Gauges Figure3 3 and 3 4 in this chapter Pre h cal Engine Oil Charge Power Cut Emergency Indicator Pressure Indicator Indicator Steering Indicator Lamp Warnes Lamp Lamp Lamp Lamp ees mS elole e dues ng Ars Low Brake 41 Far Beam Computer Fuel L rarus Pressure Indicator Workin g Prefiltration amp Warne Lamp Lamp ase Exe Indicator Lamp 54 Operation amp Maintenance Manual LG918 Wheel Loader Pre heat Indicator Lamp The lamp will come on if start switch is turned to preheat position when machine is equipped with cold start equipment the lamp will be off 1f start switch is turned to ot
25. Wheel Loader the same time Check and adjust the clearance of hand brake system Check the wear condition of brake discs and friction discs Replace them if necessary O Clean the silencer of the braking electromagnetic valve In addition do the extra maintenance in the first 500 hours as follows Check if there is leakage in the hydraulic system Check and clean the air vent of hydraulic reservoir Replace the filter cartridge of oil return filter and pilot filter Cif assembled Check the quantity and cleanness of hydraulic oil Filter the oil if possible Add them 1f deficient and replace them 1f necessary Check if there is leakage in the brake system Clean the filter mesh of the oil bowl in the booster pump Clean the air vent and replace the brake fluid 3 5 Every 1000 Hours Half a Year Service Carry out the periodic maintenance of every 10 50 250 and 500 hours with this maintenance operation at the same time O Clean the oil pan of gearbox Clean the air vent of gearbox Replace the suction filter cartridge in the oil pan of gearbox Replace the filter cartridge in the oil lines of torque converter gearbox Replace the gearbox oil Change the gear oil in the front and rear axles Check and clean the filter mesh of the oil bowl in the booster pump Clean the air vent and replace the brake fluid O Check if there is leakage in the hydraulic system Check and clean the air vent of hydraulic reservoir Clea
26. a O Keep the bucket horizontal when loading the stockpile Stacking Rock but keep the dumping angle down when loading the 73 Operation amp Maintenance Manual LG918 Wheel Loader blasted rock Notice Do not let the blasted rock go under the bucket which will make the front tires leave from the ground and slip Try to hold the load in the center of the bucket otherwise 1f the load 1s on one side of the bucket 1t will be unbalanced O Raise the lift 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 If enough material is loaded into the bucket operate the working equipment control lever to take back the bucket in order to load it fully Remark If the shovel edge moves up and down when thrusting material into the bucket or when digging the front tires will leave the ground and slip O 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 B Digging and Shoveling Material on Flat Ground Lightly set the bucket edge leaning on the ground see picture when digging and shoveling material on flat ground Be careful not to fasten the load to one side which will cause unbalance This operation should be carried out carefully in gear Lightly set the bucket edge f
27. and full Flameout Control speed Flameout Control Soft Knot This soft knot is on the cover of the heater which on the right side of the seat Pull this knot and keep for several seconds P will put out an engine flame 61 Operation amp Maintenance Manual LG918 Wheel Loader 1 2 5 Cab Door Locking Bar O Inside Cab Locking Bar When the lock of the cab is in the locked positions the door will be locked automatically after closing the door Insert key outside the cab Turn 180 clockwise and pull out key Pull the handle outside the cab and the cab door will open Turn the lock bar upward and 1t will open Outside Cab Locking Bar Open the left and 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 n Outside Cab Lock Bar Be sure to use the front and rear frame locking bar during maintenance or transporting the machine Be sure to release the frame locking bar during routine travel The frame locking bar is used to lock the front and rear frames during maintenance or transporting vehicles in order to prevent the frames from moving 1 2 7 Towing Pin During towing insert the towing pin D into the counterweight 2 1 2 8 Fuse 62 Operation amp Maintenance Manual LG918 Wheel Loader N NOTICE O Always be sure to close the startup switch b
28. electric circuit is correct and the electric components are normal Check the oil level in the oil tank and the water level in the water tank Add grease to the fan shaft jointed point between front and rear frames driving axles jointed points of oscillating frame and joint points of work equipment Check if there are other abnormalities Refer to Operation and Maintenance Manual of diesel engine for maintenance 3 2 Every 50 Hours Week Service 97 Operation amp Maintenance Manual LG918 Wheel Loader Carry out the periodic maintenance of every 10 hours with this maintenance operation at the same time Check oil level of the gearbox hydraulic oil tank and brake booster pump Tighten all connection bolts of transmission axles Check whether all connection bolts of hubs and the brake caliper are loose Check all connection bolts of teeth for tightening Check and lubricate the accelerator control parking brake and gearshift control system In addition do the extra maintenance in the first 50 hours as follows Check and clean the air vent of the gearbox Check and clean the filter cartridge of the oil line system of the torque converter gearbox Check if there is leakage in the hydraulic system Check and clean the air vent of the hydraulic reservoir Check the oil return filter cartridge of the hydraulic reservoir Check 1f there 1s leakage in the brake system Clean the filter mesh of the oil bowl
29. explosion Wear protective clothes during welding Keep the welding area ventilated Clean up the flammable materials and check the fire extinguisher Never do any modifications which may affect the performance safety and strength capability of the vehicle and the working equipment 8 11 Maintenance of Coolant System Severe burn may be caused if the cover of the oil tank and the radiator are opened after welding so pour water or oil on the cover of the oil tank immediately after finishing welding The temperature and pressure of hydraulic oil fuel and water 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 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 radiator to gauge the temperature To avoid hot oil 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 radiator to gauge the temperature While the machine is warming up do not touch engine silencer tail pipe or relay to prevent burn While the machine is warming up do not disassemble the water heat sensor of the engine oil heat sensor of
30. hook of the front and rear frame to transport the A direction Never bind like this machine to ship or train select proper lifting equipment according to the weight of the loader otherwise it 1s dangerous to surpass the weight limit Notices for lifting Make sure the loader is in the transporting state The front and rear frame should be in the middle position Lock the machine using the lock bar to prevent rotation of the front and rear frame during lifting All the 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 the machine using steel wire connecting the two hooks on the front frame It is allowed to lift the machine using 4 steel wires of the same length no shorter than 7m Keep the machine horizontal during lifting 9 999 999 Prevent damage to hood operator cab and hydraulic pipes 42 Operation amp Maintenance Manual LG918 Wheel Loader No person or car is allowed to pass under the machine during lifting Draw back the lock bar to turn the machine after lifting 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 43 Operation amp Maintenance Manual LG918 Wheel Loader CHAPTER II INTRODUCTION 1 GENERAL VIEW OF THE MACHINE
31. immediately required N NOTICE Please replace these parts in the following conditions Connectors are broken or leaking Outside of soft pipe is abrasive or cracked and the steel wire of the strengthening layer 1s bare Local of soft pip 1s upheaval Soft pipe 1s obviously torqued or staved Steel wire of strengthening layer penetrates the outside layer The end connectors are misplaced O Make sure all the pipe clamps protective board and anti heat cover are installed properly to prevent vibration and overheating due to friction with other parts 36 Operation amp Maintenance Manual LG918 Wheel Loader Choose proper container to hold liquid when replacing the hydraulic oil of the hydraulic system and when cleaning the parts Please refer to 8 20 Waste Materials in this chapter for the methods to deal with waste liquid 8 13 Preventing Fire O Stop the engine before adding fuel Do not smoke and keep fire away while adding fuel Keep fire away from the storage place of fuel grease or other flammable materials O Clean the flammable substances on the machine such as fuel grease oily cloth or other flammable materials O Keep fire away from the storage battery because explosive gas may be generated Strictly follow the program in this user manual to maintain the storage battery O Make sure there are no flammable materials such as dry grass and old paper near the high temperature par
32. it as referenced in users manual Never operate machine near flame or fire Do not short circuit 3 5 Precautions When Operating at High Temperature Just after turning off the engine the coolant engine oil and hydraulic oil are at high temperature and still under high pressure The attempt to remove the cap drain the oil or water or replace filters may lead to serious burns Always wait for the temperature to go down and follow the specified procedures when performing these operations Stop the engine wait for the water to become cool and then loosen the cap slowly to relieve the inner pressure before removing the cap of radiator a 15 Operation amp Maintenance Manual LG918 Wheel Loader 3 6 Visibility Requirements O Pay attention to the stability of the front and rear of the machine during operation since work equipment may block vision at the front while the load is concentrated on the back wheels Be sure there is no fog soot sand or dust cloud that may block vision Examine the working area and the road condition Check whether there are holes blockages slosh or ice Understand the objective of the operation be sure to understand the meaning of the flags signals and labels before the operation begins Set 3 6 3 7 Prevent Crushing or Cutting Body Parts Do not put your hand arm or other parts of your body into movable parts of equipment If the working equipment is in operation the cl
33. let impurities enter when changing and adding fuel Strictly choose the fuel brand according to this manual The fuel may be frozen at low temperatures particularly temperatures lower than 15 C So it is necessary to change the kind of fuel according to the ambient temperature Always fill the fuel tank full after operating to prevent the water which 1s condensed by the moisture in the air from entering the fuel tank 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 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 performance of dispelling the heat If the engine overheats add coolant until the engine cools down completely Add coolant to specified level If the level 1s too low it will cause the overheating of the engine system and the corrosion of the cooling system Add antifreeze to coolant if ambient temperature is lower than 0 C Drain the coolant out after working please refer to CHAPTER III 3 5 3 Operation in Cold Weather and refill oil before next working if there 1s no antifreeze in the coolant Antifreeze is flammable Keep fire away when adding the antifreeze Never use 100 antifreeze as coolant Refer to the following table to select the mixing proportion 92 Operation amp Maintenance Manual LG9
34. machine run m rampway Operation amp Maintenance Manual LG918 Wheel Loader 12 Antifreeze fluid Cif sticking Located on the left operator cab door and mouse of radiator of engine hood If coolant 35 has been added Coolant 35 has been added in the machine Notice lt che coolant 13 elycol E engine cooling Liquor Please act according to the circumstance and the illustration hen reinfusing atherviae the tfect will be reduced Selection rengt 15 advised as below 158 is used wiha temperature of 2 15 C 5415 used WEF temperature nf 3 250 iz 13 weed wiha leperarura of 2 55 C iy M 13 No fire warning Located on fuel tank If coolant 45 has been added Coolant 45 has been added in the machine e Notice the coolant is glycol engine cooling liquor e Please do according to the circumstance and the illustration when reinfusing otherwise the effect will be reduced e Selecting range is advised as below 25 is used in the temperature of 2 15 C 35 is used in the temperature of 2 25C 45 is used in the temperature of 2 35C SN AX DANGER Risk of Battery Explosion NO Smoking sparks or Flames Y 14 Warning of machine reversing Located on both sides of engine hood DANGER VEHICLE FREQUENTLY REVERS ING Operation amp Maintenance Manual LG918 Wheel Loader
35. repair the loose Lamp is not bright when the engine 1 hich d problem or open terminals and disconnections TUDS AC DIEN Speed circuit 2 Refer to the Operation and 2 Improper adjustment Maintenance Manual of diesel Lamp flickers when the engine is of fan belt tension engine to adjust the tension of fan 2 running belt Faulty alternator 1 Replace Faulty cable 2 Check and repair Improper adjustment 3 Refer to Operation and A meter does not work when of belt tension Maintenance Manual of diesel 3 engine is running engine for adjusting the tension of fan belt Abnormal noise from alternator Faulty alternator 1 Faulty cable 1 Check and repair Do not start when starting switch is 2 Insufficient battery 2 Charge turned on charge Pinion of starting motor does not mesh or keep meshing without Faulty battery charge rotation Insufficient battery 1 Charge 7 Starting motor turns feebly charge 2 Replace Faulty alternator Faulty cable 1 Check and repair Starting motor disengages before 2 Insufficient battery 2 Charge engine starts charge 3 8 2 Transmission System Low oil level in gearbox oil sump Oil leakage in the main oil lines Add oil to the specified level Clogged oil filter of gearbox Check the main oil lines Faulty converter charging pump Clean or replace the filter Shifting Improper adjustment of the Disassemble and check the converter pressure of pressure regulator valve in transmission charging p
36. scale 6 of the middle scale please add hydraulic oil Refer to CHAPTER IV 2 2 Selection of Oil Fuel and Coolant 2 Oil Replacement While replacing oil if other maintenance needs to be done do so following the relevant rules and pay attention to safety Pay attention to the clarity of the oil while replacing it never let other materials enter the hydraulic system directly 83 Operation amp Maintenance Manual LG918 Wheel Loader Clean out the in bucket Park the machine on level Boil Return amp 9 0il Obsarbing ground and put the transmission lever in the neutral Flange Co ub EN lange EE F 0 0 7 1 1 position Pull the braking control lever Start the engine and keep in the idle status for 10 minutes Raise and lower the lift arm several times and tilt the bucket forward and backward several times Raise the lift arm to the highest position tilt the Oil Adding Air ChangingFilter e Port Cover bucket backwards to the extreme position and shut the ya Level Gauge engine 2 Push the bucket control lever forward to let the bucket tilt forward freely by its weight Drain out the oil in the bucket cylinder After the bucket has tilted to the desired position push the lift arm control lever forward to let the lift arm fall down by its weight freely Drain out the oil in the lift arm cylinder The temperature of hydraulic oil may be high so wear protective clothes and o
37. the neutral position 68 Operation amp Maintenance Manual LG918 Wheel Loader Turn the start key clockwise to the ON position Connect the power switch and ring the horn Turn the starting key to the ON position Connect the power switch and press the accelerator slowly Then turn to the START position After releasing the starting key 1t will go back to the ON position automatically The starting time 1s not more than 5 10 seconds the engine starting effort not be more than 15 seconds Try again if the machine does not start the first time But the alternation time should be more than 1 minute If the engine does not start after these tries please check the machine and solve the problem 3 2 3 After Starting of Engine Lower the speed of the engine and examine the reason if engine oil pressure gauge is not in the normal position in more than 10 seconds After that start again otherwise there may be some problem 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 O 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 O 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 attent
38. the switch by your hand Rocker switch The rocker switch is on left front side of the cab top or on right control box When the start switch is at ON position the unit heater rain wiper front headlight front lighting lamp warming lamp back lighting lamp and rear headlight will be controlled separately by this switch Front Warning Front Lighting Indicator Back am Headlight Lamp Lamp Light Headight Unit Rain Heater Wiper Unit Heater Switch if assembled 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 O Rain wiper Switch Press bottom side rain wiper will work press top side the rain wiper will stop Front Headlight Switch Press bottom side the low beam of the front headlight and all back lights will come on Press top side high beam of the front headlight and all back lights will come on If no side is pressed no lamp will come on Front Light Lamp Switch Press bottom side and the front light lamp on the top of cab will come on press top side and the lamp will go off Warning Lamp Switch 57 Operation amp Maintenance Manual LG918 Wheel Loader Notice Turn 1t off during driving When this button 1s pushed down all the turning lamps will blink for an emergenc
39. vertical distance between loader and the overhead electric wire should be At least 2m 6 5ft at low voltage condition At least 4m 13 ft at high voltage condition To prevent an accident please do as follows 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 Wear rubber shoes and rubber gloves Lay a leather cushion over the operator s shoes Be sure no part of your body can touch the metal bottom Assign a signal warner who can give a warning when the machine gets too close to electric cables 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 When operating near high voltage cables make sure other persons are far from the machine 29 Operation amp Maintenance Manual LG918 Wheel Loader 7 SAFETY PARKING 7 1 Pay Attention to the Safety of Yourself and Others Park the machine on level ground The working equipment should be put on the ground Never park on a ramp If parking on a ramp 1s necessary the ramp angle should be less than 20 and put the wedge under the wheels to prevent moving Then put the bucket down to the ground If the machine is disabled or must park in a high traffic area lay bars signals flags and warning lights Make sure the other cars can see it clearly Do
40. 14 10 11 12 13 14 l Rear Headlight Rear Headlight License La z t Tail L 5 verse Buzzgr 34 9 10 11 12 13 14 Horn Group 0 01 09 O O AX 0 00 3 OO O 00 E 9 0 900000 meu E sam us 5 ad N23 N19 N21 E Tm Engine Water Temperature Sensor 000 o Oo O O O 14 iu 2 123 2 3456 12134546 1 gt 23 123 12 3 4 6 123456 1 Torque Converter Oil Temperature Sensor CN15 OO 000 9 o Oo 90 o 000000 o 15 N eN 5 o I e c 3 e oof A e e e 4 1 Proximity Switch Start Chain 0 0 o 2 0 gt 19 o 3 60 Brom 4 3 Right Lamp Group CN14 20 M Black o1 1o 3 ott 1 o 20 40 10 E Brake Air Pressure Sensor Qo 1 al xi 0 ae 30 32 Y bs 4 699 9 B 18 C ud Y SE fo go Reverse Switch j Ho 9o n Cearbox Pressure Sensor 10 17 d Nds Left Lamp Group N13 1 Fuel Level Sensor 91 Io 19 N o 1o gt 09 o3 3o o4 40 Engine o iia Switch 93 50 4 W a os so l 3 Proximity Switch Lift Arm Parking Brake Indicator Switch P o Red 13 Leo 0 E lt gt que e Yellow roximity Switch Bucket 2 Start Relay o Red E lt gt N Blue Storage Battery fellow s Fuse f i Technical Requirements 4r 4 zu uu Quick Changing Magnetic Valve 60A 0 gt Rel ERA 7 All the electric appliances of this Storage Battery Helay Quick Changing Magnetic Valve NE e L 86 86 vehicle type are DC24V 106 Figure5 7 LG918 Electric System Diagram with Yuchai engine Export type Operati
41. 18 Wheel Loader Freezing Name Glycol Proportion in Antifreeze volume Alcohol Glycerin Antifreeze 2 1 3 Lubricant Lubricant is used to reduce noise and prevent wear on the joint surfaces Joints not included in the manual connectors jointing sleeves are treated during overhaul So they do not need be lubricated When some parts become inflexible because of long term operation it 1s necessary to add lubricant O Remember to wipe off the overflow lubricant when adding it 2 1 4 The Storage of Oil and Fuel O Prevent water dirt or other impurities from mixing with the oil O Follow the rule first in first out to maintain oil quality during long term storage Use the oil with the longest shell life 2 1 5 Filters O 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 machine works in a severely bad environment Never try to clean paper filter elements and use them again Always replace them with a new one When replacing the oil filters check whether there are some metallic particles adhering to the old filter If some metal particles are found consult the maintenance people Never open the packs of new filters until they are used Always use authoriz
42. AL VIEW OF THE MACHINE amp COMPONENTS NAME seen 44 2 GEOMETRICAL DIMENSIONS oirlo dorar 45 gt PRODUCTIXPBEANDITS MBPANIN ista 46 NAMEPLATE roen EE E E E dde do lcd 46 SUSE CONDITION S einen a a E E 47 6 CIRCUMSTANCES REQUIREMEN La 48 EE LATURES rm 48 S TECHNICAL PERFORMANCE amp PARCAMETE Russian 49 CHAPTERITOPERATION AND APPELLATION td id 51 l BE EAXNIEFAR WITILNDAGLIENE lt A A eet 5 2 RUNSIN BERIOD OF NEW MACHINE zie ioa oo E o o t o Eon DEBE 66 3 OPERATION AND USE OF LOADER AAA 67 CHAPTER IV MAINTENANCE iii 90 MAINTENANCE GUIDE M 90 2 DETAILED RUEES 0PMAINTEN ANO E oarenien iiaii RA A AAA a outiu de 91 3 CONTENTO MAIN TE NAN OB css 97 CHAPTER V THE STRUCTURE AND PRICIPLE OF MAIN COMPONENTS AND SYSTEM 101 UTRAN MIS SION SYSTEM IS ooi nd peas cate cae mes eio edt iat SSSI AED P UU IE IDEA E 101 Z HYDRAULICS Y STEM oa 101 J BRAKE Y IMA x2 dni decors sincerest ead A eumdem es E E 103 A IGE CARI SST Mana tope tecti tendat de thtasssediaudedisq dude 104 Operation amp Maintenance Manual LG918 Wheel Loader PREFACE Thank you for purchasing the wheel loader produced by Shandong Lingong This manual is a guideline for users to operate and maintain this machine properly Keep this manual within easy access and have all relevant people read it before use If this manual is lost damaged or cannot be read contact our company or our dealers If you sell the machine be sure to give this manual to the new o
43. AMINATION AND REPAIR 8 1 General Knowledge Operation and maintenance people should be trained to become the licensed Do not allow anyone to enter ARA ar A A the working area except the maintenance people If necessary please assign people to guard The repair of the machine should follow the procedures Ask the Shandong Lingong Construction Machinery Co Ltd for help if you don t know how to do the repair Assure that the people who are responsible for repairs who decide the working procedures who determine the person in charge and repair the machine have been trained to assemble and disassemble the parts step by step Please wear a uniform with a tight wristband and trousers Always wear safety glasses Please use the repair tools correctly do not use broken or low quality tools 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 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 Attach the label of No Operation or other warning label to the switches or control board during repairs Never let other people operate or start the engine to prevent injury or death Fuel mobile oil grease and an oily cloth are dangerous materials which should be kept away
44. Do not use antifreeze containing formaldehyde ethanol or propanol 2 Never use any waterproofing agent independently or together with antifreeze 3 Never use antifreeze with different trademarks together 4 Replace antifreeze with the proper ratio according to the requirements Please refer to CHAPTER IV 2 1 2 Coolant Keep away from fire when adding antifreeze Attentions for using the storage battery 77 Operation amp Maintenance Manual LG918 Wheel Loader 3 If the temperature goes down the capacity of the storage battery will go down too If the charging ratio of the storage battery 1s low the electrolytes may be frozen Please ensure the charging ratio 1s near 100 and try to preserve heat so that 1t 1s easy to start the next day If the storage battery 1s frozen never charge the battery or start the engine Refer to CHAPTER I 8 16 Maintenance of Storage Battery to disassemble the battery and put it into a hothouse or warm water NEVER let water enter the battery Warm it to 15 C slowly otherwise an explosion may occur Please use an anti alpine storage battery in an anti alpine area Follow up after every working day In order to prevent the materials from freezing on the machine which may affect it working the next day please do as follows l Completely clean the silt and water on the machine to prevent silt water or snow entering the sealed parts which may freeze or break the sealed par
45. FETY DRIVING 5 Warning The warning light should be turned on to warn the other drivers on the road when the machine is broken down or operating at a low speed 5 2 Safety of self and others Develop good driving habits to ensure everyone s safety Sound the horn to ensure safety before moving Be sure there are no people or blockage on the left and right side Check the brakes on dry and firm level ground Do not put an arm or foot on the working equipment or extend outside the machine When driving on the level ground adjust the lower hinge of the arm working equipment to 400 500mm 16 201n above the ground O Always warn people near the machine in all direction by sounding the horn O The door of the cab should be locked when driving Do not open the door while driving It is dangerous to pick up other people No one should sit on the machine body 20 Operation amp Maintenance Manual LG918 Wheel Loader Never use the bucket as a people carrier Follow the traffic rules on the common roads Pass the crossing road quickly and do not block the road Drive on the side of the road and let the other vehicles go first Keep a proper distance from others Brake immediately and stop when the engine flameouts O Steering unit does not work when engine stops O Emergency brake could hurt people e It is dangerous to shift from forward to backward gear at
46. Machinery Co Ltd or the sellers before making modifications The company assumes no responsibility for any injury or damage caused by unauthorized modifications 12 Operation amp Maintenance Manual LG918 Wheel Loader 3 SAFETY OPERATION 3 1 Be Familiar with Machine O Study the operation manual for the machine Learn the structure of the machine operation and maintenance Be familiar with the positions and functions of the buttons operation handles meters and warning devices O Know all the rules in operation understand the gestures of signaling staff O If there is any oil near the operating positions that can cause slippage clean 1t immediately 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 1s 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 O Always keep the parking brake switch in the lock position Level the working equipment completely to the ground and put the gear control lever and working equipment control handle in the neutral position then stop the engine and turn off the starting switch Set the stop block on the front and rear wheels if necessary 13 Operation amp Maintenance Manual LG918 Wheel Loader
47. Make sure the loader is locked and put the key in a safe place 3 3 Mounting and Dismounting Check the handrails and pedals and if there is oil lubricant or dirt clean them first to prevent slippage Repair the broken items and fasten the loose nuts Never jump on or off the machine Never get on or off a moving machine When getting on or off the machine face the machine and use the handrails and pedals to ensure that you can support yourself Keep at least three point contact two hands one foot or two feet one hand with the handrails and pedals to ensure body stability Never hold any control levers when getting on or off the machine Never get into the operator cab from the ladder at the back of machine or get off from the wheel at the side of operator cab 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 hydraulic system hydraulic pressure shafting oil and gear oil for transmission system brake fluid and antifreeze fluid for heat elimination system Observe the following Keep fire away from flammable fluids Add refueling and lubricating oil in well ventilated areas Stop the engine and no smoking while refueling Tighten all fuel and oil tank caps firmly Put the abov
48. NCE 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 or handles to the Neutral position o o Draw up the parking brake handle to set the loader in the parking brake state O Put blocks in the front and back of wheels o 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 C to 40 C If it is lower t
49. SUm e eo W e oo eo e eo co e a e ee gt iva we S so SS mao ku E 80 3 07 3 MESI 4 daa a aca J La 0 0 d i 56066060 boo A 82 4 123456789 Low Pressure Alarm Emergency Steering Alarm 20 81 c c 18 12345 678 9 43 9 0000000 55 15 gala o E E EEES 3 LJ F 32 52 Energency Steering Switch Ressetable 49 30 Lug 1 5 2 6 s n ARA Fuse Box 13 0 4 z I o eie Flashing Amber C 150W e O 7 IO O O SS 21 21 B L 33 A 10A 104 1204 10A SA 20A 104 20A 10A 204 20A 1204 20A 104 20A 30A 20A 104 104 204 E 0 AA Reserve Socket i LE 3 Cab Wiring Group ae i e o 0 o 0 s g agaaa a S s s e m 3233S 3 e uu ett 2 els elgg ela af sl Sl al zs sl el el g 000000000000 6606000000666 _ Security Locking Switch Locked tt an ca ossi ed A ha E E Ts CG 123456739Hun zsa4s tusumupn locking Ring Unit Heater 0 Magnetic Psx 1 T Cleplacestie Unit Heater Switch Front Lighting Lamp 41 1234567890 12 1234567829101 Soldados es Valve I efe ret 1 5 2 6 45 Oo o 9 9 o 9 o Oo 0 9 Oo Qo 9 iz OOo O 9 I H OFF ame all L a ll E ala la a slo 7 I EHE 1 1 e 36 RA 1 2 zh 21 Air Conditidn al E Pa oa La 41 5 En oilo E ak H p lo po 0 0 0 i 4 S RARA n La bd d d Top Warning Lamp 30 y 30 If Asseabled E t ki X CN9 31 43 4 4 f a X 5 1l 1935 80 80 i i M o 2 19 M 36 4 36 36 Defrosting Switch Locked o Hal alos E 21
50. Therefore if procedures or actions which are not recommended in this manual are used the safety of the operator and machine must be confirmed Otherwise consult us or the dealers The safety precautions for operation and maintenance in this manual only apply to those conditions specified 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 used in safety messages and on safety labels where there is a high possibility of serious injury or death if the hazard is not avoided These safety messages or labels usually describe precautions that must be taken to avoid the hazard Failure to avoid this hazard may also result in serious damage to the machine AX WARNING This word is used in safety messages and on safety labels where there is a potentially dangerous situation Failure to avoid this hazard may also result in serious injury or death Failure to avoid this hazard may also result in serious damage to the machine NNOTICE This word is used in safety messages and on safety labels for the hazards that could result in minor or moderate injury if the hazard is not avoided This word is u
51. acing down When driving the machine forward operate the working equipment control lever to let the lift arm lower down to the proper position so that 1t can pick up a thin layer of 74 o o o o o o 9 o 9 9 s ipjea 9 8 Operation amp Maintenance Manual LG918 Wheel Loader 3 the surface each time when excavating the soil When driving the machine forward shift the working equipment control lever backward and forward slightly to reduce the resistance Keep the two sides of the bucket cutting into the material equally to prevent only a single side working Face the loader forward and never let an angle exist between the front and rear frame Conveying Operation Without Truck The loader must be used without a truck under the following conditions 4 5 Level the bucket to the ground and push the accelerator to move forward If there 1s blockage during moving raise the lift arm a little and move forward continuously When operating the lift arm to lift or lower operate the The ground is too soft and not level and the truck can not be used When the transportation distance is within 500 meters it is not economical to use a truck The transportation driving speed is determined by the road condition In order to get good visibility and stability the bucket should be turned to its upper limit location bucket lift arm touch the upper limited block and keep the lower pin connectio
52. ake switch and safety belt 1f assembled Never remove any safety devices Always keep them in good operating condition Improper use of safety devices could result in serious body injury are even death 11 Operation amp Maintenance Manual LG918 Wheel Loader 2 3 Protective Items Wear protective items such as helmet made of hard materials safety glasses shoes mask reflector protective vest earplugs heavy gloves when the machine is in operation or being maintained Make sure to wear a helmet made of hard materials safety glasses and heavy gloves if there are scattered metal chips or other minute particles in the operation particularly when cleaning the filter elements of the air cleaner with compressed air and be sure that there 1s no one near the machine 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 Avoid wearing oily clothes because they are flammable 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 All the protective items should be routinely examined for proper function before use 2 4 Unauthorized Modification Any modification without the companies authorization may result in serious personal danger Please consult Shandong Lingong Construction
53. al As shown in Figure 5 4 this system is the single line air pushing oil four wheels caliper disk brake system When the brake pedal 1s stepped on during driving the compressed air in air tank 3 flows through air brake valve 2 into the air chamber of the air booster pump 1 The compressed air pushes the piston of the booster pump to change the oil pressure 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 Release the brake pedal and the compressed air of the booster pump drains from the brake valve to the atmosphere and the brake 1s released 3 2 Driving Brake System Double Brake Pedals As shown in Figure 5 5 this system is the double brake pedals air pushing oil four wheels caliper disk brake system using two brake calipers for front and back to increase the safety of whole vehicle When the left brake pedal 1s stepped on during driving the compressed air in air tank 4 flows through air brake valve 3 and shuttle valve 2 into the air chamber of the air booster pump 1 The compressed air 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
54. ansmission oil can be found in CHAPTER IV 2 2 Selection of Oil Fuel and Coolant 2 New Oil Replacement Park the machine on level ground and put the transmission lever in the neutral N position Push the parking brake switch and wedge the front tire The gear box is at the working temperature Loosen the oil drain plug on the bottom right of the gearbox to drain the oil 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 Adding Port of the Transmission Oil Transmission Oil If the temperature of the gearbox oil is relatively high please wear protective clothes and operate carefully to prevent injury Drain all the oil out and clean the oil on the draining plug the sealing surface of the shell and the gearbox Fit it well Loosen the oil inlet cover on the right side of the gear box which is on the right joint Inject the new hydraulic transmission oil start the engine and run in the idle status The oil level should be higher than the oil checking plug Move the gears through each position one time Check the oil level again and add oil if needed 81 Operation amp Maintenance Manual LG918 Wheel Loader O Ifthe old oil is dirty do not add new oil directly Disassemble the raw oil filter which is in profile and clean all the parts If there are any metal powders or fragments please contact th
55. bled the left one should not be used 3 3 2 Gearshift Changing between Forward and Backward O Press the accelerator properly when shifting gear to avoid sharp speed increase O tis best to change the running direction from forward to backward or from backward to forward after stopping the machine to get the best driver comfort and prolonging the life of the engine O No need to stop and brake the machine to shift gears while running Release the accelerator and operate the transmission lever at the same time when changing the speed from low to high and when changing the speed from high to low release the accelerator first and then change the transmission slowly 3 3 3 Turning O Turn the steering wheel to the desired direction The machine will turn O The machine takes the articulated pin at the center And the front and rear frames turn by rotating its waist 70 Operation amp Maintenance Manual LG918 Wheel Loader Never turn suddenly or turn on a slope at high speed When driving straight the machine can not turn if the engine stops 3 4 Braking Never put your foot on the brake pedal unless necessary Never press the brake pedal again and again unless necessary Never try to stop the engine and put the high low speed control lever and the fore and aft control level in the neutral position while driving down sloping ground Never use the control lever of the manual brake switch to brake or sl
56. bucket tend to lower down or float up Hydraulic oil mixing into gearbox Foam in hydraulic oil tank and harsh noise Inlet valve of foot brake valve is clogged by dirt as damaged Loose pipe fitting or broken pipes Poor sealing performance of check valve in combination valve of oil water separator Loose pipe fitting Abnormal work of air compressor Inlet valve or diaphragm of brake valve is not sealed The bleed hole of pressure controlled valve is clogged or the diaphragm of check valve leaks air Over worn or damaged cylinders Over worn multi passage valve excessive clearance between valve spool and valve block Oil leakage of oil lines Severe internal leakage of working pump Idle suction of working pump Low set pressure value of safety valves Clogged suction tube and filter Damaged seal ring of steering cylinder piston Over worn of multi passage valve excessive clearance between valve spool and valve block Low set pressure value of safety valves Overload valve and oil complementary valve 1s blocked by dirt Aged or broken oil seals of working pump or steering pump lead to the hydraulic oil leaking into the gearbox Suction oil line is damaged and air is sucked into oil lines Low oil level and large amount of air 1s sucked into oil lines 88 Operation amp Maintenance Manual LG918 Wheel Loader Brake continuously several times to blow the dirt off or change valve Tighten the pipe fitting or chan
57. chine Shandong Lingong Construction Machinery Co Ltd assumes no responsibility for any injury accident or destruction of the machine induced by using unauthorized attachments 4 STARTING SAFEL Y 4 1 Before Starting Engine 4 1 1 Safety Operation at Working Area Before starting operations thoroughly inspect the area for any unusual conditions that could be dangerous Examine the condition of the ground and the quality of the soil in the work area and determine the proper method of operation Before starting work the ground should be planed and pressed firmly If there is a lot of sand and dust sprinkle with water first 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 In the places where objects are buried such as water pipes gas pipes or high voltage cables contact the responsible companies to confirm the position of the buried objects and take care not to damage them during operations When working in water swampland or passing a sand bank check the ground conditions speed and depth of the water Be sure not to exceed the permitted water depth After working check and clean the positions where lubricant is needed Please refer to CHAPTER IL 6 CIRCUMSTANCES REQUIREMENT for the depth of water for passage Be sure there are good ventilation conditions when working in a close environ
58. d The full hydraulic steering system with load sense and steering priority 1s portable and flexible and perform reliably Hydraulic pump employs proprietary technology coefficient of pressure reserve with long life the hydraulic component employs a domestic famous brand is reliable and the lifetime of the pipe system 1s high The articulated frame has a small turning radius and the ability of passing level 1s high The low profile skew intersection tire has strong ability for crossing and climbing and can drive and work on the bad ground conditions 48 Operation amp Maintenance Manual LG918 Wheel Loader 8 TECHNICAL PERFORMANCE amp PARAMETER 8 1 Performance of whole machine Bucket capacity Rated loading capacity Lifting time full load Lowering time empty bucket Dumping time empty bucket Travel speed Forward 1s pnd Reverse ys gnd Max breakout force Max traction force supplied by engine Max tipping load Max climbing angle Min turning radius outside of rear wheel Level passing radius outside of bucket Max turning angle Tire charge pressure Front wheel Rear wheel 8 2 Principle Dimension and Weight Length bucket on ground Width outside of wheels Bucket width Height Wheel track Wheel base 49 Standard lift arm 1 0 m 1800 kg lt 4 8 s lt 3 2 s lt 1 1s 0 10 km h 0 26 5 km h 0 9 6 km h 0 25 km h 58 kN 56 kN 36 kN 30 4546 mm 5082 mm 35
59. done after the run in period of new machine Clean the filter at the bottom of the gearbox and the oil filter cartridge of the torque converter Check the oil returning filter cartridge of the hydraulic oil tank Change the engine oil Please refer to 3 6 1 Fuel Supplying of Engine in this chapter 3 OPERATION AND USE OF LOADER 3 1 Notices for Usage The diesel must be cleaned and deposited more than 72 hours before it is to be used The trademark should suit the rules Transmission oil for the gearbox torque converter and the hydraulic oil for hydraulic system must be clean The loader must be maintained and lubricated periodically Drive the loader until the brake pressure reaches 0 4MPa after the engine starts Put some hot water or vapor in front of the engine for preheating it Preheat the engine until 30 C 40 C before starting if the environmental temperature is lower than 5 C There is no need to stop the machine or step on the brake pedal in changing the forward levers during driving When changing the speed from low to high release the accelerator a little and operate the Gear Control Lever at the same time and step on the accelerator when changing the speed from high to low release the accelerator first and then change the transmission slowly After the lift arm and bucket are moving to the required position release the control valve lever to the middle position Change the forward or backward driving direction after stopp
60. e maintenance man Assemble the parts and add a little new hydraulic transmission oil Start engine and hold in the idle status for 3 5 minutes Release the oil in the oil pan and add new oil The filter must be changed each time the oil is changed Make sure that the plug is closed after checking the oil level every time 3 6 4 Adding Oil to Axle T Oil Level Check O Park the machine on level ground and put the R transmission lever in the neutral position Pull d F m Oil Inlet Plu g the parking brake switch and wedge the front tire y J of Axle Shell cis ANI y 4 Loosen the oil inlet plug on the shells of the front and rear axles It is proper 1f 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 CHAPTER IV 2 2 Selection of Oil Fuel and Coolant 2 Oil Replacement O Park the machine on level ground and run in idle status for about 10 minutes Trample the accelerator gently to move the machine slowly to let the oil drain plug on the wheel side of the front axle go to the lowest position O Shut engine Push transmission lever in the neutral N position Pull the parking brake lever and wedge the front and rear wheels Loosen the oil drain plugs on the two wheels on the 82 Operation amp Maintenance Manua
61. e 27 or 3 lithium based grease GB7324 similar Oil Brands classified by SAE standard Oil Brands CALTEX SHELL MOBIL ESSO Diesel Machine Oil RotellaSX 40 HEIBAWANGI1300 Excelled CD and CD 15W 40 Rotella TX 40 20w 40 SAE15W 40 GB11122 Caltex Delo Rotella DX 40 15 C 50 C Essolube XT 3 Essolube XT 2 Gold HEIBAWANG1300 Diesel Machine Oil ME Rotella SX30 10w 30 SAEI0W 30 Excelled CD and CD 5W 30 Rotella TX30 20 C 40 C Essolube XT 5 GB11122 Rotella DX30 Delvac super 1 over 40 C O Hydraulic oil Similar Oil Brands CALTEX MOBIL SHELL CASTROL ESSO Hydraulic oil CALTEX L HM46 RANDO HDZ46 DTE25 Tellus 27 Hyspin AWS 32 5 C 40 C 28 C 40 C 10 C 40 C Tellus 29 Hyspin AWS 46 MOOR GB11118 1 94 Operation amp Maintenance Manual LG918 Wheel Loader Hydraulic Oil L HV46 DTE15M Hydro kinetic Hyspin AWH46 Vnivis N46 30 C 40 C 26 C 40 C Tellus T27 46 Nuto GB11118 1 1994 Hydraulic transmission oil torque converter transmission oil Similar Oil Brands Chinese Brands CALTEX MOBIL FUCHS ESSO SHELL 8 Hydrostatic Mobile E Caltex Delo Gold Titan universal Standard Torque transmission oil HEIBAWANG1300 Rotella 10W Q SH303 064 Multigradel5W 40 SAE 15W 40 HD15W 40 Fluid G7 Gear oil Axle oil Similar Oil Brands classified by API standard GL 5 Chinese Brands CALTEX FUCHS MOBIL ESSO Mobil Gear oil HD80W 90 Spirax EP oie Caltex Th
62. e flammable liquids in containers with relevant tags and put in a separate proper place for storage Do not allow unauthorized people to use 14 Operation amp Maintenance Manual LG918 Wheel Loader Electric welding and flame cutting 1s not allowed for the tubes containing flammable fluid Clean the tubes with nonflammable fluid before electric welding and flame cutting Clean thoroughly the flammable materials such as sawdust leaves and paper which collect in the engine and brake clip and clean the flammable oil lubricating oil and other substances on the machine While operating pay attention when the outlet of the muffler 1s close to flammable materials such as withered grass and old papers When parking the loader carefully select the environment especially select the places where there are no flammable materials near the parts with a high temperature such as the muffler 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 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 Do not use flame or fire match or lighter to check in a dark place The fire extinguisher should be ready for use at all times and the user must be knowledgeable about its use and function Check and maintain
63. e forward tilt neutral and rear tilt of the bucket from left to right Lift Arm Control Handle Float Put the control handle from front 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 d e position Rear Tilt 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 tilt neutral and rear tilt of the bucket Rear Tilt is used for drawing in the bucket Neutral is used for keeping the bucket in the desired position Forward Tilt is used for dumping Lifting limit location function When place the control handle in the lifting position the electromagnetic force from lifting limit location locked magnet coil of pilot valve can lock the 60 Operation amp Maintenance Manual LG918 Wheel Loader control level in the lifting position When the lift arm lifts to the highest position the lifting limit proximity switch fixed on the lift arm controls the locked magnet coil of pilot valve to power off so the control handle turn to neutral position to realize the lifting limit to prevent the working device from injury by hydraulic impact Set level automatically function When dumping in the highest position move the control handle
64. e outdoors park 1t on well drained concrete and cover it with canvas Add lubricant grease and change hydraulic oil before storage Apply a thin coat of grease to hydraulic piston rods which appear outside Disassemble the negative electrode of the battery and cover it or remove it from the machine and store it separately Ifthe ambient temperature is expected to drop below 0 C drain the coolant except the one added with antifreeze Please refer to 3 5 3 Operation in Cold Weather in this chapter 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 Open doors and windows to ensure ventilation and exhaust to allow of poisonous gas if the antirust is used in the building Start the machine once a month so that lubricant can be coated over the surface of the movable parts and other components surfaces The battery in storage can be charged at the same time Wipe off the grease which has coated the hydraulic cylinder rods before work and operation 3 7 3 After Storage Do as follows after long term storage of machine Wipe off the grease coated on the hydraulic cylinder rods O Add oil and grease to all the requisite positions 3 8 General Problems Possible Cause Remedies 3 8 1 Electrical System 85 Operation amp Maintenance Manual LG918 Wheel Loader l Faulty cable contact 1 Check and
65. e speed should be better less than 70 of the maximum speed limit Pay attention to the lubricating condition routinely add and change the lubricant according to rules 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 Check the fastening conditions of the bolts and nuts Do the following maintenance after 10 hours of run in time on the new loader Check the fastening status of bolts and nuts of all parts but especially the bolts of diesel engine cylinder cover vent pipe bolts front and rear frame bolts rim bolts transmission axle bolts and connection bolts Clean the raw and essential engine oil filter and fuel filter Check the tension status of the belts of fan electrical machine and air condition compressor Check the capacity of the storage battery electrolyte and its reserves and fasten the connect poles Check the oil level of the gearbox Please refer to 3 6 3 Adding Oil to Gearbox in this chapter Check the seal of the hydraulic system and braking system Check the connection and sensitivity of all control levers Check the temperature and the connections of the circuit system the power supply of electrical machine gauge light and lamps and turning signals Open the air storage tank to drain water 66 Operation amp Maintenance Manual LG918 Wheel Loader The following maintenance should be
66. eals Internal leakage of steering cylinder Worn steering unit High viscosity of oil or wrong brand of oil Damaged spring plate of steering unit Cracked broken or deformed centre pin and drive shaft Faulty dual overload valve Scuffed rotor and stator scuffed valve spool valve body and sleeve Faulty in steering pump or piloted valve No concentric steering column and valve spool Steering shaft axially locks the valve plug Large axial resistance of steering column Broken spring plate Phenomena medium pressure deflects from straight traveling line drop increases or the relief of steering unit fails when steering wheel stops wheel loader Un BWN Check oil pump Discharge air from system and check the suction lines Check the valve Clean if it 18 blocked by dirt Replace piloted valve Readjust the pressure to specified value Fill oil to specified level Change seals of oil circuits Change seals of hydraulic tanks Replace steering unit Change by the specified oil Change the damaged spring plate Change the center pin or drive shaft Check and repair the bi directional overload valve Disassemble check clean and assemble strictly or change parts Change the damaged parts Remove the problems according to the respective reasons Refer to Operation and Maintenance Manual of diesel engine for troubleshooting 89 Operation amp Maintenance Manual LG918 Wheel Loader CHAPTER V MAINTENA
67. earance 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 Make sure the supporter and the accessories are correctly set when some one works under the machine Do not use the hydraulic tank as support The accessories may go down and result in an accident when the control system moves or the hydraulic tubes leaks Never do any adjustments when the machine is operating or the engine is working unless there is an outstanding reason such as an emergency Stay far away from any rotating and moving parts O Make sure there is no sundry on the vane of engine Vane could shoot off or cut off the sundry tools inside Do not try to check or maintain a working engine because it is dangerous 3 8 Notice of Attachment 16 Operation amp Maintenance Manual LG918 Wheel Loader Please read the user manual for all of the attachments and the contents in the manual that refers to an attachment when the attachment 1s being assembled and used Do not use attachments that are not sold by Shandong Lingong Construction Machinery Co Ltd or the sellers specified by Shandong Lingong Construction Machinery Co Ltd Using unauthorized attachments may cause safety problems and go against the normal operation of the machine which can influence the service life of the ma
68. ecure the tires well during loading and unloading the machine to make sure it will not move Put a cushion under the gangway Slope boards should be strong enough with sufficient length and width to form a safe slope The angle with the ground should not be larger than 15 Keep a safe distance between slope board and board board and machine Make sure the height of the two sides of the board is uniform to ensure firm orientation Keep the board surface clean free of lubricant oil ice and loose materials Clean the dirt off the tires Never turn around on the slope board If it 1s necessary turn outside the board and then drive 41 Operation amp Maintenance Manual LG918 Wheel Loader back Lock the direction mechanism after assembly wedge the tires and tie the machine tightly with cords 9 2 Transportation on the Ground Obey the rules about weight height width and length prescribed by national and local laws for transporting the machine using a tow truck Obey the traffic rules Know the weight height width and length of machine regulation before deciding the transport routine Know the allowed limit of weight bearing when passing bridges or private buildings Obey the relative rules when driving on the public roads The machine may be unloaded when using other transportation Please contact Shandong Lingong Construction Machinery Co Ltd or their accredited representative 9 3 Lifting Use the
69. ed filter parts 2 2 Selection of Fuel Coolant and Lubricant 2 2 1 Selection Table of Fuel Coolant and Lubricant Please choose Shandong Lingong s preferred special oils and choose specified oils from the following table 93 Operation amp Maintenance Manual LG918 Wheel Loader o Recommended Types And Standards Using places Ambient temperature gt 15 CD 15W 40 Diesel Oil GB11122 X ehgrengms Engine oll Ambient temperature lt 15 CD 5W 30 Diesel Oil GB11122 Yangma engine Transmit 9 transmit oil Q SH303 064 oil Torque converter and 84 transmit oil Q SH303 gearbox Heavy duty gear oil for automobile GL 5 85W 90 GB13895 5x9 6L Main ici final Ambient temperature gt 5 L HM46 hydraulic oil GB11118 1 Ambient temperature gt 10 L HM32 hydraulic oil GB11118 1 Ambient temperature gt 30 L HV46 hydraulic oil GB11118 1 CALTEX superfine wind ring of temperature anti grinding Hydraulic oil tank hydraulic oil 46 100L Export Type Ambient temperature 4 C O light diesel Oil GB252 Ambient temperature gt 5 C 10Zlight diesel Oil GB252 Fuel tank Ambient temperature gt 14 C 20 light diesel Oil GB252 120L Ambient temperature gt 29 C 35 light diesel Oil GB252 Brake fluid Motor vehicle brake fluid HZY3 DOT3 GB12981 Brake oil cup Pins in every joint points of the work equipment 2 2 2 Reference Table of Foreign and Domestic Oils Engine oil Hydraulic oil tank Hydraulic Domestic Type Greas
70. efficiency especially for long distance transportation When working together the loader digs the material and the truck transports and unloads the material There are generally two loading and unloading ways Cross Load The loader faces the material then it moves backward after digging a full load and lets the auto unload truck move into the position between material and the loader This method costs the minimum time and can reduce the cycle time most effectively e V Shape Load The auto unload truck is fixed and forms almost a A E 60 angle with the backward direction 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 B Digging Piled Soil or Blasted Rock When digging piled soil or blasted rock the loader should face the material and do as follows O If the bucket must be lowered while driving the machine forward stop the machine when the bucket is about 30cm above from the ground and then lower it slowly If the bucket hits the ground the front tires will leave the ground and the tires will slip a 1 Q The operator must slow the speed immediately when the y CN machine reaches the material pile Simultaneously step on Co C q the accelerator pedal and enter the material pile with the bucket 2 tu oe 0 a a Da ut
71. efore replacing the fuse The fuse is used to protect the wiring and cable from burning out If the fuse has become corroded by oxidation or the fuse is loose in the fuse holder please replace the fuse When replacing the fuse please replace with a fuse of the same specification 1 2 9 Air Conditioning 1 2 9 1 I control panel and is operation if assembled The Appearance of Panel The panel of air conditioning is on the right operator box Operating methods a 4 4 1 Working Indicator Lamp 2 Air Volume and Power Switch 3 The Switch to Control the Temperature Refrigeration start the engine Open the air volume and power switch 2 which have three gears fan low gear fan middle gear and fan high gear and four positions O L M and H The speed of evaporating fan increases from left to right to adjust the air volume 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 switch anticlockwise slowly to obtain the desired temperature until the 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 indicator lamp 1 lightens a
72. en driving on an abrupt hill dyke or ramp 23 Operation amp Maintenance Manual LG918 Wheel Loader 5 9 Towing The bucket should be 200 300mm above the ground when driving on an abrupt hill dyke or ramp Lower the bucket and touch the ground to help brake or prevent turn over in emergency conditions Do not turn on the ramp Do not drive across the ramp or change direction which may turn over the machine until on the level place Never turn on the ramp until on the level ground Slow down and use a small turning angle when working on an abrupt hill dyke or ramp Go up and down the ramp rather than drive through alleyway or footpath Choose proper gears before going down the slope and never change the speed during going down the slopes Do not suddenly brake on the ramp because the center of gravity is on the front tire or rear tire 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 Brake slowly when driving down the ramp do not set the gearshift control lever in the position of the neutral gear Go down the ramp slowly never stop the engine If the engine stops on the ramp slope is less than 15 step on the brake padel immediately and lower the bucket to the ground to help brake use the parking brake put the gear control lever in the neutral position and then restart engine When driving with a load the bucket sho
73. er CHAPTER V THE STRUCTURE AND PRICIPLE OF MAIN COMPONENTS AND SYSTEM 1 TRANMISSION SYSTEM The transmission system includes the 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 others The transmission system diagram is shown in the Figure 5 1 2 1 l 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 system The working equipment hydraulic system is composed of a work pump multi way valve lift arm cylinder bucket cylinder hydraulic pressure oil tank and pipe attachments 101 Operation amp Maintenance Manual LG918 Wheel Loader an Bl A tp 5 fel i ux 1 i E TRATA i 4d B y m m AO ta ro EXT M e mA Ar LT 17 Aa d 4 1 l Multi way valve 2 Lift arm cylinder 3 Steering cylinder 4 Hydraulic oil tank 5 Respirator 6 Oil returning filter 7 Gear pump 8 Priority Valve 9 Redirector 10 Redirector cylinder Figure 5 2 LG918 Hydraulic System Diagram mechanical control ED TT r 1 Lr 1L 12 E z a El z len E z HIG XI Fall 13 S zi
74. erature control switch 3 1s always in the coolest position and the air volume and power switch 2 1s 1n the fan low gear L position in order to prevent the evaporator 64 Operation amp Maintenance Manual LG918 Wheel Loader from frosting lt gt Avoid the sun shining directly in summer lt Please shut the door and window of cab when using the air conditioning shut the heat source valve when using for refrigeration shut the temperature control switch for refrigeration when using for heating in winner lt gt Clean the condenser periodically using compress air and cold water but not using hot water or steam lt Run the compressor once a week when the refrigeration isn t used in winner for Imin to maintain the air conditioning in normal state 1 2 10 Adjustment of Cab s Seat Al WARNING When adjusting the cab s seat park the machine in a safe place and stop the engine Adjust the cab s seat before starting operation or replacing the operator Make sure that you can depress the brake pedal completely when your back is against the seat backrest 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 O Height Adjustment Rotate the two knobs on both sides of the seat ro Weight Adjust Knob Move the seat up and down to the desired p
75. features before working Pay attention to the depth that the tires sink and the braking effect on muddy or soft ground When working in water or swampland prevent the bottom of the axle housing from being soaked Slow down after passing through water or during rain Step on the brake pedal gently and alternately to let the skid device dry after working in water or in rain The clay piled on the ground or near the canal is usually soft Never allow a turn over caused by the weight or vibration of the loader 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 Assemble anti fall and anti turn operator cab when working in an area where there is danger of falling stone and machine turnover Continual rainy weather earthquake and explosions can cause dangerous working conditions Operate carefully in these cases Drive at a low speed prevent starting braking or turning suddenly and use the tire chain on a snowy road Brake alternately Lower the bucket to touch the ground to brake 1f necessary The load should be decreased to prevent slippage when driving on snowy ground because the adhesive force may change greatly in the piled snow The road shoulder and other road conditions can not be seen under the snow so take care with the snow shovel 5 8 Driving safely on the Ramp Turnover or slippage may occur wh
76. fie T cng 31 5 te 7 X 5 1 193 80 80 i i ulo I o 36 l 36 36 AR 21 21 21 21 49 i 49 Top Light 1 E T Quick Chadging Installation Rocket Switch ha O 4 4 gt n T los 5 oM 50 50 NAL Bos go 2 65 65 65 ele edi os ley oH 64 64 64 mi Radio 0 Mss Ilg oL 4 60 y 60 z 23 2 5 25 9 yo Sprayer Machin 0 26 26 uA O10 10 OF E 1 n5 11 110 n 3 22 2 LS s sisi line 42 42 42 i 013 130 85 85 85 85 co 9 ond s 86 86 86 86 To M 81 81 81 ek Button Switches 1and2 10 10 10 ae 11 11 11 1N4007 3 1 n 84 Rear Light Brake Switches 32 3 40 4 31 8 40 2 Horn Button 1 13 D oli ameno e nasus SS axo gagase x o oooo CN4 fe CN3 0000000000000 12 3 4 5 6 7 8 9 101112 13 M CN 1 1 CHS 123 4 5 6 7 8 9 10 M1 12 13 14 12345678 900 12 1314 rae Rear Lamp Rear Lamp License Lig Left Taill Might Taillig z verse Buzz c 1234561 8910111011 900900000000 00 0 0 OoOO090000 0000 000 0 Horn Asseably dee Saele dele dele REI Pe fe es O Q Qo Ga OQ Ga Oo al zx al eazuzzrz das Engine Water Temperature Sensor SP el cc cd d E ca ea ae Masel es ee ese a 3 CN16 N17 N23 CN18 CN19 CN21 H 0 Qu O O O oO OOOOOoOO OOOOOoOO oO O 14 Ss 123 123 12 1234556 12345 6 12 au ma 113 0113 12 12345 6 123456 12 ig Temperature Sensor of Turque Converter CN15 9 o 0 000 o 0 0 OOo 0 Oo 0 000 o 9 AA Binary poi e el el are daa ie pips a o F N12 4 5 ilio 4 i plue ar Switch Start Chain Right Combinat
77. from fire or flame Do not pile oily cloths anywhere because it may self ignite Never smoke when adding fuel or examining the storage battery Put the accessories in a safe place to prevent lost Put the handrail around and put the No Enter warning label to prevent people from entering without permission 31 Operation amp Maintenance Manual LG918 Wheel Loader No people are allowed to get close to the machine or accessories without permission Keep the working area clean and tidy without flammable materials around to prevent fire or slippage Lock the front and rear frames with a safety bar to prevent rotation before examination and repair Make sure all the levers or handles are in the neutral position and use the necessary equipment to support the life arms cylinder and tilting oil cylinder to prevent the working equipment from falling if you have to examine and repair when the bucket is lifting 8 2 Working in a Close Area Exhaust gas from the engine may cause disease or death If working in 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 When jacking up the frame do not let anyone enter the other side of the frame 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 the cushion b
78. ge brake pipes Find out the reasons for sealing failure and change parts 1f necessary Tighten the fitting Check air compressor Check and clean the inner parts of brake valve find out the unsealed parts then repair Clean air bleed hole find out the unsealed reasons of retaining valve and diaphragm then repair Change the oil seals of cylinder Change the distribution valve Find out the leaking points and repair Change the oil pump Check oil lines and remedy Regulate the system pressure to set value Clean the filter strainer and change oil Change the oil seals Change multi passage valve Change the system pressure to its prescriptive value Disassemble and clean Change oil seals or change oil pump Check the oil lines remedy the leaking parts Replace if necessary Add hydraulic oil to specified level 3 8 5 Steering System Operation amp Maintenance Manual LG918 Wheel Loader Heavy steering Increased 2 steering turns Inflexible or failure of steering system Steering wheel can not reset 3 8 6 Engine Insufficient oil supply for working pump and steering pump Air in steering system Faulty steel ball in check valve body of steering unit causes heavy steering and little pressure during either slow or quick turning of steering wheel Faulty of piloted valve Too low pressure of safety valve Insufficient oil level in hydraulic reservoir Leakage in oil lines damaged oil s
79. h Beam Indicator Lamp The lamp will come on if the high beam is used in the front head light The lamp will go off if the low beam is used in the front head light or the front head light is off Computer working Indicator Lamp The ZF or 4WG180 gearbox is selected to install the indicator lamp will come on if the starting switch is on otherwise please stop to exclude the error Fuel Prefiltration Indicator Lamp The lamp will come on when the fuel preliminary filter is blocked Please clean it or replace Turn Indicator Lamp The lamp will come on if the steering switch is connected meanwhile the steering lamp will come on The left indicator lamp will come on if turn to left and the right indicator lamp will come on if turn to right 1 2 2 Switch Starting Switch 55 Operation amp Maintenance Manual LG918 Wheel Loader This switch locating on the steering column on the right low side of steering wheel is used for starting or shutting down the electric system and the engine HEAT Position This position is used for the engine pre heating position of cold start system The domestic basic type is not mounted with pre heat system the user can select to install OFF Position Insert or remove the key in this position Turn the key to this position to cut off the electric power ON Position This position is used to turn on the electric system Keep the key in this position when the engine is running START Position
80. han this temperature be sure to warm 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 Change oil in relationship dust free places to keep impurities out of the oil 90 Operation amp Maintenance Manual LG918 Wheel Loader 11 Welding Guide Turn off the starting switch of the engine and remove the battery cables Keep the distance between the grounding cable line and welding area more than 1m Avoid welding near the seal rings and bearings Never weld any pipe or tube while has fuel as or oil in them 1 12 Fire Prevention Clean the parts with inflammable cleaner or light oil Keep spark or cigarette light away from them 1 13 Sealing Part When replacing O ring or gaskets clean the clamp faces first and make sure the O ring and gaskets are in the correct assembly position 1 14 Checking the Frame After a long time of operation in rocky conditions check for damage of the undercarriage and loose or damaged between bolts and nuts 1 15 Attention to Washing Machine Wash machine after complete cooling of the engine Do not allow water to spray on any electric components 1 16 Checking in Rai
81. harging machine with the positive pole of the storage battery Never reverse Examine the vent of the battery to prevent blockage otherwise it may explode Lower the charging voltage or current if the electrolytes are over 45 C to prevent spurt out of electrolytes due to high temperatures Never overcharge during use or charging to prevent early invalidation due to water loss grid increasing and diachylon dropping 8 18 Starting to Use Voltage Raising Method The wrong connection of voltage raising cable may lead to fire so please do as follows Two operators are needed to start voltage raising start one sits on the operator seat Two machines are not allowed to touch when one is starting Turn off all the starting switches of the normal machine and the broken machine when connecting the voltage raising cable Connect the positive cable first when the voltage raising cable is connected Cut off the negative or ground cable first when the voltage raising cable is removed Connect the ground cable to the frame of the broken machine Connection should be as far as possible away from the storage battery 39 Operation amp Maintenance Manual LG918 Wheel Loader Do not let the voltage raising cables touch each other or let the clamp touch the machine when the voltage raising cable 1s removed 8 19 Maintenance and Storage of Tires 8 19 1 Maintenance of Tires 8 19 2 Storage of Tires The Explosion of a tire can
82. he neutral position push the parking brake switch and keep it in the braked position 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 Wear protect clothes and glasses when using compressed air to clean the filter mesh 8 9 Heavy Materials Wear protect clothes safety glasses and safety helmet and put a copper bar between the hammer and the part being hit Eyes may be damaged by flying hard particles such as pin and bearing when hit by a hammer Usetools and heavy materials carefully Prevent them falling down 8 10 Welding Repair Electric welding requires a special technique proper equipment and place No person is allowed to weld without a license Escaped gas and damaged electric wires are potential problems during welding Obey the following Switch off the electricity in the terminals for storage to prevent explosion Clean the paint at the welding site to prevent the production of harmful gas Avoid welding on the hydraulic equipment or pipe or places nearby Flammable steam and sparks may be generated 34 Operation amp Maintenance Manual LG918 Wheel Loader Cover the rubber wire or pressure pipe and use anti fire plate during welding because a spark may cause a sudden crack or shatter the insulating tape Be careful when welding near tires which may cause a thermal
83. he start button 2 Start for lift 3 Limit position of lift arm 4 Danger of lift arm Lock the lift arm cylinder before entering dangerous areas Located on both sides of lift arms Located on the front of front and rear frames Located on both sides of lift arm Do Not stay under the lift arm 5 Danger of injury or death during steering 6 Notice for antifreeze fluid if stuck Located on the steering position Located on the left side of operator cab door of front and rear frames or mouse of radiator of engine hood Dooa rai i i N Coolant 25 has been added in the machine e Notice the coolant is glycol engine cooling liquor e Please act according to the circumstance and the illustration when reinfusing otherwise the effect will be reduced e Selection range is advised as below 25 is used with a temperature of 2 15C 35 is used with a temperature of 2 25T 45 is used with a temperature of 2 35 C S E Operation amp Maintenance Manual LG918 Wheel Loader 7 Notice for Hydraulic oil tank Located on the hydraulic oil tank 8 Notice for the door of operator cab Located on outside of operator cab left door N NOTICE I TAKE CARE NOT TO BE SQUEEZED THE DOOR MUST BE FIXED WHEN DRIVING HYDRAULIC OIL TANK Recommanded Scale AMBIENT T HYDRAULIC OIL 10T 400 L HM 6 30C 40T L HV46 9 Notice for operation 10 Notice for driving
84. her position Oil Pressure Warning Lamp The lamp will come on immediately if the start switch is turned on It will go off immediately after the engine is started Otherwise it means the level of lubricant is too low or there 1s some problem with the lubricant system Then shut the engine and check it Charging Indicator Lamp The lamp will come on 1f the start switch 1s 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 Power Cut Indicator Lamp The lamp will come on if the power 1s cut off and it will go off 1f the power is not cut off When braking pedals are installed on the two sides the power will be cut off and the lamp will come on if the left braking pedal 1s stepped down the power will not be cut off and the lamp will go off 1f the right braking pedal is stepped down Emergency Steering Indicator Lamp The emergency steering function 1s 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 will also come on if the brake air pressure is low Brake Air Pressure Alarm Lamp The lamp will come on for a warning if the brake air pressure 1s below 0 4MPa Hig
85. high speed Never do this 5 3 Full Load Transportation 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 insure driving smoothly Check the limit lifting weight of the loader Never overload which may hurt the machine or people Shandong Lingong Construction Machinery Co Ltd assumes no responsibility for overload injury or damage to equipment 21 Operation amp Maintenance Manual LG918 Wheel Loader 5 4 Drive at Proper Speeds Do not drive turn or brake suddenly and do not detour Never suddenly stop or lower the working equipment which may throw out the materials from the bucket or cause the loader to turn over Know the characteristics of the loader and follow the actual conditions in the working area Drive at the proper speed Select path of drive and method of machining to let the others know Keep a low speed so as to maintain control easily at all times Never drive fast turn to brake suddenly on rugged slippery or oblique ground Slow down when passing over rough or rugged ground with blocks around which may cause some problems in controlling the steering wheel Loader may turn over if operated in the wrong way Let the engine run smoothly never drive at high speed 5 5 Ensure
86. i A E A A eee a ceu UT IN o roc LIMEN a vx 7 y At Ae B E ERROREM E E LL EN 11 a emm EXE HEU p url ER ERR j O a xx cre jd 1T Ws 123P 20W 1 o 5 6 7 8 l 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 control 102 Operation amp Maintenance Manual LG918 Wheel Loader 3 BRAKE SYSTEM Brake system 1s used when the machine decelerates stops or for long term parking on the level ground or slight incline The brake system of this machine 1s composed of a driving brake system and parking brake system as shown in Figure 5 4 and 5 5 MIN brake pump of rear axle l 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 Y Rear axle brake pump SS ete l 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 103 Operation amp Maintenance Manual LG918 Wheel Loader 3 1 Driving Brake System Single Brake Ped
87. in advance When constructing a dam or unloading soil from a cliff form one pile first and use the second pile to push the first one Tal d dira LE 6 3 Ensure Ventilation in Close Environment 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 Prepare fire extinguishers for close environments and know where they are stored and how to use when working in this condition 6 4 Don t Get Close to Dangerous Environment e If the ejected gas from the silencer hits flammable material or the vent pipe is close to the 28 Operation amp Maintenance Manual LG918 Wheel Loader 6 5 Don t Get Close to High Voltage Wire may result in even when close to a high voltage wire flammable material fire may occur Be aware of the flammable materials such as lipin cotton papers dry grass chemicals and oily or oiled rags Do not touch the aerial electric wire Electroshock The distance between the loader and the electric wire should be At least 2m 6 5ft at low voltage condition At least 4m 13ft at 40KV high voltage condition electric wire is generally supported by fixed TRATA IZ insulator At least 6m 20ft at 40KV high voltage condition electric wire is generally supported by hanging insulator The
88. in the booster pump Clean the air vent and check the brake fluid Add them if deficient 3 3 Every 250 Hours Month Service Carry out the periodic maintenance of every 10 and 50 hours with this maintenance operation at the same time Check the storage battery Clean surface and terminals of the battery then coat Vaseline lamina Check whether assembling bolts of frames are loose and welding seams are cracked Check whether the front and rear axles engine and gearbox and frame are loose Check the tire pressure Inflation pressure of front tires should be 0 33 0 35 MPa while that of rear tires should be 0 27 0 29 MPa Open the water draining valve in the air tank to drain the water out In addition do the extra maintenance in the first 250 hours as follows Check and clean the air vent of gearbox Clean the oil pan of gearbox Replace the suction filter cartridge in the oil pan of gearbox Replace the filter cartridge in the oil lines of torque converter gearbox Replace the gearbox oil Replace the gear oil in the front and rear axles Check 1f there 1s leakage 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 4 Every 500 Hours Season Service Carry out the periodic maintenance of every 10 50 and 250 hours with this maintenance operation at 98 Operation amp Maintenance Manual LG918
89. ing the loader Full load work is allowed until the water temperature of the engine is above 60 C and the mobile temperature of the engine is above 50 C But the water temperature of the engine should not be over 95 C and the mobile temperature of the engine should not be over 120 C otherwise stop the loader to cool it Never lift the bucket to the highest position to transport material The lower hinge of the lift arm should be 400mm 500mm above the ground to ensure stable driving during the transporting process A diesel engine 1s used in the machine The power of the diesel engine will go down as the altitude environmental temperature and relative temperature goes up So please pay attention to the environmental conditions and calculate the real power under the current environmental condition according to the power correcting table in Diesel Engine Usage and 67 Operation amp Maintenance Manual LG918 Wheel Loader Maintenance User Manual 3 2 Starting 3 2 1 Check before Starting Check the bottom and surrounding of the machine to see whether there are lost of bolts dirt oil coolant leak or broken parts Check the status of accessories and hydraulic parts Check before Starting 1 Check the fuel in the fuel tank Refer to 3 6 2 Adding Fuel to Fuel Tank in this chapter 2 Check the hydraulic oil in hydraulic oil tank Refer to 3 6 5 Adding Oil to Hydraulic Oil Box in this chapter 3 Check the engine
90. ion e ti op to 3139 0 60 Brown Li 4 Light CN14 6 5 zo 6 u Black Y O 1 1 10 1 1o 3 39 1 1 o gotll 10 is 4 40 10 0 Brake Air Pressure Sensor 7 11 11 8 y o3 3040 o5 50 Hi 32 MY O 04 4013 n o po 12 30 4 i ii es m ro5 50 3 15 1 19 30 40 5 9 9 4 l E XX 6 60 401 8 go 40 Reverse Switch Qi 9 yo 42 n Pressure Sensor of Gearbox Eon wore H NS left Combination 5 o 11 11 85 Light N13 o 12 12 Fuel Oil Lever Sensor 10 86 o 86 1 1 al BUE 19 x Lo 10 1l o 14 uo t e 0 xr o3 30 d 00 o4 M 30 Engine 0il Pressure Switch N mer 5o 31 x dt Y 26 60 A Hand Brake Switch Proximity Switch Lift Arm Red Safety Fuse n T 2 Blue N11 1a 0 Lo pot TOA M Tello 42 4 13 lo j i9 Technical Requirement LP lo o Start Relay Proximity Switch Bucket 3 3 u emen S 2 Red oy ff yo t o o o o E an A11 the electric appliances of this Acumulator Accumulator DUE a Relay Helton vehicle type uses are DC24V Meca Me 56a 5 56 2 dt d 4 l Cul p ES Quick Changing 85 ill 604 28 5a 0 erator Solenoid Valve M _ e 0 o 1 19 0 e icrchanging 86 8 5 zoss HH Start Machine Solenoid Val olenoid Valve a 5 3 jo 86 81 uick Changing 0 O 4 49 Buzzer Figure5 6 LG918 Electric System Diagram with Yuchai engine Domestic type 105 Operation amp Maintenance Manual LG918 Wheel Loader
91. ion to the value of the gauge Do not let the engine run at high speed or low speed more than 20 minutes in the idle status O If the engine has to run at idle status the machine should be loaded from time to time or the engine should run at the middle speed 3 3 Running 3 3 1 Driving Make sure there is no other person in on or around the machine or around to prevent accident And keep the machine under control Raise the lift arm Keep the bucket backwards and keep the motor running Put the gear control lever at forward I or backward I position 69 Operation amp Maintenance Manual LG918 Wheel Loader Press the brake pedal press the parking brake level to release the brake status Release brake pedal and step on the accelerator pedal slowly to drive the machine forward or backward It 1s safe to drive only when the brake pressure 1s over the specific value of 0 45MPa Never lift the bucket to the highest position while transporting material The lower hinge of the arm working equipment should be 400mm 500mm above the ground to ensure stable driving in the transporting process Never run at high speed if the machine goes on a slope or uneven ground Select the proper transmission gears when go down a slope and never change the gears during that time Never run over speed while driving on a slope and use the foot brake pedal to slow the speed 1f the double brake pedals are assem
92. k and pull it Checking Oil Dipstick of the Engine Oil out again to check the oil level at least twice If the oil level is lower than the lower limit dil Adding oil should be added by the oil adding port Upper Limit Oil Adding If it 1s higher than the upper limit sign ee Lower Limit check the problem and solve it It 1s a Pe suitable oil level if it is between the lower limit and the upper limit Then put back the oil dipstick and close the profile door of the engine For choosing the appropriate oil please refer to CHAPTER IV 2 2 Oil Selection 2 Engine Oil Replacement O 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 C 40 C then stop the engine Rotate the oil drain plug and let the oil flow out and hold it in a container Change the oil filter After the oil is released completely rotate the oil drain plug back Open the left side door of the engine cover add prescribed engine oil about 12L from oil inlet of engine O Run the engine at idle status check whether the oil filter and oil releasing plug are leaky After the engine was stopped for 15 minutes let the engine oil flow back to the oil pan and check the engine oil level of the engine again
93. l LG918 Wheel Loader end sides of the front axle and the oil drain plugs at the center bottom of the axle shell to drain oil to the container The temperature of gear oil may be high so wear protective clothes and operate it carefully to prevent injury Drain out all the old oil and screw tight the oil drain plugs at the center bottom of the axle shell Start engine Rotate the parking brake switch gently until it rebounds Move the machine slowly with gentle acceleration to let the oil drain plug on the front axle move into the horizontal position and then shut the engine Put the transmission lever in the neutral position Pull the parking brake lever Add new gear oil from the oil drain port on the two wheels on the end sides of the front axle and the oil inlet port at the middle of the axle shell And then check the oil level again 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 Replace the rear axle gear oil according to the procedures above 3 6 5 Adding Oil to Hydraulic Oil Box T Oil Level Check Park the machine on level ground and lower the bucket to the ground Check whether there is an angle between front and rear frame Check the oil level indicator of the hydraulic oil box on the left side of the machine The oil level is normal if the level indicator scale 1s at a range of 8 2 If the oil level indicator is lower than
94. left to the rear tilt position and the control handle is locked During drawing the bucket the control handle returns to the neutral position and place it in the lowering position when in the set level automatically position Then the working device is placed on the ground and the bucket is in the bucketing position in order to realize the set level automatically function and increase the efficient of the whole vehicle Lock automatically function 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 Parking Brake Control Lever This switch is on the left side of the seat in the cab and it is used Parking Brake E lontrol Level 3 for the parking brake Pull this lever to engage the parking brake S Press the button on the end of the lever and push the lever down to N release the parking brake Brake Pedal The Brake Pedal controls the brake of the vehicle Refer to 1 1 General View of Controls and Gauges Figure3 1 and 3 2 in this chapter Accelerator Pedal This pedal controls the acceleration of the engine Refer to 1 1 General View of Controls and Gauges Figure3 1 and 3 2 in this chapter The engine speed can be freely regulated between idle
95. lever in the float position for soft ground put the lift arm control lever in the neutral position Use reverse gear to strike the ground with blade 7 Towing Operation Before towing the tires must be blocked by the parking brake to prevent the machine from rolling During towing be careful to prevent severe and fatal injury If possible the engine of the towed machine should keep the engine running to ensure braking and turning 1s possible Ifthe towed machine engine can not start disassemble the front and rear transmission axle If the machine can not turn disassemble the steering cylinder 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 O 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 loader If there is no braking system on the towed machine no one is allowed to stay on it Check whether the towing rope and towing pin are strong enough to suffer the weight of the towed machine If machine will pass over clay ground or go up a slope two towing ropes and towing pins should suffer at least 1 5 times the weight of the towed machine O Try to decrease the towing angle of the towing rope to ensure that the angle between the towing 76 Operation amp Maintenance Manual LG918 Wheel Loader
96. locks under the machine 8 4 Working under the Machine 8 5 Working on the Machine Park the machine on firm ground Lower the working equipment to the ground before working under the machine Wedge the tire firmly It is dangerous to work under the machine only using the working equipment to support the machine Never work under the machine without good support 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 32 Operation amp Maintenance Manual LG918 Wheel Loader N NOTICE Do not allow lubricant or grease to leak Do not randomly put the tools around the work place Walk slowly and carefully Never jump down from the machine When climbing up and down the machine face the machine and keep three points contact two hands one foot or two feet one hand with the handrails and pedals to ensure safety Use protective equipment if necessary Never stand on the top of the engine hood because it 1s slippery and dangerous Never stand on the top of tires because they are slippery and dangerous stand on the mudguard of the front frame and seize the handrail 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 Assign an operator to sit o
97. ment 4 1 2 Check before Starting the Engine Check the machine carefully before starting work Report to the manager if there is any abnormal condition Operate only after the abnormal conditions are resolved To avoid fire check whether there are any flammable materials such as wood chips leaves and 17 Operation amp Maintenance Manual LG918 Wheel Loader paper which have accumulated on the engine Check whether there is leakage of oil or water loose nuts abnormal sounds broken or lost parts Check the cab floor rearview mirror control lever or control handle pedal and handrails for oil grease snow or dirt and clean Check the level of coolant fuel and make sure the level of engine oil in the pan is normal Please refer to CHAPTER III 3 6 Supply of Oils to check whether the air filter is blocked Adjust the operators seat to the proper position for operation Please refer to CHAPTER III 1 2 10 Seat Adjustment to check whether the safety belt and the fixed equipment if assembled are broken The safety belt must be replaced with a new one every three years O Check the gauges for damage and make sure the control lever or control handle is in the braking position O Clean the dirt on the cab window and all the lamps to ensure better visibility 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 1f the mirror has bee
98. n damaged 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 could start the working equipment and cause an accident Check whether the floodlight and signal light 1s normal and repair if not Check whether the front and rear frames 1s unlocked O Clean oil from the handrail and the pedal and the silt and sand from the shoes to avoid slippage which may affect the operations Check whether the 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 Before boarding on the machine check the machine again to see whether there are people or blockages on or under or near the machine If there are unrelated people in the working area ask them to leave Do not begin work until they leave 18 Operation amp Maintenance Manual LG918 Wheel Loader Don t start the machine if there is the tag of NO OPERATION on the control handle of the working equipment or shift control handle Sit with the safety belt locked into place Know the meanings for all the warnings on the equipment meters and control equipment on the panel Be sure the parking brake switch 1s at the braking position and all
99. n point of lift arm at the transportation position 400 500mm above the ground Dumping Operation 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 material can be dumped by the lever control Act slowly and gently during dumping to prevent the bucket from striking the ground If the material sticks onto the bucket move the working equipment control lever cyclically to allow the bucket to tilt forward or backward to shake down the material After dumping use the bucket to level equipment if assembled Rear tilt bucket to level position and operate the working equipment control handle to allow the lift arm to lower to prepare for next operation Pushing Operation 75 Operation amp Maintenance Manual LG918 Wheel Loader control lever between lifting and lowering operation Never use the lever at the raising or lowering position to ensure pushing the bucket smoothly Watch the torque converter oil temperature gauge all the time during a pushing operation If the temperature is too high stop the machine to let it cool down and then continue to work 6 Striking Operation Tilt the bucket to let the blade touch the ground For hard ground put the lift arm control
100. n the hydraulic reservoir Replace the filter cartridge of return filter and pilot filter if assembled Check the clearance and wear condition of the pins and the bushes in every articulated point In addition do the extra maintenance in the first 1000 hours as follows O Replace the hydraulic oil And then replace once every 2000 hours 3 6 Every 2000 Hours Year Service Carry out the periodic maintenance of every 10 50 250 500 and 1000 hours with this maintenance operation at the same time Check performance of the torque converter and gearbox differentials of front and rear axles and the wheel side reducers Disassemble them for checking if necessary Check the sealing performance of multi passage valve and hydraulic tank by measuring the natural sedimentation volume of the cylinders fuel oil and then check the system pressure Check the welded seams of rim and other stress parts and adjust the deformation 99 Operation amp Maintenance Manual LG918 Wheel Loader 3 7 The maintenance principles listed above are the normal requirements The maintenance time should be determined by the closer one between the two the maintenance schedules If the working condition 1s 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 100 Operation amp Maintenance Manual LG918 Wheel Load
101. n the seat to ensure all the maintenance people can have contact with him so he can prepare to shut the engine when requested Never touch a high temperature part such as tail pipe and silencer to prevent injury Be careful 1f the repair space 1s near the rotation part Do not touch any lever or handle If necessary to touch it warn the others to go to a safe place Never let any tool or body part touch the fan leaf or fan belt Otherwise serious hurt may occur Do not make adjustments unless fully trained to do so 8 7 Do not let anything fall into the inner part of the machine 33 Operation amp Maintenance Manual LG918 Wheel Loader When opening the examination window and the oil filling port of the oil tank make sure that nothing such as nuts bolts cotton yarn or tools falls into the inside of the machine If 1t happens the machine may be disabled Pick out the fallen pieces safely Do not carry any unnecessary tools or parts in your pockets during examination of the machine 8 8 Cleaning Wear the anti slide shoes to prevent sliding when cleaning the machine Wear protective clothes when using high pressure water to clean the machine O Clean routinely to prevent dirt or mud splashing into the eyes or slippage caused by oil on the machine Do not use a flammable scour when cleaning the machine O Shut the engine to clean the inner part of the machine put all the levers or handles in t
102. nd the compressor will begin to refrigerate when the inside temperature 1s lower than the setting temperature the indicator lamp 1 turns 63 Operation amp Maintenance Manual LG918 Wheel Loader b 4 4 off and the compressor stops working Heating Before using turn the temperature control switch to the O position the state of off Open the hot water valve and start engine Open the air volume and power switch 2 to choose the position of gear and adjust to the desired air volume 1 2 9 2 I control panel and is operation if assembled a b Notice lt gt The Appearance of Panel Refrigeration 7 2 The Switch to Control the Temperature 3 Refrigeration Indicator Lamp 4 Power Indicator Lamp Operating methods Refrigeration First time use turn the air volume and power switch to high gear after the engine started turn the temperature control switch to refrigeration Turn the air volume to obtain low middle and high volume of air 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 volume of air Power indicator lamp If the system is normal the power indicator lamp will come on If the refrigeration indicator lamp comes on the compressor starts working for the refrigeration of air conditioning Avoid the temp
103. ndow and draw the key 3 4 4 Do the Followings after Work Everyday Check the fuel reserves 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 Check the oil pipes water pipe gas pipe and other parts for leaking conditions Check the gearbox torque converter steering unit fixing of front and rear frame and sealing conditions And check whether there are overheating conditions Check whether the rim bolts transmission axis bolts and other pins are loose Add antifreeze if the temperature is below 0 C drain the water out if there is no antifreeze Refer to 3 5 3 Operation in Cold Weather in this chapter Check whether the work equipment is in good working order Check whether the wheel pressure and outside surface are normal Add liquid oil to the adding points of work equipment Check the quantity of the brake oil by opening the oil bowl cover of the brake booster pump Drain the water in the air tank from the water outlet valve Clean the outside surface of machine and the inside of the bucket 3 5 Operations 3 5 1 Prepare to Work Clean the working area and fill up any hollow spaces Clear away the sharp stones and roadblocks that may break the wheels and operation 3 5 2 Modes of Work 1 Loading Operation 72 Operation amp Maintenance Manual LG918 Wheel Loader Work together with a truck which can help improve working
104. nents other than those specified by the company Be sure to keep the electric system dry when washing the machine or working in rain and snow o Avoid the electric system corroding by seawater when working on the seashore 2 5 Maintenance Tools 96 Operation amp Maintenance Manual LG918 Wheel Loader Refer to the production containerization list for details of maintenance tools 2 6 Tightening Torque of Screw The tightening torques of screw connection of the important parts are listed in the table below Abide by this table except in special conditions Material T Or No Position Thread size m Torque N m class 1 Assembling bolts of transmission base M16x1 5x70 70 100 Assembling bolts between driving axle and iine M20x1 5x70 8 8 380 460 Connection of the transmission shaft MI2x1 25x45 7157 105 5 Assembling bolts between engine oil tank and frame M16x35 8 8 185 265 Assembling bolts between fuel tank and M20x2x60 250 360 frame 8 8 M24x2x120 320 480 M16x40 Assembling bolts between teeth and bucket 45 193 257 M16x70 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 Check the sealing performance of work equipment systems such as hydraulic steering and brake system Check the flexibility and reliability of the brakes Check whether the
105. ning and Snowing Circumstances O 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 Inspect and clean air filter frequently to avoid blocking Clean the radiator frequently to avoid blocking Clean and replace fuel filter frequently O Clean the electric components especially the starting motor and alternator to avoid accumulation of dust affecting dispelling heat Refer to Operation and Maintenance Manual of diesel engine for replacing and maintaining air filter 1 18 Avoid Using Mixed Oil Never use oil mixed from different brands If only a different kind of oil from the one previously used drain the oil from the machine and fill with the new brand oil 2 DETAILED RULES OF MAINTENANCE 2 1 Detailed Rules of Using Oil Fuel and Coolant 9 Operation amp Maintenance Manual LG918 Wheel Loader Because of bad operating conditions and dusty ambient circumstances oil easily deteriorates Change oil as soon as the oil deteriorates or is mixed with many impurities Add the specified volume of oil Either too much or too little oil may cause problems Clean and replace the relative filters when changing oil 2 1 1 Fuel The fuel pump is a precision instrument If the fuel mixes with water or dirt the fuel pump will not work normally Never
106. not block traffic When parking the machine unload all the material on the machine lower the bucket to the ground stop the engine pull the parking brake switch and put it in the braking position Lock the engine and put away the keys Climb down with face to the machine slowly according to the 3 points method Never jump down to the ground WARNING NEVER get on or off the machine while 1t 1s moving 7 2 Notice for Cold Area 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 Before operation preheat sufficiently The machine won t start if do not preheat before operating the conrol handle of the working equipment and an unpredictable accident may be caused Operate the working equipment control handle to let the hydraulic oil cycle in the hydraulic system Do this by letting the pressure of the system rise up to the system setting and then release to let the oil flow back to the hydraulic oil tank to preheat the hydraulic oil so as to guarantee better reaction and prevent malfunction Do not charge the storage battery with frozen electrolytes and do not use other power to start the engine It is dangerous and can cause fire Please refer to CHAPTER III 3 5 3 Operation in Cold Weather 30 Operation amp Maintenance Manual LG918 Wheel Loader 8 SAFETY EX
107. nt Headlight high Middle Relay Start Chai Left Turning High Bean Pressure i i i Indi ir dies il a Bo Indicator LampIndicator Lamp Warning Lamp Lanp Indicator Lamp Lanp Indicator lamp Lamp Indicator Lamp Indicator Lamp gESSzzBc e INN ALBI LB sia a ai SmBGE es El Z Z e esl es eet ash ed edd th 87 85 mg snm l 80 a EG a gda fated V i l 0 000000 X 52 e 123456 Low Pressure Alarm mel 1234 5 6 43 000 99 15 e alala Elada a 14 DP pe eA S OU E 3 17 49 30 33 ji 1 19 B 0 Flashing Amber o 21 21 L 25A 10A 104 SA E 0 iring Group eo un a ol olan ws wl ma O 20 00 00 O 00 0 oO O00 0 1 S46 i a e Teese VIDT T rere en 123456 1234 9 10 11 12 Fan Unit Heater Unit Heater Switch RN ishti 1234561 1 2 9 10 11 12 1151216 Front Lighting Lamp 690900 o o E Sia p gt 4 6 o o Qo Qo ba a TS al F I ere d Li ze 42 a nA E 0 ag 93 asas Top Warning Lamp M WP eu 3 AN 1 i CN T7 36 ae o 1 o 4 90 34 36 a o3 3o 49 ha Oo 4 4 of _4 35 MEORUM Switch b 5 oH 3 m 1 5 o 6 go 23 65 I p il o1 702 t Liso Radio 0 o ida 24 60 ze 25 zl de o g go x C Sprayer Machin 10 10 97 1 on uo 2 ids sg st Rain Wip op 120 2 013 130 5 M M To 90 4 tod 014 14 0 86 i co Ta 87 87 K Buttons land 2 Blue 10 md J Rear Lighti 11 1N4007 X QD 84 Es 4 i o 6 3 40 4 4 i Parking Brake Switch d 44 M Y 666066 600000 CN 1 cm 1234556 9 10 11 12 13
108. o Ltd BL SL FR ROPS amp FOPS for Wheel loader LG918 Standards EN 13510 2000 EN 13627 2000 Certificate i lac MRA CNAS L0732 CHA 2006002012K Maximum machine mass 7000kg Address Lingong Industry Park Linyi Economic y E a oF Development Zone Shandong P R China 23 Prevent rollino Located on the inner right front upright column of the operator cab CRUSH IN CASE OF 10 mm HECK WATER LEVELS EPORT ANY FAULTS M ay J 22 Notice of required reading manual ad Located on the left front upright column of operator cab Operation amp Maintenance Manual LG918 Wheel Loader 2 SAFETY RULES 2 1 Safety Rules Only trained and authorized people can be permitted to operate and maintain the machine Follow all safety rules precautions and instructions when the machine is in operation or being maintained Never operate machine when you are less than fully alert Don t operate machine if you feel sick or feel sleepy after taking drugs or drinking alcohol when your judgment may be impaised 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 Follow all the safety rules 2 2 Safety Devices Be sure all guards and covers are in their proper positions and repair them when damaged Use the safety devices properly such as parking br
109. o not repair while in operation An overload is dangerous Shandong Lingong Construction Machinery Co Ltd assumes no resposibility for the injury or damage induced by overload 25 Operation amp Maintenance Manual LG918 Wheel Loader O It is dangerous to hit any object at a high speed Damage may be done to the loaders the goods and the operator O Keep perpendicular during loading and unloading materials If working in a side direction the steering cylinder and differential carriers may be damaged and the machine may be unbalanced Confirm the ambient conditions and the operation before driving to load and unload materials Check the status of the working area before entering a narrow passageway such as tunnel overbridge and garage Take care with the working devices during operation Operate down wind in strong windy weather O 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 slowly When unloading to the truck or tipper make sure the bucket does not hit the truck or tipper Do not allow anyone to stand under the bucket or to let the bucket go over the cab of the truck When driving backwards ensure visibility of what is behind you 26 Operation amp Maintenance Manual LG918 Wheel Loader O Install lighting systems d
110. oil in the engine oil pan Refer to 3 6 1 Fuel Supplying of Engine in this chapter 4 Open the water tank cover to check the water level 1n the water tank 5 Check the brake oil in the oil bowl of the brake booster pump 6 Check the seal ability of the oil pipe water pipe air pipe and other parts 7 Check the seal ability of the hydraulic pipes and the surrounding pipes 8 Check the wire connection of the storage battery 9 Check the pressure of the tire to see whether it is normal Please refer to CHAPTER II 8 1 Performance 10 Check the control levers or handles to see 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 safety belt 1f assembled and other safety equipment for good working order 13 Start the full checking list the engine only after completing 3 2 2 Engine Starting Points for attention of starting engine Make sure all the control levers are in the neutral position before starting make sure the gear control lever is in neutral position and put the switch in its original position Step on the accelerator slowly when starting to prevent breaking parts Follow the correct starting steps to start the engine Refer to Diesel Engine Usage and Maintenance User Manual for other operations of diesel engines Steps of starting engine e Put the shifting control lever to
111. ommanded Scale AMBIENT T DIESEL OIL AT he St 10 14 20 4 291 35 S When the oil plane is under the O line please refill fuel m tune or it can result in fameout when the machine is running on a rampyway Operation amp Maintenance Manual LG918 Wheel Loader 13 Warning to touch the machine 14 Warning of safety distance Touch the machine only after all parts stop Located on the both sides of engine hood Located on both sides of engine A 15 Notice of hot water Pay attention to the steam or hot water ejection Located on the cover of engine water tank Operation amp Maintenance Manual LG918 Wheel Loader C 17 18 19 2021 23 11 23 Ir l M ALLE pum S a ee a f i It Figure 1 2 Figure of safety label position Export Type Operation amp Maintenance Manual LG918 Wheel Loader 1 3 The Contents of Safety Label Export Type 1 Warning for starting 2 Start for lift Located above the start button Located on the lifting position of the front and rear frames After the vehicle stops the key should be in the mid position 3 Limit position of lift arm 4 Danger of Lock the lift arm cylinder before it enter dangerous zone Located on both sides of actuating arm 5 Danger of serious ac
112. on amp Maintenance Manual LG918 Wheel Loader
113. ons and methods for use 1 2 1 Vehicle Gauges and Lights Engine Water Temperature Gauge This gauge indicates the temperature of engine water When the temperature index lies in the green ranges 60 C 100 C the water temperature 1s normal Notice If the temperature index moves past green into the red range be sure to stop the machine for inspection Refer to 3 4 2 Steps to Stop Engine in this chapter for details of stopping the engine Torque Converter Oil Temperature Gauge This gauge shows the torque converter oil temperature When the temperature index lies in the green range 60 C 120 C the oil temperature is normal If the temperature index moves past green into the red ranges be sure to stop the machine for inspection Working Chronometer This indicator shows the total operation hours of the machine its value can be used as a reference for inspection and maintenance Gearbox Oil Pressure Gauge This gauge indicates the pressure of the gear shifting system lt gt Ifthe pressure index lies in the green range 1 1 MPa 1 5MPa the oil pressure is normal Be sure to stop the machine for inspection 1f the index moves outside this range lt gt If the pressure index lies in the range of 11 15 x100kPa or 15 95 21 75 x10PSL the oil pressure is normal Be sure to stop the machine for inspection if the index moves outside this range 53 Operation amp Maintenance Manual
114. osition Turn the knob in reverse to lock the seat Weight Adjustment m ir ti tors E o Fore to aft Adjust Knob Height Adjust Knob The weight adjusting knob 1s in the middle of the back rest The operator can rotate the knob to increase or decrease shock absorption 1 2 10 Rearview Mirror Rearview mirrors are on the left and right sides outside the cab Before starting work the rearview mirror must angle be adjusted for a good rear 65 Operation amp Maintenance Manual LG918 Wheel Loader 2 RUN IN PERIOD OF NEW MACHINE A new machine must have a 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 train the new machine and operate follows Run the machine in neutral at low speed to preheat the engine Never accelerate the engine suddenly in the preheating period Never start accelerate turn or brake suddenly except in an emergency When the loader 1s working without a load the gearshift should be used from low speed to high speed at each level accordingly Turn left right or brake steadily in the process of driving In the period of run in all speeds including forward and reverse should be adjusted It is better to load bulk materials in the period of run in Do not operate the loader too hard or too rudely The load should be less than 70 of the standard load and th
115. osition of brake valve spool locked piston rod damaged or faulty reset spring Improper operation of booster Pliers piston can t reset 87 Un BWN Operation amp Maintenance Manual LG918 Wheel Loader Change the seal ring Change the gasket Check and remove the leakage Add oil to the specified level Drain oil to the specified level Refer the problems 1 and 2 Clean or replace the radiator Shut down for cooling Disassemble the cut off valve find out the reasons that spool can t reset and remedy Shift gear again or readjust the gearshift control levers and linkages Change the spring of pressure regulator valve Refer to 1 2 3 and 4 of problem 1 Refer to problems 1 and 2 Refer to problems 3 Disassemble and check the torque converter change blades Disassemble and check free wheel clutch change damage parts Check and maintain the engine Change rectangular sealing ring of pump Bleed the air out Check the sealing performance of air compressor control valve storage tank and lines Change the leather cup Check or replace the seal of hub Change brake plates Refer to problem 2 Check the booster pump Check or replace the rectangular seal ring Pressure in air storage tank drops quickly after shutting down pressure drop 1s over 0 1 MPa in 30 min Slow rise of pressure reading in the brake gauge Insufficient rising force of life arms Insufficient force of the bucket the
116. ow The rotation angles of the steering wheel and the machine are not equal If the steering wheel 1s continuously turned the machine rotation angle will increase until at the needed position The faster the steering wheel turns the faster the machine turns The steering wheel will not automatically come back after turning the turning angle of the machine will be kept After finishing turning the machine turn the steering wheel in the reverse direction to keep the machine moving in a straight direction 58 Operation amp Maintenance Manual LG918 Wheel Loader 1 2 4 Control Levers and Pedals e Shifting Control Lever Refer to 1 1 Control System and the Gauge Fig 3 1 in this chapter This lever controls the direction and traveling speed of the machine The gear box of this machine has four gears Fore and afl High low Gear Control Speed Control with two forward and two reverse gears oe Let T The speed shifting control lever includes i High Speed Forward Gear r Gear high low speed control lever and the TARTAS fore and aft gear control lever The high low Neutral Gear PM T IE A speed control lever includes high speed neutral Tus TA Reverse Gear 74 7 cad AW apee and low speed The fore and aft gear control coils lever includes forward gear neutral and reverse gear With the combination of the two control levers the vehicle will get two front and two rear for a total of four gear lever
117. ow the speed of the machine while running unless in an emergency 3 4 Stopping 4 1 Steps to Stop Release the accelerator and press the brake pedal to stop the machine Put the gear control lever in the neutral position After safely stopping push the parking brake switch to lock the machine in place Level the bucket and other work equipment to the ground Stop the machine on the level ground where there is no danger of stone falling coasting or flooding If it is necessary to stop the machine on a slope wedge the wheels to prevent movement After stopping let the cooling water out The temperature is below 0 C if antifreeze is not added Please refer to 3 5 3 Operation in Cold Weather in this chapter 3 4 2 Steps to Stop Engine Let the engine run freely for 5 minutes to cool all the parts equally O Pull the flameout control soft shaft 1f assembled Turn the key to OFF position And draw it out and keep in a safe place 7 Operation amp Maintenance Manual LG918 Wheel Loader N WARNING Never pull the flameout control soft shaft before the engine 1s cooled x 4 3 Leaving Machine Use the ladder and handle to climb down facing the machine Never jump down Check whether there are particle likes materials on the engine If so clean them immediately to prevent fire Clean all the flammable materials around the machine to prevent fire Lock the door and wi
118. perate carefully to prevent injury Loosen the oil releasing spherical valve on the oil tank bottom to drain the oil to the container Open the oil inlet cover at the same time to fasten the draining process Disassemble the flange cover of the oil box bottom Clean lange the oil tank inside Cover 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 Tighten the flange cover and oil releasing spherical valve again Add oil to the oil inlet port at the top of the left bench until the oil level reaches the middle value of the indicator Tighten the oil inlet port cover Never add oil directly to the oil tank without oil filter elements Start engine and raise and lower lift arm Tilt the bucket forward and backward the bucket to the extreme position 2 3 times to let the hydraulic oil fill the cylinders and pipes sufficiently And run the engine in the idle status for 5 minutes to release the air in the system 84 Operation amp Maintenance Manual LG918 Wheel Loader O Shut the engine Check the oil level Add oil when it is not enough 3 7 Long Time Storage 3 7 1 Before Storage When putting the machine in storage for a long time be sure to do as follows After every part is washed and dried house the machine in a dry building Never leave it outdoors If the machine must b
119. perature 10 40 C 3 Water depth 500mm The loader is a general construction machine and can be used under the conditions listed in this manual Please follow the rules and utilize relative specific purpose equipment If it is used under other conditions or potentially dangerous circumstances such as areas with flammable materials explosives and asbestos dust the manufacturer assumes no responsibility for the potentially resulting damage and injury 7 FEATURES Both the wheel base and operating weight are large so the vertical stability 1s high The working equipment has automatic leveling ability which results in high efficiency and requires less operating strength of the driving person Employs the connecting structure of the new 24 cone elastic seal pipe seal and is reliable Make sure there 1s no leakage Employs new damping system The machine operation is smooth and comfortable The type of power shifting transmission is fixed axle so the structure 1s compact and the transmission efficiency is high The driving axle uses mature technology and has good performance big loading power long use life and high reliability The single stage three element torque convertors can utilize the power of the engine fully to increase the get torque and bigger traction force Adapts to the change of external resistance and realizes automatic continuous variable speed so that the working strength of the operator can be reduce
120. power of transmission box When the right brake pedal is stepped on during driving the brake principle 1s the same as left brake pedal but the power of transmission box is not cut off Release the brake pedal and the compressed air of the booster pump drains from the brake valve to the atmosphere and the brake is released 3 3 Parking Brake System This system employs the manual pliers disc braking system Pull the control lever when you want to brake Pull the brake by the soft past of the shaft to achieve braking At the same time send an electric signal to turn on the parking brake indicator by which to alarm the operator that the vehicle 1s in the braking condition 4 ELECTRIC SYSTEM The electric system is composed of a storage battery starting motor charge generator appliance switch lamps air conditioning circuit and other electric instruments The system of this machine employs D C 24V voltage negative electrode and single wire lines The relation of each electric instrument and their working theories refer to the diagram sketch of the electric system as 1s shown in figure 5 6 5 7 and 5 8 104 Operation amp Maintenance Manual LG918 Wheel Loader
121. praying Switch Ressetable Warning Lamp Switch Switch Group Fuel Level Gauge Brake Air Pressure Gauge emperature vauge Temperature Gauge Pressure Gauge Panel Wir ing Group 1 l I T 1 I Red i Of als Jalal al 8 v 1 2 6 ed 1 5 2 6 als ialala els m al slats ed 1 siale Starting Sritch d een letto dct joe iid co cS BI bet J e o e o OFF o o OFF o o OFF oo ele OFF o o OFF o o Pos Plug Bil B 3 T Off o o S gy 17 Freres Les nna i OF jo o I e 7 I eje I ojo ele I e eje I e eje oto Left Turn o 2 elo 3334 34 42 Floating Magnetic Valve op 4 amo idi diu I eje elo gx Z I eje e e ze Ze ON oto Right Turn o Lo 63 kh A i dl uA 55 p Pu P uA L START DNE MER e 2 FH sf 46 Bucket Magnetic Valve sA LIII J aa dada da Ta E 6 gt FASA SERE E A sags aaa a gi sis N o o Uu Lu Lift Arm Magnetic Valve AA AA 1 i S3993 93 i i Overtaking Light o2 Sto 4 D H H 4 ji l l Engine Oi 0 steering Bel reheat Ma Charging Low Brake Conpiter Box Front Headlight low Front Headlight high Middle Relay Start Chain HA Left Turning High Bean Pressure tndicator Prefiltration tnd cator Parking dirtke Iirostof kir Pressure Power tut Working Right Turning FEE S o Indicator Lampladicator Lanp Warning Lamp Laup Indicator Lamp Lanp Indicator Lamp Lanp Alarm Lamp Indicator Lamp Indicator Lamp Indicator Lang i salis 32525 e gt mi No e o MN eo e as e e ex e S Am a m EN TERT
122. push the parts such as tire rim and driving axle as far as 500m or more The explosion and the particles can lead to severe injury even death so please keep the pressure of the tire at the normal level Inflation pressure should not surpass the standing value The inflation pressure is shown in CHAPTER II 8 TECHNICAL PERFORMANCE amp PARAMETERS Driving at high speeds increases the temperature and therefore the pressure Never try to reduce the pressure but reduce the speed to cool the tire Continuous high speed driving can lead to over heating and tire explosion Stand at the back of the tire and stand as far as possible away from the tire when adjusting the pressure of the tire Check the tire and rim every day for cracks or bubbles Never operate in a low pressure condition 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 Never stand in the front or the rear of the rolling direction of the tire Check the tire from the side If disassembling one tire lock the other tires Take care when welding near a tire which can cause explosion of the tire Only a trained person with a professional license can repair a tire and rim using specific tools and following the proper steps Use the uniform tire with the same standard and same flower pattern for replacement It is the basic rule that tires should be stored in a warehouse No one can enter witho
123. s The working condition of each lever is shown as following High low speed Fore and aft gear control lever control lever Lowspeed Forward Gear High speed Forward Gear I Reverse Gear I Working Device Control Lever or Handle 1 Working device control lever Bucket Control Lever Refer to 1 1 General View of Controls and Gauges Figure 3 1 in this chapter This lever controls the bucket which has three positions lt gt Rear Tilt is used for drawing in the bucket lt gt Neutral is used for keeping the bucket in the desired position lt Forward Tilt is used for dumping Lift Arm Control Lever Refer to 1 1 General View of Controls and Gauges Figure 3 1 in this chapter This lever controls the lift arm which has four positions 59 Operation amp Maintenance Manual LG918 Wheel Loader lt gt Lift is used for lifting PRE Meus Lower Neutral Lift Tilt position Tilt lt gt Neutral is used for maintaining the bucket in the desired position lt gt Lower is used for lowering lt gt Float is used for moving freely under applied force Position of Bucket Position of Lift Arm Control Lever Control Lever 2 Working device control handle Refer to 1 1 General View of Controls and Gauges Figure 3 2 in this chapter This handle controls the bucket and lift There are four gears to control the lift neutral lower and float of the lift arm pro and post and there are three gears to control th
124. sed for precautions that must be taken in order to avoid actions which could shorten the life of the machine IH Operation amp Maintenance Manual LG918 Wheel Loader CHAPTER I SAFETY Read and follow all safety precautions Failure to do so may result in serious injury or death 1 SAFETY LABEL POSITIONS AND THE 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 l Operation amp Maintenance Manual LG918 Wheel Loader with safety labels is replaced please make sure the new component has the same safety label When cleaning the safety labels please use cloth soap and water Do not use chemical and gas cleansers 1 2 The Contents of Safety Label Domestic Type 1 Warning for starting The kev should be at middle position when the machine stops Located above t
125. system 8 16 Maintenance of Storage Battery Oxygen and hydrogen may be generated during battery charging because the electrolyte of the storage battery contains vitriol So mis operation of the storage battery may lead to severe injury or fire Please do as follows Keep kids away from the battery Wear safety glasses and rubber gloves to deal with the battery If vitriol gets in the eyes or on the clothes or wash with lots of water and go to hospital 1f hurt severely Keep fire away from the battery during charging because the generation of oxygen and hydrogen may cause an explosion Prevent circuit from shorting Keep fire away from the crust on the battery because it 1s flammable store the battery under dry clean and well ventilated circumstances with temperatures between 5 25 C Prevent sun light irradiation Keep the battery 2m away from a heat source The battery will be affected by high temperature Never reverse and put horizontally Prevent damage by too much pressure The storage life of a battery is 6 months under room temperature without charging If over 6 months please charge before use Pay attention to the labels on equipment before installation to prevent accidents Spread vaseline on the poles to prevent erosion The wire connections should be firm and credible Never hammer the wire pole which may cause the leak of vitriol Connect the positive pole of the storage battery with the negative pole of the machine first
126. the control equipment are in the neutral position Sound the horn for warning Start the engine Please refer to CHAPTER III 3 2 2 Starting of Engine Only start the engine in the cab Do not start the engine by short circuit It may destroy the machine if it is started from side short circuit This is very dangerous 4 1 4 Check after Starting the Engine Check after the engine 1s started to make sure there 1s no potential danger When examining the machine park the machine in a spacious place and do not let unauthorized people to get close 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 Test the control of the engine speed in the neutral gear Examine the gauges meters and warning light be sure they are in the normal working range 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 or control handles are easy to use Examine the foot brake valve and oil operation valve according to the user manual to make sure that they are normal Check whether the left turning and right turning 1s smooth at low speed Be sure the control lever of the manual brake valve is at rescission of braking state before moving forward 19 Operation amp Maintenance Manual LG918 Wheel Loader 5 SA
127. the torque converter or the water pipe of air condition to prevent burn Never let the harmful alkaline materials in the coolant system touch your skin or eyes 35 Operation amp Maintenance Manual LG918 Wheel Loader Choose a proper container to hold the liquid when replacing the coolant mobile oil of the engine oil of the transmission box and cleaning the parts Please refer to 8 20 Waste Materials in this chapter for the methods to deal with the waste liquid O Keep fire off when disassembling the connection pipe of the air condition compressor 8 12 Examination and Repair of Hydraulic System O Lock the oil tank and other hydraulic equipment safely release the pressure of all hydraulic systems before examining the hydraulic system Never bend or beat the high pressure hydraulic pipe Never assemble the hard pipe and soft pipe if they are bent abnormally or broken O Routinely repair any loose or broken fuel oil circuits lubricating oil circuits the hard and soft pipe of the hydraulic system Leakage can cause fire so routine maintenance 1s critical O 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 a physician trained for this kind of burn will be
128. ts Park the machine on the dry and hard ground If that 1s impossible park the machine on a wooden board which can prevent the tires from freezing on the ground 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 1t the next day When the temperature is below 0 C and there is no antifreeze in coolant water please open the water drain valves located at the bottom of the water tank and the engine Then drain all the coolant water in the evaporators of the cooling system and the air condition system if assembled to prevent cold cracks If antifreeze 1s added please follow the rules on the nameplate of the antifreeze After cold weather After the weather is warm the relative parts should use the proper engine oil fuel and hydraulic oil that are appropriate for the temperature 3 6 Oil and Fuel Supply 3 6 1 Fuel Supply of Engine 1 Fuel Level Checking An oil level check must be executed 15 minutes before engaging the engine or after stopping the engine O Park the machine on level ground and put the transmission lever in the neutral N position Pull the parking brake switch and put blocks in front and back of tires 78 Operation amp Maintenance Manual LG918 Wheel Loader O Open the side door on the left side of the engine cover O Pull the dipstick out and wipe it clean with a cloth Insert the dipstick bac
129. ts such as the silencer when parking the machine Check whether there is leakage of fuel mobile oil or hydraulic oil Replace the broken soft pipes Clean before operation and after repair Check the wire to see whether it is breakage and voltage leakage if so replace it or repair it O Use inflammable liquid to clean the parts do not use gasoline or other flammable materials Never weld or flame cut the pipe or tank containing flammable liquid Clean them using inflammable liquid before welding and flame cutting Check the fire extinguisher before starting repair work Know the location of fire extinguishers and first aid bag and know how to use them O Never use fire match or lighter to check dark areas 8 14 Air Storage Tank Open the drain valve of the air storage tank to drain every day This is especially important in cold weather Make M sure the drain valve is closed before starting the engine Examine the outside of the air storage tank frequently because of high pressure air Examine the 37 Operation amp Maintenance Manual LG918 Wheel Loader anti erosion layer and welding line to ensure safety 8 15 Electric System O The electric system must be maintained by a professional person with a proper license Connect the grounding cable last to prevent an explosion due to electric sparks near the battery when adjusting outside power Remove the start up key before repairing the electric
130. tuating arm injury during steering Located on both sides of Located on the steering actuating arm position of front and rear frames s DANGER CRUSH RISA KEEP CLEAR Do not stand under unsupported load Frame or Bucket i 6 Notice for the door of operator cab Located on right and left operator cab doors 7 WARNING Crush Zone The door must be locked with machine in operation Operation amp Maintenance Manual LG918 Wheel Loader 7 Notice for platform frame Located on right and left platform frames z AD WARNING Risk of Fall On Rntry amp Exit Maintain 3 points of contact Never jump off machine e Climb up forwards down backwards Ensure the steps are clean 8 Hydraulic oil tank 9 Warning of high temperature Located on the hydraulic oil tank Located on vent pipe of engine hood 3 MEE AD WARNING HYDRAULIC OIL TANK Recommanded Scale HOT e AMBIENT T HYDRAULIC OIL A0C 40C L MM6 SURFACE 30C 40C L HY46 a 10 Fuel tank 11 Notice of hot water Pay attention to steam or hot water ejection Located on fuel tank y J Located on cover of water tank of engine hood Recommanded Scale AMBIENT T DIESEL OIL E Os 51 10 l4 T 20 22010 35 F When the oi plane under the 0 line please refill fuel m tune or it can result in flamecut of engine where the
131. uban Titan Gear 20 40 C Gear oil GX Heavyduty GL 5 85W 90 GL5 EP 90 LS90 Automobile Gear oil 85 W 90 HD90 GB13895 HD85W 90 HD80w 90 CeI0 C950 6 Heavy duty gear oil for Oo Brake fluid RR 000 Oil Brands Chinese Brands Grade MOBIL ESSO British BP SHELL Motor vehicle brake SAE pa Brake fluid fluids HZY3 PE Brake fluid Disc brake Donax B 1703C brake fluid GB12981 DOT3 fluid O Grease Similar Oil Brands Chinese Brands MOBIL CALTEX CASTROL ESSO British BP SHELL Operation amp Maintenance Manual LG918 Wheel Loader ZG 2 or a eer Mobile grease ae LM grease oes Enererease L Retinax A XHP222 B Beacon EP 2 Alvania lubricant grease Purpose GB7324 2 3 The Sketch of Lubricating Points HACER LUBRICATION POINTS INDICATION 1936085 CHANGE OIL OIL POSITION CHANGE OIL AFTER RUN ADD GREASE orto HYDRAULIC HYDRAULIC DIESEL INSPECTION IN TIME OIL TRANSMISSION OIL ENGINE OIL ERAH o WIRE EH JURE on EM RUTA Xu 2 4 Detailed Rules of Electric System Maintenance o If the wire stays in the wet environment or the insulation of it is damaged the electric system may leakage which will cause hazardous accident Maintenance of components related to the electric system 1 Check the tension and distress of the fan belt 2 Check the fluid level of electrolyte 1n the storage battery Never remove or disassemble any electric components installed 1n the machine Never install any electric compo
132. uld face the high direction of the ramp at all times which means go up forward and go down backward Injury even death may occur if the disabled machine is towed incorrectly 24 Operation amp Maintenance Manual LG918 Wheel Loader Follow the direction in CHAPTER III 3 5 2 7 Towing a dangerous contion may be caused by using the wrong method Wear gloves to deal with a tightwire Before preparation for the towing confirm the signals with other people Please contact Shandong Lingong Construction Machinery Co Ltd or their accredited representative 1f the engine does not start or the brake system has problems Please tow the machine on level ground it is dangerous to tow on a ramp If a disabled machine 1s towed by an other machine the tightwire should be strong enough to pull the weight of the towed machine The tightwire with wring or radius reduction can not be used A bare of birdcage inner rope shape O People are not allowed to go between two machines when the machines are connected Do not stand on the towing steel wires or tightwires 6 SAFETY OPERATION 6 1 Keep Good Operation Habits Always be seated with the safety belt locked during operation The machine in operation should always be controlled by the operator Operate the control lever of the working equipment properly to prevent misoperation O Examine and listen to the exceptions carefully and report immediately D
133. ump or replace it every gear 1S control valve Readjust to the specified value low Invalid spring of pressure regulator Change the spring of pressure valve in transmission control valve regulator valve Pressure regulator valve of Disassemble and check to remove the transmission control valve or lock accumulator piston is locked 86 Shifting pressure of a certain gear is low The oi of torque converter overheats Machine can not move when engine runs in high speed Insufficient driving force Insufficient brake force Failure to release brake the normally Un BWN ON Damaged piston seal ring of this gear Damaged gasket in the oil lines of this gear Oil leakage in the oil lines of this gear Low oil level in gearbox oil tank High oil level in gearbox oil tank Low shifting pressure and clutch slips T Q radiator is clogged T Q operates with high load for a continuous long time Radiator is not good Cut off valve spool of transmission control valve can t reset Shift no gear Spring of pressure regulator valve in transmission valve is broken same as 1 2 3 and 4 of problem 1 Low shifting pressure High oil temperature of T Q Damaged T Q blades Damaged overrunning clutch Insufficient driving force of engine Oil leakage of pliers pump Air in brake hydraulic lines Low brake air pressure Over worn leather cup of booster pump Oil leakage from hub to brake plates Worn brake plates Wrong p
134. uring dark conditions And stop work when there is smoke fog sand or dust which affects visibility When working at night please make sure Proper lighting system is installed Fuction light works normally To carefully estimate the height and distance of objectives Keep alert and stop the engine and examine the environment and the machine frequently O Make sure that every bridge is strong enough to let the machine pass 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 O No unauthorized person is allowed to enter the working area because the working equipment will work up and down turn left and right and move forward and backward all the time Keep people away from all sides of the working equipment 27 Operation amp Maintenance Manual LG918 Wheel Loader O To ensure safety when working at the side of a road or hear a cliff where the land may shift designate a person to watch and direct at all times O Take care with the dumping position when unloading sand or rocks from the high position When pushing material off a cliff or when the highest point is reached the load may desrease suddenly Subsequently the moving speed will increase so slow down
135. ut permission Put a fence around and hang a No wedge Enter sign if the tires are stored outside the warehouse Store the tires in a dry and clean place Water can oxidize a tire and 40 Operation amp Maintenance Manual LG918 Wheel Loader dirt and oil can erode a tire No light heat insulation or ventilation are needed for storage Cover the tires with a canvas plastic or other anti dust cloth The wrong storage method can greatly reduce the quality and life of tires O Stand the tire on level ground and use a wedge to lock it to prevent it falling down The quality may be reduced if the tire is laid on its side The tire should be rotated 90 once per month at least Please stand aside if a tire starts to fall down Never try to hold a tire since the tires for engineering mechanisms are generally very heavy and you may be seriously hurt 8 20 Waste Materials Do as follows to prevent pollution Never dump waste oil under ground or into the river Contain the oil vented from the machine in a container never dump the oil directly onto the ground 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 Keep the engine speed low during loading and unloading the machine Load and unload machine on level ground and remain at a safe distance off the road S
136. view of control System with pilot single handle and three pedal 51 Operation amp Maintenance Manual LG918 Wheel Loader Fe 1007 FONG S 60 120 149 De O o eo E O 9 C Se REN 1 Working Chronometer 2 Engine Water Temperature Gauge 3 Gearbox Oil Pressure Gauge 4 Torque Converter Oil Temperature Gauge 5 Brake Air Pressure Gauge 6 Right Turn Indicator Lamp 7 Preheating Indicator Lamp 8 Parking Brake Indicator Lamp 9 Charge Indicator Lamp 10 High Beam Indicator Lamp 11 Engine Oil Pressure Warning Lamp 12 Brake Air Pressure Warning Lamp 13 Left Turn Indicator Lamp Figure 3 3 General view of gauges 12 184 12 1 I FER 3 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 wiper Switch 15 Cover Board 16 Rear Headlight Switch 17 Front Headlight Switch 18 Rear Light Lamp Switch 19 Warning Lamp Switch Figure 3 4 General view of gauges with revolution indicator and fuel level gauge 52 Operation amp Maintenance Manual LG918 Wheel Loader 1 2 Introduction of Gauges amp Controls The introduction of gauges amp controls needed for operating the machine 1s below Be sure to understand their functi
137. w Front Headlight High Start Chain ry gt Light Low Oil oarse e e e R Left Turning High Lighting 30 y A y Switch Switotr 4 Pressure Fittretiur Preheat Hand Brake Charging tow kir Power Cut Computer Box Right Turning Light Indicator i Emergency Turning A y E Light Warning Light Indicator Light Indicator Pressure Light Off Light Working Light Light g 5 4 2 82 es e o me z e e ein e HH LH e Sia 22 le e e s OR gt s S gt S3 Se 332 sm as BOS aS e ejes muweusu pam m sg a s Aas te 4 80 so a EG a ada dad ol l ol 666666646 Low Pressure 3L 82 5 123456789 Alarm 20 Y 18 123456789 B 90009 000 15 2 IE 80 96 14 E RATIAAA gala o FAA ASIA SA 3 L 32 n 17 49 30 3 i 1 1 19 Fuse Box n 0 150 Flashing Amber Reserve 104 104 104 104 7 54 104 104 104 104 104 10A 104 104 104 104 25A 1104 104 SA 104 B 0 Socket 1 Cab Wiring Assembly oo 1 C c Mj e x MA e e Mel sr MM sol e e em am e g z z E 2 aa els toos ZG sl a N OO0000000 0 O O N7 0 0 0 0O O0 0 0 0 OO G OO 0 W Ai Bl R k s Sx Mises etree Wo 45679000 Bain E ee ee Fan 0 l Blower Switch 41 L234 5 TES 1234567891011 agdas a0 bad islas 45 OO0O00 00000000 9 OO0Oo0000000 9 OFF m o O 1 Lit g 39 21 7 li 2 41 t m Air ot To 36 ll Y Condition de ds sss Joo 0 Q4 La 0 0 0 d A Top Warning Light OT 30 A 30 i 30 can Be msi
138. wners Parameters figures and information included in this manual apply only to basic loaders For those derivative products please consult us or refer to the relative manuals When selecting working equipment please follow the user manual of the working equipment to assemble and disassemble replace and use In addition please read carefully the attached technical user manual 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 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 the right to maintain it The design operation and user information in this document is subject to change without notice Customer feedback is very welcomed If you would like to comment on any aspect of this manual or our products in general please feel free to contact us Please give us feed back about the shortcomings immediately upon using our products so that we can continue to improve our products to satisfy your requirements All rights are reserved The contents of this publication may not be reproduced in any form or communicated to a third party without prior written permission of Shandong Lingong Construction Machinery Co Ltd Operation
139. y circumstance sending light to warn the other vehicles and passersby Press the button once again and the button springs back so all the turning lamps will stop blinking Rear Light Lamp Switch Press bottom side the rear light lamp and the front and rear side indicator lamps will come on press top side the lamps will go off Rear Headlight Switch Press bottom side and low beam of the rear headlight on the engine hood will come on Press top side and the high beam of the rear headlight on the engine hood will come on If no side 1s pressed no lamp will come on Top Lamp Switch This switch 1s behind the ceiling lamp in the operator cab see picture Press ON position to turn 1t on z Bn E SN x Li ad Press OFF position to turn it off d Fan Switch Press the bottom side for low air speed Press the top side for high air speed Press the middle of the button and the fan will stop Horn Switch Press the button in the middle of the steering wheel and the horn will sound 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 amp Operation Manual 1 2 3 Steering Wheel The steering wheel and steering unit are connected Turning the steering wheel clockwise the machine turns right turning the steering wheel counter clockwise the machine turns left The features are listed bel

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