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2. r P Torque Converter 011 Tont Main faper Spraying Rocker Front Lighting Lanp Rear Headlight Rear Lighting Lanp ret ret tne PRS MEN etn Presse Su Pannel Viring Group ocker Switch Switch Resselable Rocker Switch Rocker Switch Rocker Switch vel Level Gauge AS rake Ait Pressure Gauge Rotate Spee ae igation Water Temperature Gauge i N M Croup OFF Jo L fol lo omfellowked Blacktray Rios Orsag hite SE e s E _ Starting Switch sn omfrenrtet acktray the trag 5 E 1 B B 3 Hl Ulf dieti L d oN Met ote Alen a haha ee ss elel ca L iL 19 E uu xd f oy munuezsz eee 79 J START TIT 0 Brake Air L Warning L 4 High n t _ Charging 1 l 1 Op Warning Lam 3s Fon Preheater Failure Indicator High Light Power Cut3q Computer Bor Pressure over Cul Lett Turning Fuel Prefiltration i p T ceria Indicator Indicato
3. 103 YCONTENT OF MAINTENANCE 103 Every 10 Houts Days NER T T 104 3 2 Every 50 Hours Week Service RE P v mm 104 3 3 Every 100 Hours Month Service oun odia erani ioo Diete 104 3 4 Every 250 Hours Month Service 105 3 5 Every 500 Hours SEASON 105 3 6 Every 1000 Hours Half a Year Service nennen nennen nennen enne nen en nennen 105 3 7 Every 2000 Hours Year SetylQG tese ni asco deese Epor EE HE PEE EE UE RARE E EE ORAE RR EE RSEN bus ERES EROS 106 2 0 a AC CEE OO 106 3 9 Replace the Air Storage Tank after 3 Years of Service nennen 106 CHAPTER V THE STRUCTURE AND PRICIPLE OF MAIN COMPONENTS AND SYSTEM 107 MERRIE SONG SYSTEM 107 ESAE BIN IOS Mns E A 108 d OI CR TEM m 109 3 1 Driving Brake System Single Brake Pedal atta o a ruere nnn n 110 3 2 Driving Brake System Double Brake 5 110 3 3 Emergency and Parking Brake System ssssssssssssssssssseeeeeeeeeee eene enne e ene ne nene eene EERE essen nennt 110 SMS iM M C ere 111 LW ZR io L SDLG Operation amp Maint
4. LI 8 2 2 ICES eo mare 8 2 T0 ECHO MEMS Gee 9 ZA NRO CMICAIO p md diuturno atlas rebus Mariam Seiad 9 OO Ee Re 10 vtto tn Pasi N ees 10 3 2 W hen Operators oto to tiet eee 10 2 2 Mounting and DIMOUNN eii odiis Ede uae eee 11 Prevento N 11 3 5 Precautions When Operating at High 12 3 5 Road DM VAIN uus ain eed 13 2 7 Prevent Grusmine op uttme Body Parts sius ee rii tet imr iit uae rie a 13 3 9 NOU CE Ol Ata DHDEBIE p LS od ae cU ROS Uu 14 3 9 Notice of using FOPS amp ROPS prevent falling and rolling cab if assembled 14 sic y 20 AMIE NT 14 ZI Betoretartins BN OMG oin 14 S DATDETLY DRIVING o t pute ou d D ee E ee ae ai te Nie teas 17 Sol D oe eese terat eee 17 5 2 Sateby OF e and AE de EE 17 3 Eoad Transportatiomniioccomo On Qe cues ge n Eee c 19 54 Driv
5. 95 KIO OLE Teva ceca 95 lS L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader DRE Io NG Rm ERmRR M 95 MU tr caters tec ce sts caters 95 MNT 95 1 44 Checking th Frame 95 1 15 Attention to Washing Machine Ere E 95 1 16 Checking in Raining and Snowing Circumstances eene eene eene nennen nennen nennen 95 1 17 Dusty 96 Lis Avoid Miked Oil 96 2 DETAILED RULES OF MAINTENANCE 96 2 1 Detailed Rules of Using Fuel and 1 96 2 2 Selection of Fuel Coolant and Lubricant eese ee emen nenne teer ee nennen nan 98 2 3 The Sketch of Lubricating POTIS oe eer tton HE o Ant notae Aa SR o ds 102 24 Detailed Rules of Electric System Maintenance ie heh net eate a ee e a eater a o de dd and 102 2 Esto INC vil Fore 103 2 6 Tightening Torque of SCrew
6. site Re ee ee RE ee edes 30 5 5 Working the secum oe et e dete dieta Se Poet Poeta bd ds eed 30 8 6 Maintenance While the Engine is 3l 8 7 Do Not Let Anything Fall into the Inner Part of the 31 RS We AM 11 31 oes Meis had NY Cy ee ee TT ee 32 LU Z amp ll SDLG 7 Operation amp Maintenance Manual LG958L LG959 Wheel Loader S10 RENA at ca cea 32 s 11 Maimenance or Coolant Syste cesce EErEE EE OE REOR rO 32 8 12 Examination and Repair of Hydraulic System sssssseseeescesseeeseeeeseeeeeeseeeeeeesesseeeeeseeseeeees 33 8 13 Proventing E 34 Storage 09982008 1362286 HE 35 SON eo wl RITE 35 8 16 Maintenance of Storage 35 5 17 Charpin ol Storace riens EEE 36 8 18 Starting to Use Voltage Raising a7 B T9 Maintenance did Storage Of 37 B20 Waste MGT E OTT E EES 38 SAFETY TRANSPORTATION 39 9 1 Assemble and Disassemble the UNE ese Ea Radix 39 9 2 the ound RENE T T 39 Oy MEUM cheese ther
7. 3 1 Driving Brake System Single Brake Pedal As shown in Figure 5 3 this system is the single line 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 brake pedal is stepped on during driving the compressed air in air tank 3 flows through air brake valve 2 into 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 piston of the caliper disk brake and makes the friction disk contact the brake plate to achieve the purpose of slowing and braking In this time turn on the select switch of cutting power At the same time output the signal of air pressure and cut off the power of transmission box In some specific conditions ramp operation the power of transmission box is not cut off which is braking Release the brake pedal and the compressed air of the booster pump drains from the brake valve to the atmosphere and the brake 15 released 3 2 Driving Brake System Double Brake Pedals As shown in Figure 5 4 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 is stepped on during driving the compressed air in air tank 4 flows through air brake valve 3 and shuttle valv
8. Press the accelerator properly when shifting gear to avoid sharp speed increase It is best to change the running direction from forward to reverse or from reverse to forward after stopping the machine to get the best driver comfort and prolonging the life of the engine 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 Turn the steering wheel to the desired direction The machine will turn The machine takes the articulated pin at the center And the front and rear frames turn by rotating its waist Never turn suddenly or turn on a slope at high speed When driving straight the machine can not turn if the engine stops 3 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 left one if the double brake pedals are assembled when the machine goes on a slope in order to avoid dangerous from power cut Never use the parking brake switch to brake or slow the speed of the machine while runnin
9. 1 4 s 1 0053 MAL tt D o 1 1 uL LLL l dict sev to l _ Rn m 1 Lighting Dar 2 1 L ee 2 paetic Talse s LE es VR Durex a j n trm HR Ue Fee I II a alt ee ee SL Cere n Firing Dr 5 1 Fe eee aw a y Parting Brake Suited left i 97 NEN ood y i Nez Rei Hiper ail j HP Ht ki Od a TTT I HEISE Hove 3 0 HHHH m ESCONHNESNN i A A 28 1 l 1 TT Rear Frame Viring Group keat Rear Headlight C7 BE CN Tarat Comet tor 011 Seater d imm iii Tur Packing Babe Indicatoe Switch TT BIacrgeacy Parklog Brake Switch Presvare Sensor Brake Lir Pressure Ssasor OLL Preasore Seltch Vater Temperature Sencar a zt pis RR ns belay 1 Figure5 6 1 69581 Electric System Principle Diagram with Weichai Engine Export 113 1 SDLG Operation amp Maintenance Manual LG958L LG968 Wheel Loader Figure5 7 Electric System Principle Diagram
10. 13 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 8 Notice of Attachment Please read the user manual for all of the attachments and the contents in the manual that refers to an attachment when the attachment is 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 machine Shandong Lingong Construction Machinery Co Ltd assumes no responsibility for any injury accident or destruction of the machine induced by using unauthorized attachments 3 9 Notice of using FOPS amp ROPS prevent falling and rolling cab if assembled Install the FOPS amp ROPS to prevent falling and rolling when engine woks and protect the operators The ROPS device can be used to support the load when the toppling occurs and can absorb the impacting energy Pay attention as follows The normal function is not satisfied if the strength reduces because of damage In this case please contact Shandong Lingong Construction Machinery Co Ltd or the sellers specified by Shandong Lingong Construction Machinery Co Ltd and ask for the repairing method Only the operating person ties the safety belt to obtain the effecti
11. 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 brake 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 and even death In the circumstance with the risk of hurt caused by falling objects user should purchase the machine with falling object protective structures 8 AX SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 2 3 Protective Items protective vest or mask earplugs heavy gloves when the machine is 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 low
12. 1 2 9 1 control panel and its operation if assembled The Appearance of Panel 60 1 Working Indicator Lamp 2 Air Volume and Power Switch 3 The Switch to Control the Temperature lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader The panel of air conditioning 15 on the right operator box Operating methods a 4 4 b 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 15 higher than the setting temperature the indicator lamp 1 lightens and the compressor will begin to refrigerate when the inside temperature is lower than the setting temperature the indicator lamp 1 turns off and the compressor stops working Heating lt Before using turn the te
13. 94 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader before draining 1 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 fuel strainer while fueling 1 10 Oil Changing Change oil in relationship dust free places to keep impurities out of the oil 1 11 Welding Guide Turn off the starting switch of the engine and remove the battery cables Keep 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 nonflammable 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 Raining and Snowing Circumstan
14. oil should be added by the oil adding port 78 Operation amp Maintenance Manual LG958L LG959 Wheel Loader Oil Adding Port of shangchai Engine Move full limit _ Still full limit Adding oil limit Notice Check the other side of the dipstick when the machine under the idle speed It 1s a suitable oil level if it is between the adding oil graduation line and the oil motion full graduation line If the oil level is lower than the adding oil graduation line oil should be added B Dongfeng Cummins 6CATS 3 It is a suitable oil level if it 1s between the ADD and FULL scale If the oil level 1s lower than the ADD scale oil should be added by the oil adding port ae ATL Ad i LJ N E Side Oil Inlet Port Cummins Engine Top Oil Inlet Port of Cummins Engine 79 Operation amp Maintenance Manual LG958L LG959 Wheel Loader Then put back the oil dipstick and close the profile door of the engine For choosing appropriate oil please refer to CHAPTER IV 2 2 Oil Selection 2 Engine Oil Replacement Park the machine on level ground and put the transmission lever in neutral position N 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 then stop the engine Rotate the oil drain plu
15. when reinfusing otherwise the effect will be reduced Selecting range is advised as below 25 is used in the temperature of 2 157 35 is used in the temperature of gt 25 C 45 is used in the temperature of 2 35C SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 5 Notice for the operator cab door 6 Notice of required reading manual Located on the left of operator cab door Located on the right front upright column of operator cab 7 Prevent rolling Located on the right front upright column of operator cab 8 Check before starting Located on the right rear upright column of operator cab WARNING T I THE RESPONSIBILITY OF THE OPERATOR T CHECK ATR PRESSURE HECK OIL LEVELS DAILY GREASE DAILY CHECK FURL DAILY CHECK WATER LEVELS REPORT ANY FAULTS 9 No passenger warning Located on the right rear upright column of operator cab WARNING e e DRIVER ONLY Strictly NO passenger s 10 Warning to avoid noise lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 11 Wearing seat belt warning Located on the right rear upright Located on the right rear upright column of operator cab column of operator cab S WARNING Implements may increase noise level Hear ing protection must be worn 12 Logo of
16. 2000 hours 3 7 Every 2000 Hours Year Service Carry out the periodic maintenance of every 10 50 100 250 500 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 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 3 8 Refer to Operation and Maintenance Manual of diesel engine for maintenance 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 is very severe please shorten the maintenance cycle and increase the maintenance times according to the real conditions 3 9 Replace the Air Storage Tank after 3 Years of Service 106 war us SDLG LU L operation amp Maintenance Manual LG958L LG959 Wheel Loader CHAPTER V THE STRUCTURE AND PRICIPLE OF MAIN COMPONENTS AND SYSTEM 1 TRANMISSION SYSTEM The transmission system includes the hydraulic torque converter transmission box transmission axle front and rear driving axle wheel and others The transmission system diagram is shown in the Figure 5 1 diesel engine
17. 3 Disassemble and check the torque converter change blades Check and maintain the engine SDLG 3 8 3 Brake System No lli Problems Insufficient brake force Failure to release the brake normally Pressure in air storage tank drops quickly after shutting down pressure drop is over 0 1 MPa in 30 min Slow rise of pressure reading in the brake gauge Possible Causes 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 position of brake valve spool locked piston rod damaged or faulty reset spring Improper operation of booster Pliers piston can t reset 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 9 Operation amp Maintenance Manual LG958L LG959 Wheel Loader Remedy 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
18. Loader 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 loading 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 Install lighting systems during 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 Make sure that every bridge is strong enough to let the machine pass 24 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 No unauthorized person is allowed to enter the working area because the working equipment will work up
19. ON position Connect the power switch and ring the horn Press the accelerator slowly then turn the start key clockwise to the START position After releasing the starting key it 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 minute If the engine does not start after three 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 break the turbo charger 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 Keep the engine at an idle speed for several minutes after starting Increase the speed to 1000 1200r min gradually and then enter the partial load running status Pay attention to the value of the gauge Do not let the engine run at high speed or low speed more than 20 minutes in the idle status If the engine has to run at idle status the machine should be loaded from time to time or the en
20. 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 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 1s poor When visibility is not good stop working until the weather cleans 19 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 headlights and working lamp on when working in dark areas 5 6 Pay Attention to Blockages 5 7 Driving in Dangerous Conditions If there are blockages roof of buildings or the door frame keep the loader away from the blockages when turning or passing Notice the environment Slow down and check whether there are some blockages when turning or going through a narrow passa
21. 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 of whole machine 10 Check the control levers or control 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 engine only after the whole checking list completed 3 2 2 Engine Starting 67 lli SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 Put the shifting control lever to the neutral position Turn the start key clockwise to the
22. cover of the oil box bottom Clean the oil tank inside 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 box 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 raise and lower lift arm tilt the bucket forward and backward and turn left and right 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 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 be outdoors park it 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 Lower the bucket to the ground and set all contr
23. e J 0 0 B l 4 fS 2456 n 0 ij de gt Switch N31 Groun 29 mo Relay Blectric Pump Pre heat unit Pre heat Relay UN Blectric Power 31 7 f 0709 m _ 0 rake Air Pressure Sensor Engine Oil Pressure Sensor y Ta 1 a wx z gt i ectrie Power 10a Approaching Switc N20 trom 3 4 35 eu 18 a j ello m p y H Camshaft Position Sensor Sigual 19 1 1 gt ted mm 7 5 VN Electric Poser i Blectric pump 28 Mee 3 521 Grown m 55 Coolant Temperatrue Sensor 5102 14 Fuse 394 P Sc S64 Pressure and Temperature Pressure Signal Relay of Storagy g Temperature signal 48 A Sensor of Input dir Electric Power 5 m l Battery Signal t E Fuel Temperature Sensor A Ground P i Ly 2 Fuse E Engine Water Temperature Sensor Storagy Battery p 604 A 14 P HN J A pui Power Switch Wi starti ea o 4 d Engine Oil Pressure Switch l 1 1 generator LN E O Figure 5 9 1 69581 Electric System Principle Diagram with DDE Engine 116
24. for lifting Neutral is used for maintaining the lift arm in the desired position Lower is used for lowering Float is used for moving freely under applied force Notice Never put the lift arm down when it 15 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 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 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 58 Opera
25. l Input Gear 2 KR Reversing Gear 3 Mid Axle Gear 4 4 Gear 5 K34 Gear Ring 6 3 Gear 7 Output Gear 8 2 Gear Group 9 KR2 Gear 10 Working Pump Driving Gear 11 Steering Pump Driving Gear 12 1 Gear 13 Gear 14 KV Reversing Gear Figure 5 1 Transmission System Diagram 107 AX SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 2 HYDRAULIC SYSTEM As shown in Figure 5 2 the hydraulic system includes the working equipment hydraulic system and steering hydraulic system The working equipment hydraulic system is composed of a work pump guiding valve multi way valve lift arm cylinder bucket cylinder hydraulic pressure oil tank and pipe attachments The hydraulic operating system employs a hydraulic guiding control system The bucket unit includes dumping neutral and receiving bucket in three positions The lift arms unit controls four actions including floating lowering neutral and lifting The set pressure of the safety valve is 18 18 5MPa The overload pressure of the rocker cylinder s large cavity is 20 5MPa while that of the small cavity is 12 x 1 lt gt V y 1 Work Pump 2 Hydraulic Tank 3 Pressure Oil Tank 4 Pair Pump 5 Priority Valve 6 Steering 7 Combination of Valves 8 Steering Cylinder 9 Guiding Valve 10 Multi Passage Valve 11 Lift Arm Cylinder 12 Bucket Cylinder Figure 5 2 Hydraulic System Diagram The
26. messages and on safety labels where there is a high possibility of serious injury or death if the hazard 15 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 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 NOTICE 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 used for precautions that must be taken in order to avoid actions which could shorten the life of the machine A URISI SDLG Operation amp Maintenance Manual LG958L LG959 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 1 1 Safety Label and Its Position The positions of safety labels of this machine are shown in the figure 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 with safety labels is re
27. shell 2 Oil Replacement Park the machine on level ground and run in idle status for about 10 minutes Trample 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 83 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Shut engine Push transmission lever in the neutral position N Pull the parking brake lever and wedge the front and rear wheels Loosen the oil drain plugs on the two wheels on the 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 be careful of the hot oil splash 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 Press the hand braking control valve 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 regular gear oil about 32L 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
28. spanner Assemble Add diesel oil full in the filter element and smear engine oil on the rubber seal ring Tighten 3 4 1 cycles after the seal ring connects with the base Start the engine and check whether the seal ring is seal If not disassemble the filter element and check the sealing surface After changing the filter elements the engine must run in the idle status at least 1 minute to ensure the engine 15 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 Park the machine on level ground and check the fuel level by dipstick on the outside of fuel tank If the fuel level 1s 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 e LLM 7I rernm RN adding port with lock Oil adding port of gearbox 81 lS L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 6 3 Adding Oil to Gearbox 1 Oil Level Check Park the machine on level ground and put the transmission lever in the neutral position N Pull the parking brake switch and put blocks in front and back of tires Start engine to run in the idle status about 1000r min Loose the checking Uupper limit gauge in the left gearbox adding port o
29. 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 is longer than 10 km or the towing speed faster than 10 km h the front and rear transmission axle must be disassembled or put the loader on towing truck for transportation 76 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 5 3 Operation in Cold Weather Attention for cold weather If the temperature is very low the engine will be difficult to start And the radiator may be frozen so please do as follows Use fuel hydraulic and lubricant oil with low viscosity Refer to CHAPTER IV 2 2 2 Selection Table of Fuel Coolant and Lubricant for the details of using oil Attentions for using antifreeze 1 Do not use antifreeze containing formaldehyde ethanol or propanol 2 Never use any waterproofing agent independently or together with anti
30. 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 Make sure the loader is locked and put the key in a safe place 10 AX SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 If this machine s cab assembled tow doors on the left and right in order to prevent to mistake operation please insure to make the door on the control lever side as urgent exit and please don t get on or off th
31. the environmental conditions and calculate the real power under the current environmental condition according to the power 66 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader correcting table in Diesel Engine Usage and Maintenance User Manual Engine is shut up when the machine is working Pull the operation handle to neutral position turn the starting switch to ON to restart the engine If the engine is normal it is allowed to continue to work If the engine fails push the operation handle to floating position to lower the working devices on the ground slowly For the residual pressure in the system pull the boom and bucket handles back and forth 10 times until the pressure remained in the system is released radically then repair the machine 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 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 in the water tank 5 Check the
32. the fuel pump will not work normally Never let impurities enter when changing and adding fuel 96 lli SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Strictly choose the fuel brand according to this manual The fuel may be frozen at low temperatures particularly temperatures lower than 15 So it 15 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 is condensed by the moisture 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 In order to avoid causing scale which can make the radiator stop or influence the performance of dispelling the heat please always use glycol type engine antifreeze as coolant about Shandong Lingong stated in whole year Strictly forbid to use water as to coolants Use Engine antifreeze of glycol type as coolant 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 Antifreeze is flammable Keep fire away when adding the antifreeze When adding the antifreeze choose different model according to the ambient temperature recommend range If the ambient temperature 15 C use 25
33. 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 1s 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 it as referenced in user s 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 12 AX SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 6 Road Driving Pay attention to the stability of the front and rear of the machine during operatio
34. to problem 2 Check the booster pump Check or replace the rectangular seal ring Brake continuously several times to blow the dirt off or change valve Tighten the pipe fitting or change brake pipes Find out the reasons for sealing failure and change parts if 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 lli 1 SDLG Problems 3 8 4 Hydraulic System of Work Equipment Possible Causes Over worn or damaged cylinders Over worn multi passage valve excessive clearance between valve Operation amp Maintenance Manual LG958L LG959 Wheel Loader Remedy Change the oil seals of cylinder Change the distribution valve Find out the leaking points and spool and valve block repair Oil leakage of oil lines Change the oil pump Severe internal leakage of working Check oil lines and remedy pump Regulate the system pressure to Idle suction of working pump set value Low set pressure value of safety valves Clean the filter strainer and Clogged suction tube and filter change oil Insufficient 1 rising force of life arms Damaged seal ring of steering cylinder piston 2 Over worn of multi passage valve excessive clearance between valve Change the oil seals 2 Change multi passage valve 2 bucket tend to 3 Cha
35. 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 40 C before starting 1f the environmental temperature is lower than 5 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 stopping the loader Full load work is allowed until the water temperature of the engine is above 60 and the mobile temperature of the engine is above 50 But the water temperature of the engine should not be over 95 and the mobile temperature of the engine should not be over 120 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 400 500mm above the ground to ensure stable driving during the transporting process The power of the diesel engine will go down as the altitude environmental temperature and relative temperature goes up So please pay attention to
36. with Cummins Engine 114 ll 1 SDLG Operation amp Maintenance Manual LG958L LG968 Wheel Loader Figure 5 8 Electric System Principle Diagram with Shangchai Engine 115 1 SDLG Operation amp Maintenance Manual LG958L LG968 Wheel Loader
37. 01 MPa 0 39 0 01 MPa Rear wheel 0 33 0 01 MPa 0 33 0 01 MPa 47 lli 1 SDLG 8 2 Principle Dimension and Weight Length bucket on ground LG958L Length bucket on ground LG959 Width outside of wheels Width outside of wheels Bucket width Height Wheel track LG958L Wheel track LG959 Wheel base LG958L Wheel base 1 6959 Min ground clearance LG958L LG959 Max dumping height 45 dumping angle Dumping space 45 dumping angle Dumping angle 8 3 Product Standard Product Standard Q LGJ 001 wheel loader 48 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 8079 mm 8017 mm 2785 mm 2799 mm 3024 mm 3382 mm 2190 mm 2204 mm 3200 mm 3179 mm 457 mm 3120 mm 1130mm gt 45 8380 mm 2785 mm 3024 mm 3382 mm 2190 mm 3200 mm 457 mm 3500 mm 1160 mm gt 45 4 lm Member of Volvo s Grc CHAPTER III OPERATION AND APPLICATION 1 BE FAMILIAR WITH MACHINE 1 1 Control Systems and Gauges Figure 3 1 General View of Control System With Two Pedals 1 Steering Wheel 2 Panel 3 Gear Control Lever 4 Brake Pedal 5 Accelerator Pedal 6 Seat 7 Parking Brake Switch 8 Equipment Control Lever 9 Switch Group 10 Starting Switch 11 Horn Button GE EE 5 1 Steering Wheel 2 Panel 3 Speed Change Control Lever 4 Brake Pedals on both sides 5 Accelerator Pedal 6 Seat 7 Parking Brake Switch 8 Equipment Control Lever 9 Switch
38. AMEPLATE 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 15 shown in the following Fig The other configurations of nameplate refer to CHAPTER II 8 TECHNICAL PERFORMANCE amp PARAMETERS CERERA WHEEL LOADER ATE kg kg Rated Load Operating Mass AAAS ABLE ET kW Engine Model Engine Power AME R mm XL ERI km h Dimension Max Speed dI 85 lir Ig Serial Number Manufacturing Year amp L 1 2 Wl BS SHANDONG LINGONG CONSTRUCTION MACHINERY CO LTD Ms or 22 at 3 IN 7E ARX TT Mb pa LINGONG INDUSTRY PARK ECONOMIC amp TECHNOLOGICAL DEVELOPMENT AREA LINYI SHANDONG P R CHINA Nameplate of LG958L LG959 Wheel Loader 44 lS L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 N WARNING The following operations are forbidden for the loader 1 Over loading Unbalan
39. Group 10 Starting Switch 11 Horn Button 49 SDLG 7 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 17 16 15 147 137 12 1 Gearbox Pressure Gauge 2 Brake Air Pressure Gauge 3 Working Chronometer 4 Turn Indicator Lamp 5 Indicator Lamp 6 Right Turn Indicator Lamp 7 Fuel Level Gauge 8 Engine Water Temperature Gauge 9 Torque Converter Oil Temperature Gauge 10 Starting Switch 11 Switch Group 12 Water Spraying Switch 13 Rain Wiper Switch 14 Cover Board 15 Rear Headlight Switch 16 Front Headlight Switch 17 Rear Light Lamp Switch 18 Warning Lamp Switch Figure 3 3 General View of Gauges 1 Gearbox Pressure Gauge 2 Brake 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 50 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 1 2 Introduction of Gauges amp Controls The introduction of gauges amp controls needed for operating the machine is below Be sure to understand their function
40. If the ambient temperature 25 C use 35 If the ambient temperature 35 C use 45 2 1 3 Brake fluid Never mix the brake fluid with different brands If you want to replace new oil that 1s different from the used one drain the used brake fluid radically and conduct a feasibility test before replacement or the problems caused by the replacement of brake liquid will lead to the failure of brake and cause accidents SDLG Construction Machinery Co Ltd will not be responsible for the results In order to maintain and use your machine please use the specified brake fluid according to the requirements of SDLG 2 1 4 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 is necessary to add lubricant 97 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Remember to wipe off the overflow lubricant when adding it 2 1 5 The Storage of Oil and Fuel Prevent water dirt or other impurities from mixing with the oil 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 6 Filters Filters are extremely important safety components They can prevent impurities in the fu
41. LG958L LG959 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 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
42. LU ZR li SDLG Operation amp Maintenance Manual LG958L LG959 WHEEL LOADER 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 lli SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader LG958L LG959 WHEEL LOADER Operation amp Maintenance Manual 880x1230 mm 162 6 5pieces Ind Edition in 2011 12and 2st Print SHANDONG LINGONG CONSTRUCTION MACHINERY CO LID Address Linyi Economic Development Zone Shandong 276023 Tel 86 0539 8785624 86 0531 66590955 Fax 86 0539 8785618 86 053 1 66590959 Website www sdlg cn Services Tel 86 0539 8785800 400 6587999 Table of Contents IV SAFETY INFORMATION deum dla TETI EE UU TT 1 SAFETY LABEL POSITIONS AND THE 1 1 1 Safety Label and Is POSEGOLG e abd Dr atium bro oin ela culis tu utes 1 ID The Contents OF ateby aA DE E dea cines done 2 fr 8 PA
43. TENANCE 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 handles to the Neutral position Press the parking brake handle Put blocks in the front and back of wheels Lock the front and rear frames with frame locking bars 1 2 Hanging Warning Tag Attach the warning tag near the starting switch before maintenance to prevent someone starting the engine during maintenance 1 3 Fitting preparation Useonly 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 tis very dangerous to drain hot oil and refrigerant water or remove the filters immediately after the engine stops Make sure the engine 1s cool The temperature of the oil drained 1s appropriately about 20 to 40 Ifit is lower than this temperature be sure to warm it up to this temperature
44. Tits RR 66 ANI Loos DUBBI MEI AE EE IPIE 67 CES 1 NE 69 9 9 OG AON E edet st tt 12 SNR EEUU Bal 78 3 7 Long Time 8 ener 87 3 6 General Problems Possible Cause e anea 89 CHAPTER IV MAINTENANCE 94 I MAINTENANCE GUIDE cessed 94 1 1 Attention to Maintenance and Inspection ssssssssssseeeenenenneneennen enne nennen enne eene seen 94 WORT 39 ugue at E atte eio uisu 94 T a net ene eet eee meee eee ee MP UMP EUM UP DRUMS 94 I Secus Noii ICQ NPRTTR iR 94 1 5 Usi the Prescriptive EU ue cotes ett oat auta 94 1 6 Keep the Machine 94 1 7 Pay Attention to the Refrigerant Water and Oil in High 94 1 8 Check the Oil MENTEM 95 1 9 et mp tdm Emu EDI
45. 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 without permission Put a fence around and hang a No 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 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 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 38 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader ground Obey the relative rules and laws when dea
46. amp 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 is some problem with the lubricant system Then shut the engine and check it Charging Indicator Lamp The lamp will come on if start switch is turned on It will go off immediately after the engine is started Otherwise it means there is some problem with storage battery Please examine and repair it Power Cut Indicator Lamp The lamp will come on if the power is cut off and it will go off if the power 15 not cut off Emergency Steering Indicator Lamp The emergency steering function is selected to install When the wheel loader is steered emergently the lamp will come on if the emergency steering pump works Parking Brake Indicator Lamp If the brake air pressure is normal the lamp will come on when the parking brake switch is pushed down The lamp will go off when the parking brake switch springs back the lamp 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 High Beam Indicator Lamp The lamp will come on if the high beam 15 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 Box Working Indicator Lamp The ZF or 4WG180 gearbox is selected to install t
47. and down turn left and right and move forward and backward all the time Keep people away from all sides below front rear inside right and left sides of the working equipment 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 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 slow down 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 25 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 e If the ejected gas from the silencer hits flammable material or the vent pipe 1s close to the flammable material fire may occur Be aware of the flammable materials such as lipin cotto
48. and for the details please refers to Radio and CD player Assembly amp Operation Manual Radio wiring is reserved for the uninstalled machine Ask the professionals to install 1 2 3 Steering Wheel The steering wheel and steering gear are connected Turning the steering wheel clockwise the machine turns right turning the steering wheel anticlockwise the machine turns left The features are listed below 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 1 2 4 Control Levers and Pedals Shifting Control Lever Refer to 1 1 Control Systems and Gauges Figure3 1 3 2 in this chapter This lever controls the direction and traveling speed of the machine The gear box of this machine has four forward and three reverse gears Place the speed shifting control lever in the proper position and control the accelerator pedal to obtain the desired speed Place the speed shifting control lever in the N position which 15 the neutral gear Put the control lever forward to 1 position can obtain the forw
49. antity and cleanness of hydraulic oil Filter the oil if possible Add them if deficient and replace them if 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 6 Every 1000 Hours Half a Year Service Carry out the periodic maintenance of every 10 50 100 250 and 500 hours with this maintenance operation at the same time Change the gear oil in the front and rear axles Replace once at least annually 105 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Check and clean air vent of gearbox Clean the oil pan of gearbox and 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 once at least annually Check and clean the filter mesh of the oil bowl in the booster pump Clean air vent and replace the brake fluid Check the clearance and wear condition of the pins and the bushes in every articulated point Replace the filter cartridge of oil suction and return filter If assembled In addition do the extra maintenance in the first 1000 hours as follows Check if there is leakage in the hydraulic system Check and clean the air vent of hydraulic reservoir Clean the hydraulic reservoir Replace the hydraulic oil Then maintenance once every
50. anual LG958L LG959 Wheel Loader 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 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 15 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 Try to decrease the towing angle of the towing rope to ensure that the angle between the towing rope and the towed machine 15 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
51. ard 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 60 angle with the backward direction of the loader After digging the loader moves backward and turns the 72 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 If the bucket must be lowered while driving the machine forward stop the machine when the bucket is about 30cm 70 above from the ground and then lower it slowly Om If the bucket hits the ground the front tires will leave the t Q ground and the tires will slip 2 9 a a Dau a The operator must slow the speed immediately when the cline Back machine reaches the material pile Simultaneously step on the accelerator pedal and enter the material pile with the bucket Keep the bucket horizontal when loading the stockpile but keep the dumping angle down when loading the blasted rock Notice Do not let the blasted rock go under the bucket whi
52. ard gear when turn it to 2 position can obtain the forward gear II when turn it to 3 position can obtain the forward gear when turn it to 4 position can obtain the forward gear V Put backward to 1 position can obtain the reverse gear when turn it to the 2 position can obtain the reverse gear ll when turn it to the 3 position can obtain the reverse gear Before starting put the control lever in the N position and put it in the P position after stopping Working Device Control Handle Refer to 1 1 Control Systems and Gauges Figure3 1 3 2 in this chapter 57 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader This handle controls the bucket and lift arm There are four gears to control the lift neutral lower and float of the lift arm from front to rear and there are three gears to control the forward tilt neutral and rear tilt of the bucket from left to right Two buttons of handle is used for linking or shifting off attachments Quick change Equipment Control if assembled Left button controls piston rod of double beam hydraulically cylinder extend to link attachments Right button controls piston rod of double beam hydraulically cylinder draw back to shift off attachments Notice Never come away the attachment in operation Lift Arm Control Handle Put the control handle from front to back to control the lower float neutral and lift of the lift arm Lift 15 used
53. aseline 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 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 is an indicator on the cover of the battery The green light means it can be used the black light means it should be charged and the white light means it should be replaced Replace with a new battery after the white light indicator Routinely recharge the battery if 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 Complementary charge charge 16 hours at 16 0 Voltage max current is less than 25A gt Normal charge charge 24 hours at 16 0 Voltag
54. ce from others Brake immediately and stop when the engine flameouts Steering unit does not work when engine stops Emergency brake could hurt people It is dangerous to shift from forward to backward gear at high speed Never do this 18 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 5 3 Full Load Transportation 5 4 Drive at Proper Speeds 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 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
55. ced Digging hard material 2 3 4 Lifting heavy material using a rope hung directly on the bucket 5 Dig with the bucket above the machine level 6 CIRCUMSTANCES REQUIREMENT Requirements for this machine as follows 1 Altitude lt 3000m 2 Temperature 15 C 40 C 3 Water depth lt 500mm The loader 15 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 1s 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 Low speed large torque engine according to National II emission standard is equipped with 45 lS L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader great power and high reliability Use ZF gearbox The gears are set as front 4 gears and rear 3 gears KD key 15 used to change between gear and gear which makes the operation more reliable reduce the fatigue strength and improve the working efficient ZF drive axle is used it is manufactured by famous tranmission company with high reliability Wet disc brake is safe and reliable Optimize the efficient radiator Optimize design of cooling system to reduce the engine temperature oil temperature of the hydrau
56. ces Clean the machine immediately after working in rain and snow Lubricate and coat anti rust oil to 95 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 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 N WARNING Because of bad operating conditions high temperature and load 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
57. ch will make the front tires leave from the ground and slip Try to hold the load in the center of the bucket otherwise if the load 1s on one side of the bucket 1t will be unbalanced Raise 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 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 73 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 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 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 facing down When driving the machine forward operate the working equipment control lever to let the lift arm lower down to the proper position
58. ck and clean the positions where lubricant is needed Please refer to CHAPTER II 6 CIRCUMSTANCES REQUIREMENT for the depth of water for passage Be sure there are good ventilation conditions when working in a close environment 4 1 2 Check before Starting the Engine Check the machine carefully before starting work everyday 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 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 operator s seat to the proper position for operation Please refer to CHAPTER 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 Check the gauges for damage and make sure the control lever or control handle is in the braking position Clean the dirt on the cab window and all the lamps to ensure better visibility Adju
59. d 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 Outside Cab Locking Bar 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 it will open 1 2 6 Frame Locking Bar 59 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader A WARNING 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 1 into the counterweight 2 1 2 8 Fuse N NOTICE Always be sure to close the startup switch before replacing the fuse The fuse is used to protect the wiring and cable from burning out If the fuse has become corroded by oxidation or the fuse is loose 1 the fuse holder please replace the fuse When replacing the fuse please replace with a fuse of the same specification 1 2 9 Air Condition if assembled
60. dio H 4 9 9 14 Sprayer Machine C Fri QU 3 RE E PEN Me yi Il mm 3 21 pi 1 n Top taap I m 4l ront Sprayer Machine n i NEY a 799 y 7 U m 3 H Black m 9 25 Mite 26 26 he i 10 n Rear Lighting Lamp if 5 12 n n n A um j 4 3 E Middle RelayMiddle Relay X D i J Lift Arm Bucket m 0002 8 263 12 H Floating r 8 Spare Interface s S onn C l Ta bead MEAM uu d F LAU 10 10 n xum 63 or 1 D Top Warning Lanp 11 11 Lu Bucket 0 20 30 3 It sad t T cq Rear Sprayer Machine Switch Assembled with ROPS 65 65 65 mra 1 Lift A i ET 64 64 135 JE 4 1 a 4 T ete ote a 1 Jeb LI ere 1 48 esi 1 1 il Rear Rain Hiper 6 Left Parking Swi eft Parking Swite ee aap 40 gt i A Por VT SS v Widdle Relay Middle Relay Middle Relay Power Cut ECU Power Relay ight Parking Switch EE Chain em n Computer Box HEETY Lu B gen Lasas Loss Og Ph ouo EIE HHBU SID21631111 pisi pisi gini aaa 4 aloe s s4 4 CN4 B NS Key Switch 28 8 28 4 Preheating Indicator La M n M4 T Sut Horn Button Yellow Failure Indicator Lanp B63 NN 3 12 Fai i Gil Pr
61. draulic system directly Clean out the in bucket Park the machine on level ground and put the transmission lever in neutral 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 bucket backwards to the extreme position and shut the engine 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 Gil Absorbing Flange Cover Adding Port Cover Onl Return Flange 8 A AN Flange Cover Oil Inlet Port and Oil Draining Ball Valve Air Changing Filt Oil Draining Plug 86 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader The temperature of hydraulic oil may be high so wear protective clothes and operate 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
62. e max current is less than 25 36 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Connect the positive pole of the charging machine with the negative pole of the storage battery and then connect the negative pole of the charging machine with the positive pole of the storage battery Never reverse Examine the vent of the battery to prevent blockage otherwise 1 may explode Lower the charging voltage or current if the electrolytes are over 45 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 15 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 15 removed Connect the ground cable to the frame of the broken machine Connection should be as far as possible away from the storage battery Do not let the voltage raising cables touch each other or let t
63. e 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 send an air pressure signal and cut off the power of transmission box When the right brake pedal 15 stepped on during driving the brake principle is the same as left brake pedal but the power of transmission box 15 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 15 released 3 3 Emergency and Parking Brake System This system employs the electric air control inside shoe brake system During driving rotate the operating button of brake magnetic valve slightly the button will bounce out automatically and then the compress air in the air tank through the brake magnetic valve to the parking brake air chamber to pull the plug away and release the brake When stopping press the operating button of brake magnetic valve the compress air in parking brake air chamber through the air draining port of 110 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader brake magnetic valve to aerospace Then the brake is pulled up under the spring to arrive to brake The parking brake indica
64. e al Proper ded edem ihn iu ish rc bere NS DEL EE 19 5 9 Ensure Good VISIDITID eet e Ete ta e ea tpa f m 19 25 0 Pay Attention to BLOC KA GC Sao 20 S Divine 1 Dangerous Condos cuite otio obire e obe as Teetietu ue eo Feci 20 5 5 Dryvinsssately on the ioc oer io Rr t t o Ee P e t Renata teat 21 2 9 NON MMM sehr ducenti sates ot EE Lo aN sean Mess set sR Gaels uk E T 22 GO OAPE TY OPERATION NU Eod Esp be 23 6 Keep Good Habits d e e N 23 6 2 Pay toS UrFOURLH ES eos esse eot sueta OE inquo actu Dem Emo uer DR Lie 25 6 9 Ensure Ventilation 10 Close Environment RA eR 26 6 4 Get Close to Dangerous Environtilehit esie oer 26 65 Don t Get Close to Hiph Voltage Wire ener rea e eeu eo ea ou eee 26 acid diccre 2T 7 1 Pay Attention to the Safety of Yourself and Others ccccccccccccccceeeeeeeeeseeeeeeeeeeeeeeeseeeeeeeeeeeeeeseeeeees 27 TINO TICE TOL C ie 28 BO ALE eA YOR REPAIR e orm aera 28 Sl Cre nerab 28 5 2 WOrkino Tina C IOS I Pease nes 29 5 93 Maintenance of Frames during Jacking UD o ni o EU 30 SA
65. e axle brake after replaced or maintained 6 Working temperature The continuous operation temperature should be not over 90 If over 130 stop and check the brake system and axle Lubricant grease Use multi role lubricant grease with the follow characteristics Lithium based lubricant grease dropping point is 170 NLGI2 It must be anti corrosion water resistance and extrusion stability Inject grease from grease fitting once a week Check the tightening torque of connecting bolts of the frame shaft and rim regularly do the first check after 50 hours 3 6 5 Adding Oil to Hydraulic Oil Box D 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 is at a range of 12 2 If the oil level indicator 1s lower than 10 please add specified hydraulic oil 85 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Refer to CHAPTER IV 2 2 Selection of Oil Fuel and Coolant for selection of oil 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 while replacing it never let other materials enter the hy
66. e machine from it 3 4 Fire Prevention The following fluids are flammable and must be kept away from high heat and fire engine fuel and 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 or fire while refueling Tighten all fuel and oil tank caps firmly Put the above flammable liquids in containers with 11 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader relevant tags and put in a separate proper place for storage Do not allow unauthorized people to use Electric welding and flame cutting 15 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 is 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
67. e of the machine It needs 60 hours to train the new machine and operate follows Run the machine in neutral at low speed for 5 minutes to preheat the engine fully 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 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 the 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 essent
68. e sete teres tetas cain needle tv eaten 40 TINTRODUCTIO N Per E 41 1 GENERAL VIEW OF THE MACHINE amp COMPONENTS NAME cene nennen 4 2 GEOMETRICAL DIMENSION S aeui 42 SPRODUCT TYBEJZANID TIS MEAN eer 44 Meg UNUM M 44 SUSE CONDITION 45 6 CIRCUMSTANCES 45 Jac agudo 45 8 TECHNICAL PERFORMANCE amp 45 8 1 Performance of Whole ennt nennen nnne 47 5 2 Principle Dimension and 48 G Product Standatrd epeen EE EEE E EESE ES 48 CHAPTER II OPERATION AND APPLICATION ext uta uaa uad entum us atate EE 49 1 BE FAMILIAR WITH 49 1 1 Control Systems and Gauges teh rper roi oo tr re opener haa ao qune qu n una Ra qud esu eura us eo Fees aba 49 12 Introduction oT Gantes ates oth era e RIS SESS PEERS ENARRARE 5 2 RUN IN PERIOD OF NEW 65 3 OPERATION AND USE OF LOADER 66 S NM ToU B
69. ed Know the meanings for all the warnings on the equipment meters and control equipment on the panel Be sure the parking brake switch is at the braking position and all the control equipment are in the mid 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 1s started from side short circuit This 1s very dangerous 4 1 4 Check after Starting the Engine Check after the engine is started to make sure there is no potential danger When examining the machine park the machine in a spacious place and do not let unauthorized people to get close 16 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 mid and rear gears are in the correct positions Make sure all the control levers 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 whet
70. el 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 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 authorized 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 98 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader ae Recommended Types And Standards Using places 201 Weichai engine Ambient temperature gt 15 CD 15W 40 Diesel GB11122 2006 Ambient temperature lt 15 CD 5W 30 Diesel Oil GB11122 2006 Shangchai engine 27 5L Engine oil 19L DDE engine Caltexoils caltex Delo Gold 15W 40 22 6L Cummins engine Torque converter and Transmit Caltexoils caltex Delo Gold 15W 40 35L gearbox oil LG Axle main transmission and hub reduction ZF Axle main transmission and hub reduction Heavy duty gear oi
71. enance Manual LG958L LG959 Wheel Loader Corrigendum Change content content Serial Change Change Change B aL After Remark number date page eee E reason change change IV LU SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader PREFACE Thank you for purchasing the wheel loader produced by Shandong Lingong This manual will teach you how to use and maintain the machine properly and place it in the bag behind the cab seat or inside the door All personnel should be ready to read it at times If this manual is lost or damaged please contact with our company or dealers for a new one If you sell the machine be sure to give this manual to the new owners 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
72. er than 0 3MPa All the protective items should be routinely examined for proper function before use 2 4 Unauthorized Modification Any modification without the authorization of the company may result in serious danger Please consult Shandong Lingong Construction Machinery Co Ltd or the sellers before making modifications The company assumes no responsibility for any injury or damage caused by unauthorized modifications wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 SAFETY OPERATION 3 1 Be Familiar with Machine 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 Know all the rules in operation understand the gestures of signaling staff If there is any oil near the operating positions that can cause slippage clean it 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 15 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 Always keep the parking brake switch in the lock position Level the working equipment completely to
73. er the bucket to touch the ground to brake if 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 when driving on an abrupt hill dyke or ramp So take care 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 when driving down the ramp do not set the gearshift control lever in the position of the neutral gear Go down the ramp slowly n
74. essure Alarming Switch Input 31 31 p Failure Inspecting output NE id Braking Switch Signal Input 8 8 Preheating Relay E61 _Hand Brake Switch pep E _ 2 Vie E 26 a g 24 1 227 43 B26 mm 26 to Pover Cathode Oa 1 B 37 Pover Cathode Oa B ar o3 Power Cathode w Weak Sigua Cathode 8105 Full Lost Multi mode Fule Economy Switch HH ae mj Lt 47 Rel temperature Sensor Signa ADT Mr Speedup Pedal Position Sensor 1 Bo ai Mi 1 Sensor Ground a4 Ho Input Air Pressure Signal w VI 366 Sensor Signal cc Input Air Pressure Sensor Gromd 9 Y 315 Sensor Power 715 Water Temperature Sensor Sigoal 6 H0 Sensor Power 46 c3 m Yer 110 Vater Teaporature Sensor round u Sensor Signal 1853 3 HS Gba Speedup Pedal Sensor 1 6 Sensor Grad 7 Position Sensor Power Speedup Pedal Position Sensor 2 Canshaft Position Sensor Signal m n Front Frame Wiring Group 2345678 9 101112 Presse Sensor Toer ET Horn Group CAAA 0 __ Engine Gil Pressure Sensor Signal p E s Be sada 3 D Tagine Qil Pressure Sensor Ground B i MOS Crankshaft Sensor Power Sensor Sig sel ale aa as tna mA em i al el ce
75. ether 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 15 leakage in the hydraulic system Check and clean the air vent of the hydraulic reservoir Check and clean the oil return filter cartridge of the hydraulic reservoir Check if there 15 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 3 3 Every100 Hours Month Service Carry out the periodic maintenance of every 10 and 50 hours with this maintenance operation at the same time Cleaning radiator set Cleaning gasoline filter of fuel tank In addition do the extra maintenance in the first 100 hours as follows Change the gear oil in the front and rear axles 104 lli SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Check and clean the air vent of gearbox Clean the oil pan of gearbox and 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 3 4 E
76. ever stop the engine zi SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader the bucket to the ground to help brake use the parking brake put the gear control lever in the neutral position up forward and go down backward If the engine stops on the ramp slope is less than 15 step on the brake padel immediately and lower and then restart engine When driving with a load the bucket should face the high direction of the ramp at all times which means go 5 9 Towing WARNING Injury even death may occur if the disabled machine is towed incorrectly 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 if 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 bare of inner rope 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 People are not allowed to go between two machines when the machines are connected Do not stand on the towing steel wires or tightwires Keep
77. f the loader then take it out and clean a rnddle limit Put the oil gauge into the oil level pipe and fasten Take out when arrive to the lower limit desired position at least twice The oil level should be between the lower limit and middle limit when the oil temperature 15 about 40 The oil level should be between upper limit and middle limit when oil temperature 15 about 80 C If the oil level 15 not in the regular range hydraulic transmission 01 should be added The choice of the hydraulic transmission 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 position N Push the parking brake switch and put blocks front and back of tires The gear box 15 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 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 left side of the gear box which 15 on the left joint Inject the new hydraulic trans
78. freeze 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 3 Coolant Keep away from fire when adding antifreeze Attentions for using the storage battery 1 If the temperature goes down the capacity of the storage battery will go down too If the charging ratio of the storage battery 15 low the electrolytes may be frozen Please ensure charging ratio is near 100 and try to preserve heat so that it 1s easy to start the next day 2 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 slowly otherwise an explosion may occur 3 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 1 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 parts 2 Park the machine on the dry and hard ground If that is impossible park the machine on a wooden board which can prevent the tires from freezing on the ground ry Operation am
79. g the conrol handle of the working equipment and an unpredictable accident may be caused Operate the working equipment control levers or control handles 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 8 SAFETY EXAMINATION AND REPAIR 8 1 General Knowledge Operation and maintenance people should be trained m 1 ee to become the licensed Do not allow anyone to enter 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 28 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Please wear a uniform with a tight wr
80. g and let oil flow out and hold it in a container Change oil filter D E L d i 4 rf T F E CX A i is ER pi Draining Plug of Cah Drang Flue eichai Engine EM shangcha Engine T IT 1 ie Draining Plug of After the oil is released completely rotate the oil drain plug back Add prescribed engine oil from oil inlet of engine B WeichaiWD615G Open the left door of engine cover add prescribed engine oil about 20L from oil inlet of engine B Shangchai C6121ZG50 Open the right left door of engine cover add prescribed engine oil about 27 5L from oil inlet of engine B Dongfeng Cummins 6CATS 3 Open the right door of engine cover and add prescribed engine oil from oil inlet of the engine side or open the left door of engine cover and add prescribed engine oil about 22 6L from oil inlet of the top of engine Run the engine at idle status check whether the oil filter and oil releasing plug are leaky 80 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 3 Engine oil Filter Replacement Disassemble Clean the area near the engine oil filter Disassemble it with filter elements
81. g unless in an emergency 70 AX SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 4 Stopping 3 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 parking state 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 1s necessary to stop the machine on a slope wedge the wheels to prevent movement 3 4 2 Steps to Stop Engine Let the engine run freely for 5 minutes to cool all the parts equally Pull the flameout control soft shaft Turn the key to OFF position And draw it out and keep in a safe place N WARNING Never pull the flameout control soft shaft before the engine Is cooled 3 4 3 Leaving Loader Use the ladder and handle to climb down facing the loader 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 window 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 le
82. geway Operate carefully to prevent unstable loads when the ground is uneven and the load 1s 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 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 20 SDLG 7 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 Low
83. gine should run at the middle speed 68 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 3 Running 3 3 1 Driving Make sure there 1s 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 reverse I position Press the brake pedal rotate the parking brake switch 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 400 500mm above the ground to ensure stable driving in 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 if the double brake pedals are assembled the left one should not be used 69 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 3 2 Gearshift Changing between Forward and Backward
84. he clamp touch the machine when the voltage raising cable is removed 8 19 Maintenance and Storage of Tires 8 19 1 Maintenance of Tires The Explosion of a tire can 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 37 SDLG 7 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 8 19 2 Storage of Tires 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
85. he indicator lamp will come on if the starting switch 1s on ON otherwise please stop to exclude the error Fuel Prefiltration Indicator Lamp The lamp will come on when the fuel preliminary filter 1s 53 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader blocked Please clean it or replace Turning Indicator Lamp The lamp will come on if the steering switch 15 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 This switch locating on the panel is used for starting or shutting down the electric system and starting the engine Refer to 1 1 Control Systems and Gauges Figure3 1 3 2 in this chapter HEAT Position This position is used for the engine pre heating position of cold start system The Weichai engine 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 1s running START Position This is the engine start position Keep the key at this position during starting After the engine has started immediately release the key it will return to ON position automatically Switch Group Refer to 1 1 C
86. hen 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 39 LU Z amp ll SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Lingong Construction Machinery Co Ltd or their accredited representative 9 3 Lifting A direction Use the hook of the front and rear frame to transport the Never bind like this machine to ship or train LX Select proper lifting equipment according to the weight y ESS of the loader otherwise it is dangerous to surpass the W weight limit m Simp LLOR OLE Notices for lifting S C EL 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 1s 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 Prevent damage to hood operator cab and hydraulic pipes No person or car is all
87. her 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 S SAFETY DRIVING 5 1 Warning 5 2 Safety of self and others 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 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 161n 20in above the ground 18 20 in 17 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Concentrate when operation and always warn people near the machine in all direction by sounding the horn 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 Never use the bucket as a platform or 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 distan
88. ht side rocker switch of driver s seat refer to the following fig Upper Lever Reserve Unit Heater Switch Power Cut Switch Lower Lever Reverse Warning Reverse Quick Lamp Switch Changing Switch Lubrication Switch Reverse Centralized The right side rocker switch of driver s seat If there 1s a power cut switch Reverse Rear cue Reverse Quick Upper Lever Changing Switch Reverse Unit Lower Lever Reverse Centralized Reverse Warning i Heater Switch Lubrication Switch Lamp Switch The right side rocker switch of driver s seat Water Spraying Switch Press bottom side the water spraying engine begins working and water is sprayed to clean the 55 Operation amp Maintenance Manual LG958L LG959 Wheel Loader front glass of the cab press top side stop spraying Rain Wiper Switch Press bottom side rain wiper will work press top side the rain wiper will stop Front rear Lighting Lamp Switch Press bottom side and the front rear lighting lamp on the top of cab will come on press top side and the lamp will go off Rear Headlight Switch Press bottom side the 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 is pressed the rear headlight will not come on Warning Lamp Switch Press bottom side all the turning lamps will blink for an emerge
89. ial 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 or control handles 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 65 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader The following maintenance should be 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 Clean 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
90. ight Operation Box Firing Group Computer Box Group i 14 Tater Spraplag lich Lighting lamp Owlleh Rear Lighting Lamp Switch Prot Wiper Startlog Selic ToT ET Em SS a Johto Engle Ac 5 55 1 Start Qnin IST Tuenjag Migh Beam Indiontet Packing Broke lit and a p lih ig P 1 belt mm lictor La Varus Lap lamp Indicator Lamp Laag lamy fic Laie iiis H LIE x mi fy ted fe fg A mer ie TESS Ri ILI TB EE Er ie r Ln ail T m Cab Wiring Group B ud gt Q 0 XX 4 ITI Lighting Lang Reserve Socket i m HEEL ETT e er ES TEGERE HH mitt H ae HTT i nn a a el eia d TIER H A I Radio nod CP 4 i 3 i BE 0 dE iue ES 0 T Mr Condi tien 3 Sprayer kachi E e i Ju x vue Dra He BRE Ep ee t n I I I 7 pes zd ol z inj LIII ds dai a M 5
91. ine to adjust the tension of fan belt 1 Replace 2 Check and repair 3 Refer to Operation and Maintenance Manual of diesel engine for adjusting the tension of fan belt Abnormal noise from alternator Faulty alternator Do not start when starting switch 15 turned on Pinion of starting motor does not mesh or keep meshing without rotation Starting motor turns feebly Starting motor disengages before engine starts Faulty cable Insufficient charge battery Faulty battery charge Insufficient battery charge Faulty alternator Faulty cable 2 Insufficient charge 89 battery 1 Check and repair 2 Charge 1 Charge 2 Replace 1 Check and repair 2 Charge SDLG lli 1 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 8 2 Transmission System Problems Shifting pressure of every gear 15 low Shifting pressure of a certain gear 15 low No The oi of 3 torque converter overheats Machine can not move when engine runs in high speed Insufficient driving force Possible Causes Low oil level in gearbox oil sump Oil leakage in the main oil lines Clogged oil filter of gearbox Faulty converter charging pump Improper adjustment the pressure regulator valve in transmission control valve Invalid spring of pressure regulator valve in transmission control valve Pressure regulator valve of transmission control valve accumu
92. istband 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 1s 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 control levers or control handles 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 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 1 a safe place to prevent lost Put the handrail around and put the No Enter warning label to prevent people from entering without permission No people are allowed to get close to the machine or accessories without permission Keep the working area clean and tidy without oily cloth or flammable lubricant oil or grease 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 leve
93. keeping distance from wires Located on the right rear upright column of operator cab AN 13 No fire warning Located on battery box 14 Personal safety range Located on both sides of engine hood AX URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 15 Warning of safety distance 16 Notice of hot Liquid Located on the cover of water Located on both sides of engine hood tank of engine hood 17 Fuel tank 18 Warning of high temperature Located on fuel tank Located on the cover of water tank of engine hood a x FUEL TANK RECOMMEND RANGE W B TT ts i IL 4 t T 2 5 10 2140 2 9 19 Start for lift 20 Hydraulic oil tank Located on the lifting position of the front and rear frames Located on the hydraulic oil tank 4 Ak A kx HYDRAULIC OIL TANK RECOMMEND RANGE THER REMS AMBIENT 1 HYDRAULIC OIL 10C 400 L HN46 30C 40 L HV46 SDLG lli Operation amp Maintenance Manual LG958L LG959 Wheel Loader 21 Notice for keeping touch with 3 points Located on the right and left platform frames 22 Select switch of cutting power If there 1s the switch Located on the right operation box fr DMG RETK select switch of cutting power m cp PETI power disengage power engage 24 Manual control sign Located on the right operation b
94. l for automobile GL 5 85W 90 13895 65L Gear oil Caltexoils extra EP gear oil 90 Thuban GL5 EP 90 2X 34L Ambient temperature2 5 L HM46 Hydraulic oil GB11118 1 Ambient temperature gt 10 C L HM32 Hydraulic oil GB11118 1 Hydraulic Ambient temperature gt 30 C L HM46 Hydraulic oil GB11118 1 oil Hydraulic oil tank internal 210L CALTEX superfine wind ring of temperature anti grinding hydraulic oil 46 Ambient 1 gt 4 O light diesel Oil GB252 Ambient temperature2 5 C 10 light diesel Oil GB252 loL Hydraulic oil tank export Fuel tank Ambient temperature gt 14 C 20 light diesel Oil GB252 300L Ambient temperature gt 29 C 35 light diesel Oil GB252 Brake fluid Motor vehicle brake fluid HZY3 DOT3 GB12981 AL Brake oil cup 2 or 3 lithium based grease GB7324 Engine coolant of glycol type SH0521 Pins in every joint points of 2 8kg the work equipment e S Fr E 99 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 2 2 2 Reference Table of Foreign and Domestic Oils Engine oil Similar Oil Brands classified by SAE standard Oil Brands CALTEX SHELL MOBIL ESSO Diesel Machine RotellaSX 40 HEIBAWANG1300 Excelled CD and CD 15W 40 Rotella TX 40 20w 40 SAE15W 40 Essolube XT 3 GB11122 Caltex Delo Rotella DX 40 15 C 50 C Essolube 2 Gold HEIBAWANG1300 Multig
95. l ool Position Sensor Ground ED BASS A ARSS MESS nc Qu MI rN EN N3 23456789101112 2 134 o E Z 2345678 9101112 E o Registration Mark Light Brake Electromagnetic u RA Left Tel MM ra ee Rear frame wiring group Right Lamp Group UT dq XXX Q N13 N ight 100 Qu QU Q8 YF 5 T 1 O80 T 09 s 3 1 eylinder Monoblock Pump w 1 1 ep Lin 2 Vedat 2 101 i 123 123 135456 4 125456 d n n 2 cylinder Monoblock Pump 2 LoW 199 2 T CRAY 12 m oo e d J ad 2 A igh ew 2 3 cylinder Monoblock Pump V gt w 99 4 im T 106 4 eft Lamp Group T ight 6 Gearbox Pressure Sensor X FREE 4 eylinder Monoblock Pump Y A 7 Lc 1 17 h 1 1 Sy Pn 0 0 ight 1 Torque Converter 011 Temperatur Sensor IU S eylinder Monoblock Pump Lw 1 13 3t 4 4 L 15 pee 10 55 T LE i 93 2 Fuel Level Sensor 6 apie cylinder Monoblock uel Level Approaching Switch Lifting arm Howe Legh Pomp te E Low 15 40 StL 28 9 E Bom RENE 0 rgent Brake Switch 64 64 i i
96. lator piston 1s locked 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 Insufficient driving force of engine 90 Remedy Add oil to the specified level Check the main oil lines Clean or replace the filter Disassemble and check the converter charging pump or replace it Readjust to the specified value Change the spring of pressure regulator valve Disassemble and check to remove the lock 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
97. lic system and to improve the overall cooling efficiency Use load sensoring full hydraulic steering hydraulic system and single pump working device hydraulic system with large flow The steering 1s smooth and the lifting speed is large to improve the productivity Optimize and improve the sealing structure of the pipelines to improve the sealing performance of the hydraulic system Adjustable console applies high quality instruments and sensors to ensure high reliability of the whole electrical system Optimize the design of working devices The lifting force of boom 15 large and the loading ratio of bucket is large Bucket structure after designing optimally is equipped with blades made of high hardness steel plate and high abrasion resistance The working life is longer if the standard boom 15 equipped with rock bukcet The whole wheelbase is long tipping load 15 large and longitudinal stability is high Articulated frame structure and big steering angle 38 the radius of turning is small son that the whole is mobile and flexible Tapered roller bearings are used in joints which has long working life e Optimize the damping system to offer a good operation environment for operator New type damping seat is with great damping effect to improve the comfort of operator Luxury streamlined design and widened the rear of the hood 15 generous in appearance e The low profile skew intersection tire has strong ability for crossing a
98. ling 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 Take good care for there are potential dangers Load and unload machine on level ground and remain at a safe distance off the road Secure 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 15 necessary turn outside the board and then drive 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 w
99. losion due to electric sparks near the battery when adjusting outside power Remove the start up key before repairing the electric 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 if hurt severely 35 lS L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 is flammable Store the battery under dry clean and well ventilated circumstances with temperatures between 5 25 Prevent sun light irradiation Keep the battery 2m away from a heat source The battery will be affected by high temperature Never reverse and put horizontally Prevent damage by too much impulse and 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 v
100. luids HZY3 746 brake fluid Brake fluid Disc brake Donax B GB12981 fluid DOT3 Grease Similar Oil Brands Chinese Brands MOBIL CALTEX CASTROL ESSO British BP SHELL ZG 2 or Mobile grease Mara Lithium based multi LM grease XHP222 lubricant grease Purpose GB7324 Ronex Retinax A Energrease L Beacon EP 2 Alvania 101 WRIS SDLG LU L operation amp Maintenance Manual LG958L LG959 Wheel Loader 2 3 The Sketch of Lubricating Points Y 4 es 4 m m 4 dx LUBRICATION POINTS INDICATION 1936000951 A RAH o e KRH cS AIRDE Z CHANGE OIL OIL POSITION CHANGE OIL AFTER AUN ADD GREASE GEAR OIL HYDRAULIC HYDRAULIC V DIESEL INSPECTION N TIME OIL TRANSMISSION OIL ENGINE OIL p 2 4 Detailed Rules of Electric System Maintenance If the wire stays in the wet environment or the insulation of it is damaged the electric system may leakage which will cause hazardous accident Maintenance of components related to the electric system 1 Check the tension and distress of the fan belt 2 Check the fluid level of electrolyte in the storage battery Never remove or disassemble any electric components installed the machine Never install any electric components other than those specified by the company Be sure to keep the electric system dry whe
101. mission oil Start the engine and run in the idle status Add oil until the oil level 15 between lower limit and middle limit 82 Operation amp Maintenance Manual LG958L LG959 Wheel Loader Move the gears through each position one time Check the oil level again and add oil if needed If the old oil is dirty do not add new oil directly Disassemble the raw oil filter which 15 in profile and clean all the parts If there are any metal powders or fragments please contact the 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 specified oil The filter must be changed each time the oil 1s changed 3 6 4Adding Oil to Axle 3 6 4 1 Adding Oil to LG Axle Oil Level Check Park the machine on level ground and put the transmission lever in the neutral position Pull the parking brake switch and put blocks in front and back of tires Loosen the oil inlet plug on the shells of the front and rear axles It is proper if the oil level 1s 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 Oil Inlet Plug of Axle shell Oil Drain Plug of Axle
102. mperature control switch to the O position the state of off lt Open 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 1 control panel its operation if assembled The Appearance of Panel 61 SDLG a b Notice lt gt Operation amp Maintenance Manual LG958L LG959 Wheel Loader Refrigeration Power Refrigeration 1 Air Volume and Power Switch 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 15 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 temperature control switch 3 15 always in the coolest position and the air volume and power switch 2 is in fan low gear L position in order
103. n papers dry grass chemicals and oily or oiled rags 6 5 Don t Get Close to High Voltage Wire Do not touch the aerial electric wire Electroshock may result in even when close to a high voltage wire The distance between the loader and the electric wire should be At least 2m 6 58 at low voltage condition At least 4m 13ft at 40KV high voltage condition electric wire is generally supported by fixed 777777277 7727222777777 insulator At least 20ft at 40KV high voltage condition electric wire is generally supported by 26 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader hanging insulator The 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 seat 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 o
104. n since work 3 7 Prevent Crushing or Cutting Body Parts equipment may block vision at the front while the load is concentrated on the back wheels Be sure there 15 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 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 clearance will change and this may lead to serious damage or personal injury when standing too close The engine must be turned off and the working equipment must be locked if people have to work between the moving components Make sure the supporter and the accessories are correctly set when some one works under 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 Stay far away from any rotating and moving parts 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
105. n the middle of transmission shaft 14 1 5 55 8 8 125 165 Connection of engine oil tank and frame M16x35 185 265 24 2 130 5 Connection of fuel tank and frame 8 8 320 480 M24x2x80 20 85 16 Connection of dipper teeth and bucket 45 376 502 M20x62 3 CONTENT OF MAINTENANCE Maintenance content includes the run in period of a new machine and the periodic maintenance of every 10 50 100 250 500 1000 and 2000 hours 103 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 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 Open the water draining valve air tank to drain the water out 3 2 Every 50 Hours Week Service 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 wh
106. n washing the machine or working in rain and snow Avoid the electric system corroding by seawater when working on the seashore 102 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 2 5 Maintenance Tools 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 table below Abide by this table except in special conditions Material or Position Specification character Torque N m class 1 Fixing bolts of transmission M18x40 240 280 Middle cover bolts of transmission box 14 35 Connect bolts between rim and brake plate M20x1 5x50 4 Connect bolts of main driving left and right differential cover 16 1 5 150 40Cr 280 330 5 Connect bolts between main driven move helical gear and right cover of differential 16 1 5 55 40Cr 280 350 Connect bolts between main driving bearing chock and bracket M22x100 40Cr 500 600 7 Lock bolts of main driving input flange M33x1 5 320 400 Connect bolts between plane frame assembly and rim M20x1 5 200 600 10 Rim nuts M20x1 35 480 580 Connection between the bracket of main driving and axle shell 16 1 5 45 8 8 193 257 1 Connect bolts between brake clip assembly and stent M20x1 5x56 40 376 502 Assembly of driving axle and frame M30x2x175 530 670 13 Supporting bolts i
107. nce the machine touches the wire When operating near high voltage cables make sure other persons are far from the machine 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 is 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 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 NEVER get on or off the machine while it is moving 27 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 operatin
108. ncy circumstance sending light to warn the other vehicles and passersby Press the top side all the turning lamps will stop blinking Unit Heater Switch if assembled Press bottom side the unit heater will work press top side it 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 Power cut switch Press bottom side power cut Press the top side power on Top Lamp Switch This switch is behind the ceiling lamp in the operator cab Press ON position to turn it on Press OFF position to turn it off Notice Turn it OFF during driving 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 Power Switch 56 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader The switch locates 1 the left side of rear frame The power of the whole vehicle is shut off when the switch turns to the position The power of the whole vehicle is turn on when the switch turns to position Please shut the power switch if park the vehicle for a long time Radio and CD Player Control Panel if assembled This switch is at the right side of the ceiling cab
109. nd climbing and can drive and work on the bad ground conditions New steel cab is with spacious vision cab is laid out with greater operating space full coverage cab trimming is damped with seals the front console is used to blow the wind Choose air conditioning optionally to provide users with a comfortable environment 46 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 8 TECHNICAL PERFORMANCE amp PARAMETER 8 1 Performance of Whole Machine Standard lift arm Long lift arm Bucket capacity 3 0 m 2 8 m Rated loading capacity 500003 450003 Lifting time full load 6 4 s 6 4 5 Lowering time empty bucket lt 3 6 lt 3 6 Dumping time empty bucket lt 1 3 5 lt 1 3 5 Forward 1 0 6 5 km h 0 6 5 km h 2 0 11 5 km h 0 11 5 km h 3 0 23 km h 0 23 km h 4 0 38 km h 0 36km h 4 LG959 0 36km h Reverse p 0 6 5 km h 0 6 5 km h 2 0 11 5 km h 0 11 5 km h 3 0 23 km h 0 23 km h Max breakout force 2180 kN 161 kN Max traction force supplied by engine 150kN 2150 Max traction force mounted with DDE engine gt 155 wenn Max tipping load gt 110 kN gt 98 kN Max tipping load LG959 2100 Max climbing angle 30 30 Max turning angle 38 38 Min turning radius Outside of Rear wheels 6036 mm 6036 mm Min through radius Outside of bucket 6746 mm 6936 mm Tire charge pressure Front wheel 0 39 0
110. nge the system pressure to Insufficient force of the bucket the spool and valve block 3 Low set pressure value of safety valves 4 Overload valve and oil complementary valve is blocked by dirt its prescriptive value 4 Disassemble and clean lower down or float up Hydraulic oil Aged or broken oil seals of working pump mixing into or steering pump lead to the hydraulic oil gearbox leaking into the gearbox Change oil seals or change oil pump Check the oil lines remedy the leaking parts Replace if necessary Add hydraulic oil to specified level Suction oil line is damaged and air is sucked into oil lines Low oil level and large amount of air 15 sucked into oil lines Foam in hydraulic oil tank and harsh noise 92 SDLG lli 1 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 8 5 Steering System Problems Heavy steering Increased steering turns Possible Causes 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 seals Internal leakage of steering cylinder Worn steering unit High viscosity of oil or wrong brand of oil Damaged spring plate
111. 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 Remedy Check oil pump Discharge air from system and check the suction lines Check the valve Clean if it 15 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 Steering wheel can not reset Broken spring plate Phenomena medium pressure drop increases or the relief of steering unit fails when steering wheel stops wheel loader deflects from straight traveling line No Inflexible 3 failure of steering system 3 8 6 Engine Refer to Operation and Maintenance Manual of diesel engine for troubleshooting 93 lli SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader CHAPTER V MAINTENANCE 1 MAIN
112. 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 4 2 Adding Oil to ZF Driving Axle 1 Oil Level Check Park the machine on level ground Clean all the oiling position before check and dump oil after the machine run a little time The temperature of gear oil may be high Be careful of the hot oil splashing when twisting off the screw cork to add or dump the oil Use protection tools and operate it carefully to prevent injury 2 Oil level type Wheel side oil level Rotate the hub until the word Olstand on level position Oil level is with the oil overflowing the oil plug hole Axleoil Oil level is with the oil overflowing the oil plug hole or oil adding hole 84 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 Check Adding oil if the oil level go down after several minutes until the oil level keeps stable Notice Check the oil level every month especially after new driving axle installed or before the maintained axle to work 4 Oil Replacement Replace oil after the first 500 hours and then do it every 1000 hours The oil should be replaced at least one time a year 6 Brake oil Refer to CHAPTER IV 2 2 Selection of Fuel and Coolant for selection of brake oil Notice Other brake fluids without ZF permission are not allowed Deflate th
113. of the safety belt 1s at the left rear side of seat and put the lock into the opening of clamper to jam the lock There is a red button on the side of opening of clamper Press the button and the lock will jump out from the clamper Before using the safety belt please check the clamper of safety belt whether lock and loose normally 1 2 12 Rearview Mirror Rearview mirrors are on the left and right sides outside the cab and left upper inside the cab Before starting work the rearview mirror must be adjusted for a good rear 1 2 13 extinguisher The prepared mounting hole of bracket about fire annihilator located on the frame on the right of the operator seat please fix the fire annihilator of meet national law and the place request Each dealer of our company has reserved the fire annihilator and its bracket to choose 1 2 14 Key This loader equips two key for every using condition The starting switch key for engine The key of left and right doors of cab The key of left and right doors of engine hood The key of left and right otter boards of engine hood The key for adding fuel port of fuel box 1f equipped 64 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 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 lif
114. ol levers to the Neutral position Press parking brake switch and lock the cab door 3 7 2 During Storage 87 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader N WARNING Open doors and windows to ensure ventilation and exhaust to allow of poisonous gas if the antirust 1s 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 Add oil and grease to all the requisite positions 88 A URISI 3 8 General Problems Possible Cause Remedies 3 8 1 Electrical System Lamp is not bright when the engine runs at high speed Lamp flickers when the engine 15 running A meter does not work when engine is running Possible Causes Faulty cable contact problem or open circuit Improper adjustment of fan belt tension 1 2 Faulty cable 3 Improper Faulty alternator adjustment of belt tension SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Check and repair the loose terminals and disconnections Refer to the Operation and Maintenance Manual of diesel eng
115. ontrol Systems and Gauges Figure3 1 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 light tail light and back light is lightened if the D switch group turns to the position of D Control of high and low light 54 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader When the starting switch is in the ON position the low beam of front headlight is lightened if the switch group turns to the position of D The high beam of front headlight is lightened when the switch 1s put down Control of turning lamp The left turning lamp is lightened when the switch 15 put forward and the right turning lamp 15 lightened when the switch 15 put backward Notice The turning indicator lamp 1s lightened when operating the switch After the operation of turning finished please put back the switch by your hand Rocker Switch Rocker switch includes panel rocker switch and the right side rocker switch of driver s seat For panel rocker switch refer to 1 1 Control System and the Gauge Figure 3 3 3 4 When the start switch is at ON position the sprayer rain wiper rear lighting lamp front lighting lamp rear headlight and warning lamp will be controlled separately by this switch For the rig
116. owed to pass under the machine during lifting 999 99 9 99 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 40 Operation amp Maintenance Manual LG958L LG959 Wheel Loader CHAPTER IT INTRODUCTION 1 GENERAL VIEW OF THE MACHINE amp COMPONENTS NAME Work Light Rock Arm Engine Hood Lift Arm Bucket Front Wheel Rear Wheel Figure 2 1 General view and components name 41 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 2 GEOMETRICAL DIMENSIONS 5493 4128 ine o acr A 8079 3024 zr e Figure 2 2 Geometrical dimensions of LG958L wheel loader mounted with standard lift arms LU ZR ll SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 63 A Sad 5493 4128 1600 X 5 EE ZI FT IKI E be n NS me 3024 c 9cQ9x Figure 2 3 Geometrical dimensions of LG959 wheel loader mounted with standard lift arms ll L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 PRODUCT TYPE AND ITS MEANING LG 9 5 8 9 L Upgrade Code Platform is 8 9 Load limit is 5 ton Wheel loader Shandong Lingong 4 N
117. ox 23 Warning for cutting off power If there is the switch Located on the right operation box z H E H e WARNING S B E qi 5 Tl PARKING BRAKE BUTTON P 5 PARKING BRAKE sa Jl RELEASE BRAKE HARF The handle is not allowed to be on the Power disengage position while working on the slope lli SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 25 Danger of serious injury during steering 26 Warning for starting Located on the steering position Located above the start button of front and rear frames PER ART EP The key should be on the mid position after the vehicle stops wk isc SDLG Operation amp Maintenance Manual LG958L LG959 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
118. p Maintenance Manual LG958L LG959 Wheel Loader 3 The capacity of storage battery will obviously go down in cold weather So cover it or move the storage battery to a warm place and install it the next day 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 Park the machine on level ground and put the transmission lever in the neutral position N Pull the parking brake switch and put blocks in front and back of tires Open the side door on the right side of the engine cover Pull the dipstick out and wipe it clean with a cloth Insert the dipstick back and pull it out again to check the oil level at least twice B Weichai WD615G It is a suitable oil level if it is between the H and L scale If the oil level is lower than L scale oil should be added by the oil adding port Lipstick of Wecha Engine _ P sb Oil Adding Port of Weichai Engine E k o 1 B Shangchai C6121ZG50 It is a suitable oil level if it is between the adding oil graduation line and the oil static full graduation line If the oil level 1s lower than the adding oil graduation line
119. peration amp Maintenance Manual LG958L LG959 Wheel Loader Brake Air Pressure Gauge This gauge indicates the air pressure of the brake system lt 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 Ifthe pressure index lies in the range of 4 8 x100kPa or 5 8 11 6 lt 10PSI the oil pressure is normal Be sure to stop the machine for inspection if the index moves outside this range Fuel Level Gauge 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 4in this chapter 22 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 011 Pressure Charging Power Cut Emergency Warning Lamp Indicator Indicator steering Lamp Lamp Lamp Indicator Lamp cl eme ir Breesure High Bean Working Brake be indicat or Uam or o ion 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 if start switch is turned to other position Oil Pressure Warning L
120. placed 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 3 4 j 6 1 8 9 10 i 12 3878 UI ud mM HL 1 Lm m Bee 19 25 M 23 2 21 2 19 18 17 4 3 16 15 14 23 lt A IN aS AY AX URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 1 2 The Contents of Safety Label 1 Limit position of lift arm Located on both sides of lift arm wre 3 Antifreeze fluid If coolant 35 has been added Located on the left operator cab door and engine hood Coolant 35 has been added in the machine Notice the coolant is glycol engine cooling liquor Please do according to the circumstance and the illustration when reinfusing otherwise the effect will be reduced Selecting range is advised as below 15 15 used in the temperature of 2 15C 35 15 used in the temperature of 2 25 45 18 used in the temperature of 2 35C 2 Danger of lift arm Located on both sides of lift arm 4 Antifreeze fluid If coolant 45 has been added Located on the left operator cab door and engine hood Coolant 45 has been added in the machine Notice the coolant is glycol engine cooling liquor e Please do according to the circumstance and the illustration
121. r Lamp Indicator Lamp Indicator loup Warning lamp Indicator Lamp Indicator Lempydicator Lamp Warning Lamp Right Turning ocker Switch t i ec lap 09 95 6 e e 69 199 lamp Warm Machine Rocker Switch i a 5 2 os al aa zs ag m Wm Machine L3 Air Condition T Position 952 6 5 2 xo LL is jo em 15 43 BESE LLA x 15 y o 1 i e cn ESI M B NUR AUR NR los Pressure 4 5 434 44497 2 an NON 1 1 1234556289511115 1 d 3 s 30 Front Headlight Lox Front Headlight High 1 m i erry Held og as al eals el ES 1 s 2 a979 E 18 i a i 5 85 Cab Wiring 1508 10A 104 10 104 104 7 5 104 104 104 104 14 104 10A 10 254 1104 5A 5A 104 393339399337 OREL ab Wiring Group AAAAAAAA d ddd 5 344 Spare Socket LG GN T GI 23456789111 9 lt 12345678 9101112 E ALAVA IS INS I IAS IN IN IS s 2 E t 1 n 5 seu 47 ront Lighting Lamp 45 i 3 4 Lu 6 4 1 M 43 1 34 5 0 50 50 Ra
122. rade Diesel Machine Oil 15W 40 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 Hydraulic oil Similar Oil Brands Chinese Brands CALTEX MOBIL SHELL CASTROL ESSO Hydraulic oil L HM46 DTE25 Tellus 27 Hyspin AWS 32 5 C 40 C 10 C 40 C Tellus 29 Hyspin AWS 46 GB11118 1 CALTEX RANDO HDZ46 Hydraulic Oil 25 C 40 C L HV46 DTEI5M Hydro kinetic Hyspin AWH46 Vnivis N46 30 C 40 C 26 C 40 C Tellus T27 46 Nuto GB11118 1 Nuto H46 Hydraulic transmission oil torque converter transmission oil Similar Oil Brands Chinese Brands CALTEX 8 Hydrostatic Mobile Mn a Caltex Delo Gold HEIBAWANG 1300 Titan universal Standard Torque Rotella 10W Q SH303 064 Multigradel5W 40 SAE 15W 40 HD15W 40 Fluid G7 100 A URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Gear oil Axle oil similar Oil Brands classified by API standard GL 5 Chinese Brands CALTEX FUCHS MOBIL ESSO Mobil Gear oil Ho HD80W 90 Spirax EP Se ae Caltex Thuban Titan Gear 20 C 40 C Gear oil GX Heavyduty GL5 EP 90 LS90 Automobile Gear oil 85W 90 HD90 HD85W 90 HD80w 90 10 C 50 C Brake fluid Similar Oil Brands Chinese Brands CALTEX MOBIL ESSO British BP SHELL Super Motor vehicle brake Brake fluid performance f
123. rd 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 Rear tilt bucket to level position and operate the working equipment control handle to allow the lift arm push forward to prepare for next operation 5 Pushing Operation Level the bucket to the ground and push the accelerator to move forward If there 15 blockage during moving raise the lift arm a little and move forward continuously When operating the lift arm to lift or lower operate the 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 1s 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 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 75 lli SDLG Operation amp Maintenance M
124. re there are no flammable materials such as dry grass and old paper near the high temperature parts such as the silencer when parking the 34 wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 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 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 5 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 anti erosion layer and welding line to ensure safety 8 15 Electric System The electric system must be maintained a professional person with a proper license Connect the grounding cable last to prevent an exp
125. 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 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 is used for any unintended purpose that 1s 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 VI lli 1 SDLG Operation amp Maintenance Manual
126. rs or handles are in the mid position and use the necessary equipment to support the life arms cylinder and tilting cylinder to prevent the working equipment from falling if you have to examine and repair when the bucket 1s 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 15 no releaser please open the door 29 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 in the middle and wedge the tire from the opposite side Put the cushion blocks under the machine 8 4 Working under the Machine e Park the machine on firm ground Lower the working equipment to the ground before working under the machine e Wedge the tire firmly e 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 8 5 Working on the Machine 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 N NOTICE Do not allow lubricant or grease to leak Do not randomly pu
127. s 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 60 100 the water temperature is 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 The below is the same Torque Converter Oil Temperature Gauge This gauge shows the torque converter oil temperature When the temperature index lies in the green range 60 120 the oil temperature is 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 Ifthe pressure index lies in the green range 1 5MPa 1 7MPa the oil pressure 15 normal Be sure to stop the machine for inspection if the index moves outside this range lt Ifthe pressure index lies in the range of 15 17 x100kPa or 21 75 24 65 x10PSI the oil pressure is normal Be sure to stop the machine for inspection if the index moves outside this range 5 lli 1 SDLG O
128. s which may affect the performance safety and strength capability of the vehicle and the working equipment 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 32 SDLG 7 Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 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 the torque converter or the water pipe of air condition to prevent burn Never let the harmful alkaline materials
129. so that it can pick up a thin layer of the surface each time when excavating the soll When driving the machine forward shift the working equipment control lever backward and forward slightly to reduce the resistance S Dur 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 The loader can be used without a truck under the following conditions 4 The ground is too soft and not level and the truck can not be used When the transportation distance 1s within 500 meters it is not economical to use a truck The transportation driving speed is determined by the conveying distance and 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 connection 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 pile And operate 74 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader working equipment control lever to tilt the bucket forwa
130. st rear view mirror and keep the surface clean to ensure the best view from the operator s seat Replace with a new one if the mirror has been damaged 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 handle which could start the working equipment and cause an accident Check whether the floodlight and signal light is normal and repair if not 15 LU Z amp ll SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader Check whether the front and rear frames is unlocked 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 4 1 3 When Starting the Engine to the loose hub nut and repair or replace for any abnormal situations 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 the working area ask them to leave Do not begin work until they leave 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 if assembl
131. steering hydraulic system 15 the load sensing hydraulic system This system 15 made up of a pair pump priority valve steering steering cylinder and the pipe attachments In the process of turning this system supplies oil to the steering hydraulic system first and then supply oil to working system through radiator The safety valve is on the priority valve The adjusting pressure of the system 15 16MPa 108 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 3 BRAKE SYSTEM Brake system is used when the machine decelerates stops or for long term parking on the level ground or slight incline The brake system of this machine is composed of a driving brake system and parking brake system LER Front Axle Brake volve K LES a Rear Axle Brake volve e E E d 6 1 Air Booster Pump 2 Brake Valve 3 Tank 4 Combination Valve of Oil Water Separator 5 Air Compressor 6 Brake Magnetic Valve 7 Parking Brake Air Chamber Figure 5 3 Single Brake Pedal Braking Diagram Rear axle brake pump d NS 1 Booster Pump 2 Shuttle Valve 3 Air Brake Valve 4 Air Tank 5 Combination Valve of Oil Water Separator 6 Compressor 7 Brake Magnetic Valve 8 Parking Brake Air Chamber Figure 5 4 Double Brake Pedals Braking Diagram 109 lS L SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader
132. t the tools around the work place Walk slowly and carefully Never jump up and down 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 30 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 15 Working Routine maintenance of the machine should never be done while the engine is working to prevent injury When it is necessary please follow the rules below Assign an operator to sit on the seat to ensure all the maintenance people can have contact with him so he can prepare to shut the engine when requested Never touch a high temperature part such as tail pipe and silencer to prevent injury Be careful if the repair space 1s near the rotation part There 15 the danger to be volumed 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
133. the coolant system touch your skin or eyes 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 Keep fire off when disassembling the connection pipe of the air condition compressor 8 12 Examination and Repair of Hydraulic System 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 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 15 critical 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 immediately 33 LU Z amp ll SDLG 7 Operation amp Maintenance Manual LG958L LG959 Wheel Loader required avoid the leakage of oil and to prevent the high pressure liq
134. the hook of the towing machine and the towing parts a horizontal line 22 birdcage shape wk isc SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 Examine and listen to the exceptions carefully and report immediately Do not repair while in operation An overload is dangerous Shandong Lingong Construction Machinery Co Ltd assumes resposibility for the injury or damage induced by overload It is dangerous to hit any object at a high speed Damage may be done to the loaders the goods and the operator Keep perpendicular during loading and unloading materials If working 1 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 23 URISI SDLG Operation amp Maintenance Manual LG958L LG959 Wheel
135. the seat Pull the fore and aft handle B and move the seat forward or backward to the desired position it will lock automatically after pushing it down Backrest Angle Adjustment Put the backrest angle adjust handle C upward to pull the backrest until the angle 1s comfortable The backrest angle is locked when loose the handle Height Adjustment There are three positions for the height of seat and the operator can adjust according to the need During adjusting set the base under the seat by two hands and draw up forcibly and stably When the cracking sound is sounded please loose your hands then the seat will fix in this position Adjust the position of seat to the highest position and draw up forcibly and then press down the seat will fall to the lowest position Headrest Height Adjustment set the headrest of seat by two hands and then draw up or press down forcibly to adjust the height of headrest 63 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 1 2 11 Use of Safety Belt if assembled If the safety belt is assembled on the seat please tie it when operating the machine Before using safety belt please check the degree of wear and firm Replace it if it is necessary Adjust the length of safety belt before using to make sure the safety belt can be used for safety guarantee and comfort Move the position of lock on the safety belt to adjust the length of safety belt The clamper
136. tion amp Maintenance Manual LG958L LG959 Wheel Loader 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 15 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 Brake Pedal The Brake Pedal controls the brake of the vehicle Refer to 1 1 General View of Controls and Gauges Figure3 1 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 3 2in this chapter The engine speed can be freely regulated between idle and full speed Parking Brake Switch This switch is on the right operator box and it is used for the parking brake Pull this switch to engage the parking brake Rotate the switch clockwise and the button springs back to release the parking brake Flameout Control Soft Knob if assembled This soft knob is on the cover of the heater which on the right side of the seat Pull this knob and keep for several seconds will put out an engine flame 1 2 5 Cab Door Locking Bar Outside Cab Locking Bar Open the left and right door to 180 an
137. to prevent the evaporator from frosting Avoid the sun shining directly in summer 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 Clean the condenser periodically using compress air and cold water but not using hot water or steam 62 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 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 Weight Adjustment The weight adjustment handle is in the middle of seat bottom Turn the handle anticlockwise to reduce the damping stiffness Backrest adjust handle and turn clockwise to increase the damping stiffness Rotate B Fore and aft the damping stiffness adjust handle A by hand according to the operator s weight until feel comfortable A Weight adjust handle Fore and Aft Adjustment This handle is on the left bottom side of
138. tor lamp controlled by output air pressure is lightened at the same time and cut off the power of transmission box When the system air pressure 15 lower than 0 4Mpa the brake magnetic valve will cut off automatically to control the compress air in the parking brake air chamber 8 to drain into the aerospace by hand so that the emergency brake is utilized to protect the safety of vehicle and people 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 15 shown in figures 5 5 5 6 5 7 5 8and 5 9 111 SDLG Operation amp Maintenance Manual LG958L LG968 Wheel Loader Figure5 5 LG958L Electric System Principle Diagram with Weichai Engine Domestic 112 Operation amp Maintenance Manual LG958L LG968 Wheel Loader a a Jerque O tart ____ ______ ____ Pol lem a e oe S Panel Viring Group R
139. trained to do so 8 7 Do Not Let Anything Fall into the Inner Part of the Machine 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 it happens the machine may be disabled Pick out the fallen pieces safely Do notcarry 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 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 Shut the engine to clean the inner part of the machine put all the levers or handles in the middle 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 31 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 E
140. uid from spraying and hurt somebody the damaged hose should not be allowed to repair and use instead it should be replaced with the new component as a whole one N NOTICE Please replace these parts 1n the following conditions Connectors are broken or leaking Outside of soft pipe 1s 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 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 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 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 lubricant oil or other flammable materials Clean the flammable substances on the machine such as fuel grease oily cloth or other flammable materials 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 su
141. ve protection even if the ROPS is installed Always tie the safety belt when operate the loader The safety belt must be replaced once every three years although it is not abnormal Never drill holes and weld inside and outside of the ROPS to prevent the strength of ROPS from damage or reducing 4 STARTING SAFELY 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 1s a lot of sand and dust sprinkle with water first 14 lli 1 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 che
142. vel is too high or diluted find the reasons and solve them 7 SDLG Operation amp Maintenance Manual LG958L LG959 Wheel Loader 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 Check whether the work equipment is in good working order Check the appearance and the pressure of the tire to see whether it 15 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 Work together with a truck which can help improve working efficiency especially for long distance transportation When working together the loader digs the material and the truck transports and unloads material There are generally two loading and unloading ways Cross Load The loader faces the material then it moves backw
143. very 250 Hours Month Service Carry out the periodic maintenance of every 10 50 and 100 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 39 0 01 while that of rear tires should be 0 332 0 01 MPa In addition do the extra maintenance in the first 250 hours as follows 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 check the brake fluid Add them if deficient and replace them if necessary 3 5 Every 500 Hours Season Service Carry out the periodic maintenance of every 10 50 100 and 250 hours with this maintenance operation at 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 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 suction and return filter Check the qu
144. yes 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 8 11 Maintenance of Coolant System Switch off the electricity in the terminals for storage to prevent explosion For the loader with control unit ZF separate the connectors of the transmission s computer control panel before welding to prevent the panel burned by the impulse current when welding Connect the heads after repair Otherwise the machine can not start and drive by itself 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 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 explosion A NS W ive clothes during weldi 2 S ear protective clothes during welding RAY gt Keep the welding area ventilated Clean up the flammable materials and check the fire extinguisher Never do any modification

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