LG958L Training Material RELIABILITY 1 IN ACTION
Structure and Overview of Complete Machine CONTENTS
Overall Structure of Complete Machine Definition of Loader Model
Meaning of Loader Ordering Number
Performance Characteristics of LG958L (E5816215A3601) RELIABILITY 2 IN ACTION
Product Configuration Optional Configuration Optional Attachments
Section I Structure and Overview of Complete Machine Chapter I Overview of LG958L Loader
I. Overall Structure of Complete Machine RELIABILITY 3 IN ACTION
LG958L wheel loader is SDLG's 4th generation loader product built elaborately by SDLG in response to
medium- and high-end markets both home and abroad, featuring European style, lon g wheelbase,
and high breakout force. This product adopts the world s leading technologies and is fitted with
fixed shaft electro-hydraulic shift transmission and single-lever pilot control. Featuring outstanding
characteristics of high working efficiency, light and flexible operations, high boom lifting force, and
good stability of complete machine, it s especially suitable for operations under harsh working
II. Definition of Loader Model 1. Numbering Rule for Loader Model
In accordance with the requirements of standard QJ/LGJ QJ/LGJ 02.03-2006, the pr oduct
model is composed of enterprise logo, characteristic code, product category code , main
parameter code, platform code, and upgrade code. LG 9 5 8
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Enterprise logo (LG denotes SDLG) Characteristic code
Product category code Main parameter code Platform code
(1) The characteristic code is expressed by 1~3 Latin letters in upper case. Articulated steering wheel loader Track loader Skid steering wheel loader RELIABILITY 5 IN ACTION
Product category Characteristic name Characteristic code Note
Earthmoving machinery
Articulated steering wheel loader Track loader C
(2) Product category code
9 denotes earthmoving machinery 6 denotes excavation machinery RELIABILITY 6 IN ACTION
(3) The main parameter code of the product is expressed by the Arabic numbers and shall be chosen as per the following regulations:
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The loaders with rated carrying capacity no less than 2 tons are expressed by rounded value of rated carrying capacity. For instance, the rated carrying capacity of LG958L is 5 tons and therefore the main parameter code is 5.
The loaders with rated carrying capacity less than 2 tons are expressed by
rounded value of rated carrying capacity (unit: ton) multiplied by 10. If the value obtained is only one digit, suffix 0 to the value obtained. For instance, the rated carrying capacity of LG918 is 1.8 tons and therefore the main parameter code is 18.
(4) Platform code
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The product platform is determined depending on the product status,
technical specification, and main structural configuration. Generally, the product platform is classified into 5 levels, namely economic level,
medium level, medium and high level, and high level, which are expressed by number 2, 3,6 , 8, and 9 respectively.
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No platform code is used for the loaders less than 2 tons, in which case a letter is used to denote the drive mode. M denotes mechanical drive mode, H denotes static hydraulic drive mode, and no letter is used for hydraulic drive mode.
(5) Upgrade code
In event of major change in product structure or performance, which requires the redesign, prototype build, or authentication, the upgrade code shall be given. The upgrade code is expressed by Arabic number RELIABILITY 10 IN ACTION
in succession. The - after the main parameter code shall be removed if no upgrade code is available.
For instance, for the medium-end wheel load product with rated
carrying capacity of 5 tons that is upgraded for the 2nd time, the product model is LG953-2.
2. Meaning of Ordering Number
In accordance with the numbering method for ordering number of loader product (abstract from QG/LGJ03.07 2006), the format and composition of ordering number for wheel roader is as below:
Manufacture code Identification code Engine code
Main parameter and upgrade code
Operating
environment code
RELIABILITY 11 IN ACTION Transmission code
Drive axle code Hydraulic configuration code Multifunctional configuration code Composite configuration code Cab code
(1) The first letter denotes operating environment code E Export model
Export model Underground model CE model Domestic model 12 RELIABILITY IN ACTION
C CE model
T Underground model None Domestic model
(2) The first and second numbers denote main parameter. For instance, 58 denotes LG958 and 36 denotes LG936. The third number denotes upgrade number.
1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t 1 Yuchai YC6J125ZT21 Shangchai SC11CB240.1G2B1 2 Weichai WD10G220E23 Weichai WD10G240E21 3 Weichai Deutz WP6G125E22 Weichai WP6G160E201 Shangchai SC11CB220G2B1 Weichai WD12G31 0E221 4 5 Weichai YC4D80- T20 Dongfeng Cummins 6BT5.9 Yangzhou Diesel
(3) The 4th number denotes engine model. RELIABILITY 13 IN ACTION 6 Engine Co., Ltd. WP3.9G65E2 DDE BF6M2012 DDE BF6M1013 7 8 VOLVO D13 VOLVO D13 9 Weifang Huafeng ZHBG44 A B Deutz Deutz
(4) The 5th number denotes transmission model. SDLG transmission ZF transmission VRT200 transmission Hangzhou Advance transmission Shantui transmission RELIABILITY 14 IN ACTION 1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t
1 SDLG transmission SDLG transmission SDLG transmission 2 Shantui transmission Hangzhou Advance/Shantui/ZF transmission VRT200 transmission/ ZF transmission VRT200 transmission / ZF transmission VOLVO transmissio n VOLVO transmission
(5) The 6th number denotes drive axle. ZF axle SDLG axle Feicheng axle
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1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t 1 SDLG axle /
Feicheng axle SDLG axle SDLG axle SDLG axle SDLG axle SDLG axle
SDLG axle
1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t 0
Dual swing arm mechanical control Single regulator constant flow
Mechanical control
(6) The 7th number denotes configuration of hydraulic system. Pilot control Mechanical
control RELIABILITY 16 IN ACTION 1 Single regulator constant flow 2 3 Pilot control Flow amplification 4 Mechanical control Load sensing Mechanical control Load sensing Mechanical control Load sensing Mechanical control Load sensing 5 Pilot control Load sensing Pilot control Load sensing Pilot control Load sensing Pilot control Load sensing Pilot control Load sensing Pilot control Load sensing Pilot control Load sensing
(7) The 8th number denotes boom type.
Standard Ultralong-Wheelbase Long-Wheelbase RELIABILITY 17 IN ACTION
1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t
A Standard Standard Standard Standard Standard Standard Standard G Long-
Wheelbase Long-Wheelbase Long- Wheelbase Long-Wheelbase Long- Wheelbase
Q Ultralong-
Wheelbase Ultralong- Wheelbase
R Short boom dual swing arm Short boom
(8) The 9th number denotes multi-functional configuration code Duplex valve Triple valve Rapid coupling device
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1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t
2 Duplex valve Duplex valve Duplex valve Duplex valve Duplex valve Duplex valve
Duplex valve
3 Triple valve Triple valve Triple valve Triple valve Triple valve Triple valve
k Rapid coupling device
Rapid coupling
device Rapid coupling device
(9) The 10th number denotes cab model. Underground cab Standard cab ROPS cab RELIABILITY 19 IN ACTION 1.6-2.0t 3.0t 4.5t 5.0t 6.0t 7.0t 8.0t 0 Underground cab Underground cab Underground cab Underground cab
6 ROPS ROPS ROPS ROPS ROPS ROPS
3. Performance Characteristics of LG958L (E5816215A3601) Item Performance (1) With 8.079m body length, the RELIABILITY 20 IN ACTION complete machine features outstanding stability.
Item Performance (2) Ultra-high breakout force and RELIABILITY 21 IN ACTION ultra-high lifting force.
Item Performance (3) 6.4s boom lifting time (fully loaded) and Start RELIABILITY 22 IN ACTION =11.3s total cycling time feature high working efficiency. End
Item Performance (4) retraction angle of bucket achieves high loading coefficient, solving the RELIABILITY 23 IN ACTION industry s common existed problem of incomplete loading Large of bucket.
Item Performance (5) SDLG s patented dual-seal hydraulic oil pipe connectors RELIABILITY 24 IN ACTION completely eliminate the oil leakage. Photo of seal ring
Item Performance (6) KD function Neutral start interlocking 2F 2R 1F 2F Press KD button Pull backward To reverse gear Push forward To forward gear 25 RELIABILITY IN ACTION function
Item Performance (7) The DDE BF6M1013 Euro-III emission compliant engine RELIABILITY 26 IN ACTION features strong power, high torque, and low fuel consumption and noise.
Item Performance (8) ZF transmission features power cutoff RELIABILITY 27 IN ACTION function. Change photo
Item Performance (9) SDLG s selfmade heavyduty drive axle boasts best reliability in the industry. RELIABILITY 28 IN ACTION The external dry type brake features easy maintenance and lower cost.
Item Performance (10) High strength frame passes RELIABILITY 29 IN ACTION 100,000 cycles of enhanced fatigue test.
Item Performance (11) New steel structure cab boasts luxury upholstery, RELIABILITY 30 IN ACTION front air vents, large space, and shock absorbing seat.
Item Performance (12) The pilot control RELIABILITY 31 IN ACTION features lightweight and flexibility.
Item Performance (13) Widened engine hood makes the RELIABILITY 32 IN ACTION heat radiation and repair easier.
Section II Product Configuration I. Optional Configuration
Ordering
number Engine Transmissio n Operations Cab Quick coupling device Bucket capacity E5812215A39 Weichai WD10.G220 ZF Single-lever Conventional cab / 2.7 m3
E5813215A39 Shangchai C6121 Conventional cab /
E5814215A36 Dongfeng
Cummins ROPS cab /
RELIABILITY 33 IN ACTION transmissio n LG drive axle pilot control Load-sensing system Triple valve m 3.0 m3 3.6 m3 4.2 m3 4.5 m3 6CT8.3 E5814215A39 Dongfeng Cummins 6CT8.3 Conventional cab / E5812215AK6 Weichai
WD10.G220 ROPS cab Optional E5814215AK6 Dongfeng
Snow bucket Rock bucket Fork I. Optional Attachments RELIABILITY 34 IN ACTION
Bale grab Timber grab Multifunctional bucket RELIABILITY 35 IN ACTION
Section III Technical Specification of Complete Machine I. Main Parameters (E5816215A3601)
Item Parameter
Bucket capacity (m3) 3.0 Item Parameter
Tipping load(kN) =110.0
1. Main Parameters Complete Machine RELIABILITY 36 IN ACTION
Rated load(kg) 5000 Overall weight(kg) 16900 L×W×H (mm) 8079×3024×3382
Maximum traction force(kN) =155.0 Maximum breakout
force(kN) =180.0
2. Main Parameters Traveling Speed Item Parameter
Gear Forward Reverse 1st (km/h) 0~6.5 0~6.5 RELIABILITY 37 IN ACTION 2nd (km/h) 0~11.5 0~11.5 3rd (km/h) 0~23 0~23 4th (km/h) 0~38 /
3. Main Parameters - Engine Item Parameter Model BF6M1013 Type Inline, water-cooled, turbocharged, direct Item Parameter Number of cylinders 6 Cylinder bore/stroke (mm) 108/130 RELIABILITY 38 IN ACTION injection Rated power (/kW ) 169 Rated speed (r/min) 2200 Displacement (L) 7.146 Minimum fuel consumption (g/kW.h) =210 Top torque(N.m) 925
3. Main Parameters Torque Converter Item Parameter
Type Single-stage, three-way, single turbine, hydraulic torque converter
Torque conversion coefficient 2.55 RELIABILITY 39 IN ACTION
Oil cooling mode Recirculated water-cooling Inlet oil pressure of torque converter (MPa) 0.85
Outlet oil pressure of torque converter (MPa) 0.5
4. Main Parameters Transmission Item Parameter
Model ZF
Type Fixed shaft electro-hydraulic shift RELIABILITY 40 IN ACTION
Number of gears Four forward and three reverse Transmission pump model Transmission built-in Gearshift working pressure (MPa) 1.6 1.8
5. Main Parameters Drive Axle Item Parameter
Type Full-time 4-wheel drive Tire specification 23.5-25
Pressure of front tires (MPa) 0.39±0.01 RELIABILITY 41 IN ACTION
Pressure of rear tires (MPa) 0.33±0.01
Type of wheel reducer 1-stage planetary reduction Wheel reduction ratio 4.4
6. Main Parameters - Brake Item Parameter
Type of service brake Air-assisted hydraulic caliper disc brake RELIABILITY 42 IN ACTION
Braking pressure (MPa) 0.784
7. Main Parameters Steering Hydraulic Item Parameter
Type Load-sensing fully hydraulic articulated steering Priority valve YXL-250-16
Steering pump JHP2100/Gj0010C-XF RELIABILITY 43 IN ACTION
Steering gear BZZ6-800 Steering angle (º) 38° Steering pressure (MPa) 16
8. Main Parameters Working Hydraulic Item Parameter
Type Hydraulic pilot control Working pump JHP3160
Multi-way valve D32-17.5, pressure: 17.5MPa, flow: 250L/min RELIABILITY 44 IN ACTION
Total cycling time (s) =11.3 System working pressure (MPa) 17.5
9. Main Parameters Filling Capacity (Recommended Oils) Item Recommendation Parameter
Engine (L) 19 Transmission (L) 35 Drive axle (L) 2X16 RELIABILITY 45 IN ACTION Brake system (L) 4 Fuel (L) 300 Hydraulic oil (L) 210
Operation Specification of Complete Machine CONTENTS
Maintenance Specification of Complete Machine RELIABILITY 46 IN ACTION
Section I Operation Specification of Complete Machine
Chapter II Operations, Maintenances, and Checking of Complete Machine I. Preparations before Start
1. Get familiar with and master safety operation practice of loader Only the specially trained and approved personnel can
operate and maintain the machine.
Operate and maintain the machine under good RELIABILITY 47 IN ACTION
physical state.
Properly wear all labor protection appliances. Abide by the instructions and coo perate with each
2. Get familiar with the safety signs of complete vehicle. Starter switch warning sign,
located above the starter switch. High temperature warning, located on
engine hood and at exhaust pipe Fuel tank sign, located on fuel tank. Rotate key to neutral position after parking Warning Take cautions against scalding by hot portions. Recommended scope Recommended scope Caution
The driver must have official driver s license Caution
1. Guard your hands against squeezing.
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Hydraulic oil tank sign, located on hydraulic oil tank.
Parking brake sign, located on right operating panel.
Hoisting sign, located at hoisting position of frame.
Operation caution sign, located on left front window within cab.
Cab door caution sign, located on outer side of cab door.
and fulfill the maintenance as per the requirements in the operation and maintenance manual of this machine.
Before start, check the machine and fulfill the preparation works as per the specified
requirements.
Before the startup or backup of the machine, observe the surrounding area for presence of pedestrian and obstacle and sound the horn for signaling.
The engine water temperature must be higher than 55ºC, the oil temperature must be higher than 45ºC, and the air pressure must be
higher than 0.45MPa before the machine is put into high speed and full load operations. The engine water temperature shall not
exceed 95ºC and the oil temperature shall not exceed 120ºC.
2. Make sure to lock the doors during traveling.
Loader traveling caution sign, located on right front window of cab.
Lifting boom safety sign, located on both sides of boom.
Caution
It s prohibited to get on or off the machine during the traveling. No person is allowed to sit in any place of the machine, except the driver seat.
The bucket or other working device shall load the material as even as possible and prevent the
excessive offset towards one side.
It s prohibited to travel at high speed under loaded condition.
Make sure to slow down during steering and avoid the sudden steering and sudden braking.
Do not travel at high speed under rainy or snowy weathers and avoid the steering on slopes as far as possible.
Pay attention to observe the readings of the instruments and park the machine away from fire source.
While parking the machine on a slope, tightly set the parking brake and block the wheels with
triangle woods.
Avoid the checking and maintenance with the engine running.
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Under-boom danger sign, located on both sides of boom. There is injury danger at articulations during
steering. The sign is located at front and rear frame articulations.
Warning Never stand beneath the boom.
Antifreeze sign, located on left cab door and
engine hood water tank filler port. Hot water caution sign, located at engine ho od water
tank cap.
This machine is filled with (-25#) antifreeze.
Note: The antifreeze is glycol engine coolant.
While adding the antifreeze, operate as per the operation instructions of the antifreeze purchased in accordance with the required environment conditions, or it will impair the antifreeze effect.
Recommended operation scope: -25#: For use under = -15º environment condition. -35#: For use under = -25º environment condition. -45#: For use under = -35º environment condition. RELIABILITY 50 IN ACTION
Safety distance warning sign, located on both sides of engine hood.
Machine contact warning sign, located on both sides of engine hood.
3. Get familiar with information of instrument panel
Left turn indicator Right Central warning lamp turn indicator Engine speedometer Warning indicator Warning indicator
51 RELIABILITY IN ACTION Torque converter oil temperature gauge Instrument panel
Brake pressure gauge Fuel level gauge Working hourmeter Engine water
Low fuel level warning Safety locking indicator Handbrake indicator Seat belt
High beam indicator RELIABILITY 52 IN ACTION
Transmission oil filter blockage warning
High coolant
temperature warning
Air cleaner blockage warning Power cutoff indicator
Low transmission oil
Charging indicator warning pressure warning Low engine oil pressure
warning 53 RELIABILITY IN ACTION Preheating indicator Mute indicator Fuel-water separator warning Engine malfunction warning
4.1 Engine oil level;
4.2 Transmission oil level; 4.3 Hydraulic oil level; 4.4 Coolant level;
4.5 Brake fluid level;
4. Checking items before start: RELIABILITY 54 IN ACTION
4.6 Checking of lubrication status at lubricating points; 4.7 Checking of battery;
4.8 Checking of tire air pressure;
4.9 Water drainage from fuel-water separator and air reservoir; 4.10 Checking of hydraulic pipeline;
Parking:
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Before the checking, park the machine on a level and solid ground, shift the gea rshift
operating lever to neutral position, press the parking brake switch, lower the b ucket
level onto the ground, align the front and rear frames without any angle, place the
blocks before and after the tires, and leave the complete machine still for 15mi n.
4.1 Engine oil level; H L
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(1) Pull out the oil dipstick and wipe clean the lubricating oil on the oil dips tick with clean
lint-free paper.
(2) Re-insert the oil dipstick into the engine and pull it out and then observe the mark of
lubricating oil on the dipstick. If the mark is between L and H, it indicates th at the
lubricating oil level is normal. If the mark is below L, add lubricating oil to specified
level. If the mark is above H, find out the cause and operate for 2~3 times. (3) Ensure that the oil level is within normal range and the oil dipstick is rei nstalled
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If the engine is short of lubricating oil, the poor lubricating oil is used, or the lubricating oil is not replaced for a long period, it will probably lead to seizure of bushing or scuffing of
cylinder.
Seizure of bushing Scuffing of cylinder Warning!
4.2 Check the transmission oil level. Transmission oil
dipstick
Oil level under hot Filler port state
Oil level under
cold state Upper mark Lower mark
Middle mark
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(1) Star the engine and idle run (approximate 1,000r/min). Loosen and withdraw t he
transmission oil dipstick and wipe clean the oil from the oil dipstick with clea n lint-free paper.
(2) Re-insert the oil dipstick into the transmission, tighten and withdraw and t hen observe the
oil mark on the oil dipstick.
(3) When the oil temperature is approximate 40ºC, the oil level shall be between l ower mark and
middle mark. When the oil temperature is approximate 80ºC, the oil level shall be between
upper mark and middle mark. If out of above range, add transmission oil as speci fied.
(4) Ensure that the oil level is within normal range and the oil dipstick is rei nstalled properly.
4.3 Check the hydraulic oil level. The scale of oil dipstick is 8~12 RELIABILITY 59 IN ACTION
(1) Shift the gearshift operating lever to neutral position, start the complete machine, lift the boom to highest position, tilt forward the bucket to
level state by means of bucket leveling mechanism, and stop the engine. Then operate the pilot lever to slowly lower the boom and place level the bucket, shift the operating lever to neutral position, and stop the engine. (2) Observe the oil dipstick on the left side of the hydraulic oil tank. The oil level shall be within 8~12. If insufficient, add to specified level.
4.4 Check the coolant level. 4.5 Check the brake fluid level. (1) Open the water tank cap under cold state of engine.
(2) Observe
the coolant amount
within radiator and ensure that the radiator is full of coolant. If insufficient, add coolant timely. (3) Install the water tank cap.
(1) Open the access cap of booster pump assembly oil cup.
(2) Observe the brake fluid amount in the oil cup. The fluid amount shall be 3/4 of oil cup capacity. Add brake fluid if insufficient. (3)
Observe the oil cup filter screen for presence of impurity and clean if any. RELIABILITYINACTION60
4.6 Check the lubrication status at lubricating points; RELIABILITY 61 IN ACTION
Check the lubrication status at lubricating points and timely add the lubricatin g
grease. The adding method of lubricating method is as below: (1) Remove oil dirt from vicinity of lubricating points.
(2) Connect grease gun to the grease nipple and operate the grease gun to add th e
lubricating grease. Observe the articulated surfaces, till the used grease is completely squeezed out and the new grease just overflows.
(3) Remove over-flown used grease and properly protect the grease nipple with a small amount of new grease.
4.7 Check the battery; RELIABILITY 62 IN ACTION
(1) Remove foreign material from the top of battery and observe the battery for presence of
damage or leakage.
(2) Check the battery charge indicator. It indicates good battery if the indicto r is green. If the
indicator is black, it s necessary to charge the battery. If white, it s necessary t o replace
battery.
4.7 Check the tire air pressure; RELIABILITY 63 IN ACTION
(1) Screw off the tire valve protective cap and check the intactness of tire val ve. Remove the
impurity and dirt from the vicinity of the valve, connect the pressure gauge to the tire
valve, and observe the reading of pressure gauge.
(2) The pressure shall be 0.333~0.353MPa for front tires and 0.275~0.294MPa for rear tires. If
the measurement is out of above range, inflate or deflate the compressed air (Th is
standard is applicable for the tires with 16 ply rating. For tires with 18 ply r ating, add
0.05MPa on the basis of above standard for the tire pressure).
(3) At completion of checking, properly preserve the pressure gauge and install the valve
protective cap.
caution: While checking the air pressure and inflating the tire, do not face you r body towards
4.7.1 Hazard of over-high or under-low pressure to tires: RELIABILITY 64 IN ACTION
While the loader is traveling with over-high tire pressure, the
contact area of the tire crown is reduced and the partial load is increased, which will accelerate the wear and lead to tire burst under worse cases.
While the loader is traveling with under-low tire pressure, the wear is accelerated and the overheating is caused for the tire shoulder, which will lead to separation between sidewall rubber and cord ply and lead to burst under worse cases.
4.9 Drain water from fuel-water separator and air reservoir;
(1) Place an oil container beneath the water (1) Open the water drainage valve o f
Water drainage valve
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drainage valve of the fuel-water separator.
(2) Remove the dirt from the vicinity of the water drainage valve of the fuel-water
separator and loosen the water drainage valve of fuel-water separator, till the water flows out.
(3) Observe the water drainage status. When the clean fuel flows out, close the water drainage valve. Properly dispose the drained water.
the air reservoir.
(2) Close the water drainage plug when the water in the reservoir is fully drained.
4.10 Check the hydraulic pipeline; RELIABILITY 66 IN ACTION
Before the start, carefully check all hydraulic pipelines and air pipelines for presence of leakage. If any, tighten timely. Check the pipelines for presence of damage and timely replace if any.
II. Start Requirements
Position Position STOP ON Position START
1. Before start, shift the gear operating lever to neutral gear.
2. Rotate the starter key to position ON, observe the power-on status of the ins trument
panel, and check that all instruments display normally and there is no alarmed m alfunction
lamp. At the same time, sound the horn for warning purpose. 67 RELIABILITY IN ACTION
3. Rotate the starter key to position START. In such case, the starter will driv e the rotation of
engine. When the engine is started, immediately release the key. The starter key will
automatically return to position ON. If the engine fails to start, wait for at l east 1min
before retry. If the engine fails to start after three consecutive attempts, che ck for the
cause.
4. After the engine is started, do not operate under high load immediately. Idle run the
engine for 3~5min, gradually increase the engine speed, and operate the boom cyl inder
III. Checking after Start
1. Check the readings of instruments. No malfunction warning lamp shall light up .
Water temperature gauge, normal if pointer is within green zone (60~100 .)
Torque converter oil temperature gauge, normal if pointer is within green zone (60~120 .)
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Transmission pressure gauge, normal if pointer is within green zone
(1.5~1.8MPa)
Brake air pressure gauge, normal if pointer is within green zone
2. Check the functional actions:
2.1 Check the steering flexibility; 2.2 Check the service braking effect. RELIABILITY 69 IN ACTION
Operate the loader for left and right turns while the engine is running at moderate speed. The steering shall be flexible without stagnation.
While the loader is traveling at 24km/h on a dry and level cement road, the braking
2.3 Check the running status of engine. RELIABILITY 70 IN ACTION
(1) The fuel lines and air lines shall be free of leakage during the running of engine.
(2) Listen to the engine sound and ensure that there is no abnormal sound such as noise.
(3) Observe the exhaust gas color of the engine. The exhaust gas shall be free o f
clear black, blue, or white smoke. In event of continual abnormal smoke, stop the engine for checking.
IV. Operation Specification 1. Startup
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(1) To prevent accidents, ensure that there is no irrelevant person on the loader or in the vicinity of the loader and keep the loader away from the obstacles, high voltage wires, and cables before the traveling.
(2) Lift the boom, tilt backward the bucket, and maintain
the traveling state. The lower articulated point of boom shall be
400~500mm off the ground.
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(3) Shift the gearshift operating lever to 1st forward gear or 1st reverse gear, depress the brake pedal, and lightly rotate the parking brake switch to pop up to release the parking brake. (4) Release the brake pedal and slowly depress the throttle pedal to drive forward or backward the loader.
2. Stop
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(1) Release the throttle pedal, depress the brake pedal to stop steadily the loader, and shift the gearshift operating lever to neutral position.
(2) Push down the parking brake switch.
(3) Lower the bucket or other working device onto the ground.
(4) Idle run the engine for approximate 5min, rotate the starter key to position OFF to stop the engine, and withdraw and properly preserve the key.
3. Operation Method Rock pile
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(1) To load the rock material, the bucket shall have a downward tilting angle. To load the earthwork, the bucket shall place horizontally onto the
ground and shovel straightly perpendicular to the material.
(2) After the bucket is fully loaded, make sure to retract the bucket before lifting the boom.
4. Loading and Unloading Method RELIABILITY 75 IN ACTION
(1) Cross loading/unloading
Align the loader with the stockpile, load the material, and travel
rearward. Then, the dump truck
drives in between the loader and the stockpile. This loading/unloading method features shortest cycle time. (2) V-shaped loading/unloading
Position the dump truck so that the dump truck forms an approximate 60º angle
with the backward direction of the loader. After the bucket is fully loaded with material, the loader travels backward, steers for certain angle, and drives towards the dump truck. The smaller the V-shape angle is, the higher the working efficiency of the loader is.
5. Safety Precautions
It s prohibited to lift the boom without retracting the bucket during the loading of material.
It s prohibited to load or unload the material during steering.
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It s prohibited to lift the boom to highest position for excavation operations.
It s prohibited to travel laterally on a slope. Travel slowly to drive down a slope. It s prohibited to coast with engine
stopped. While traveling down a slope under heavily loaded condition, travel the loader under backup mode.
The maximum water depth shall not reach the drive axle housing and brake disc.
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Make sure to keep good ventilation during compartment (and underground) operations. The engine must be fitted with exhaust gas treatment device.
Do not operate the operating lever further after the cylinder reaches limit position and operate slowly at uniform speed during unloading.
Section II Maintenance Specification of Complete Machine I. Safety Rules
(1) At the maintenance of the machine, affix a maintenance label to the steering wheel,
which shall indicate the name of maintenance operator, date, and time.
(2) No one is allowed to remove this label, except the one who affixed this label.
(3) The operator who affixed this label shall also preserve the starter key.
(4) Operate on a solid and level ground. RELIABILITY 78 IN ACTION
(5) Close the working device to the ground and place level the bucket.
(6) Shift all operating levers to neutral positions. (7) Pull up the parking brake lever.
(8) Place blocks before and after the tires. (9) Lock the front and rear frames with frame locking levers.
(10) Pay attention to high temperature oil and coolant, in order to guard against scalding.
II. Mandatory Maintenance Contents
No. Mandatory Maintenance Description 50- 100h
500- 600h 1000- 1200h
1 Determine whether the customer fulfilled the maintenance as per the Operation and Maintenance
Manual. v v v
2 Check and tighten the connecting bolts of all drive shafts, wheel rims, and br ake calipers; v v v
3 Check and fasten connecting bolts of bucket blades or anti-wearing plate. v v v
4 Check the throttle control, parking brake, and gearshift control systems. v v v
5 Check whether the circuits and electric units of the electric system are norma l. v v v
6 Check the fuel tank and radiator for normal levels. v v v
7 Check the sealing performance, reliability, and flexibility of the brake syste m. v v v
8 Check the brake booster pump for normal level. v
9 Check all portions of brake system for presence of leakage, clean booster pump oil cup filter screen,
clean breather port, and check brake fluid and add if insufficient. v v v 10 Check and clean breather port of transmission. v v v
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11 Check the sealing performance of hydraulic and steering systems of working de vice. v v v
12 Check all portions of hydraulic system for presence of leakage and check oil level of hydraulic oil tank. v v v
13 Clean breather port of hydraulic oil tank and check and clean oil return filt er element of hydraulic oil
tank. v v
14 Add lubricating oil or grease to all lubricating points, including all articu lated points of working device,
fan shaft, frame articulated points, drive shaft, and rear axle swing articulate d points. v v v
15 Check for presence of other abnormality. v v v
16 Conduct the maintenance for the diesel engine strictly as per the requirement s of Operation and
Maintenance Manual of Diesel Engine. v v v
17 Strictly follow the regulations of ZF AG for the maintenance of ZF axles and transmissions. v v v
18 Check and adjust other portions as required, such as drain residual fluid fro m bottom of air reservoir
19 Clean the transmission oil sump and replace the oil suction filter element of transmission oil sump. v v v
20 Replace the filter element in the torque converter transmission oil line syst em. v v v
21 Replace transmission oil. v v v
22 Replace the gear oil of front and rear axles. v v
23 Check the battery, clean the battery surfaces and wiring terminals, and apply a film of Vaseline to the
surfaces of wiring terminals. v v
24 Clean the muffler of brake solenoid valve. v v
25 Check and fasten the connecting bolts between front and rear axles, diesel en gine, transmission, and the
frame. v v
26 Check the working device and frame for cracked welds and loose connecting bol ts. v v
27 Check the tire pressure. v v
28 Check and adjust the braking gap of the handbrake system. v v RELIABILITY 80 IN ACTION
29 Check the wear status of the brake disc and frication plate of the foot brake system and when necessary
replace. v v
30 Open the water drainage valve of the air reservoir to drain the water. v v 31 Replace the brake fluid v v
32 Replace oil return filter element of hydraulic oil tank. v v 33 Replace pilot oil filter element. v v
34 Check the hydraulic oil amount and cleanliness and filter if possible, add if insufficient, and replace if
necessary. v
35 Check the gap and wear status between hinge pin and sleeve at all articulated points. v
36 Check and clean the breather port of hydraulic oil tank and clean hydraulic o il tank. v
III. Mandatory Maintenance Method
By taking 1,000~1,200h maintenance for instance, the section below describes the mandatory maintenance method. The operation method to stop the
machine is same with that of checking before stop.
1. Check and tighten the connecting bolts of all drive shafts, wheel rims, and brake calipers
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(1) Remove the mud and sundries from the vicinity of the fastening bolts of drive shafts, wheel rims, and brake calipers.
(2) Lightly rotate every bolt with wrench to check for presence of looseness and tighten any loose bolt to specified torque.
2. Check and fasten connecting bolts of bucket blades or anti-wearing plate. RELIABILITY 82 IN ACTION
(1) Remove mud and sundries from the vicinity of the connecting bolts of bucket blades or anti-wearing plate.
(2) Lightly rotate every bolt with wrench to check for presence of looseness and tighten any loose bolt to specified torque.
3. Check the throttle control, parking brake, and gearshift control systems. RELIABILITY 83 IN ACTION
(1) Check the throttle operating pedal for flexible movement without any stagnation and check whether the engine speed rises steadily and
uniformly following the depressing of the pedal.
(2) Check all pipelines of the parking brake system for presence of air leakage, check brake buttons for flexible operations, check brake air chamber spring for normal return, and check for clear braking effect.
(3) The gearshift operating lever shall be free of stagnation and all gears shal l
4. Check whether the circuits and electric units of the electric system are normal.
RELIABILITY 84 IN ACTION
(1) Check the connectors of all harnesses for secure connections and ensure that the harnesses are free of damage.
(2) Check all instruments for normal functioning and check all electric units for normal functioning without any damage.
(3) Check all switches of electric system for flexible functioning and good contact.
5. Check the fuel tank and radiator for normal levels. Filler cap
Level gauge
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(1) Park the loader on a level ground and observe the level gauge from the outside of the fuel tank. If the reading of level gauge is below the
marking 0, add fuel through filler port of fuel tank.
(2) Under the cold state of the engine, open the water tank cap and observe the coolant amount in the radiator. Ensure that the radiator is full of coolant. If insufficient, add coolant timely.
6. Check the sealing performance, reliability, and flexibility of the brake syst em.
Water drainage plug
(1) Check all pipelines of brake system for presence of damage and check pipelin e
connections for presence of leakage.
(2) The brake system shall operate flexibly and reliably during the traveling. W hile
traveling at 24km/h on a dry and even cement road, the braking distance shall not be more than 9m.
7. Clean booster pump oil cup filter screen, clean breather port, and check brak e
fluid and add if insufficient. Breather hole
(1) Open the booster pump oil cup cap and take out the filter screen. Ensure tha t
the filter screen is free of damage, remove foreign materials from filter screen ,
and clean breather hole.
(2) Check and ensure that the brake fluid in the oil cup is above 2/3 of the oil cup
RELIABILITYINACTION87
8. Check and clean breather port of transmission.
(1) Remove the foreign materials and oil dirt from the vicinity of the breather port.
(2) Disassemble the transmission breather port and clean with clean gear oil. (3) At completion of cleaning, install breather port to the transmission. RELIABILITYINACTION88
9. Check the sealing performance of hydraulic and steering systems of working de vice.
(1) Check the pipelines of working device hydraulic system for presence of damag e
and, if damaged, replace timely.
(2) Check the connections between all pipelines for presence of leakage and, upo n
detection of leakage, find out cause and timely repair. RELIABILITYINACTION89
10. Check the hydraulic oil tank level. Scale range of oil dipstick
RELIABILITY 90 IN ACTION
Observe the oil dipstick on the left side of the hydraulic oil tank. The oil lev el
shall be within 8~12. If insufficient, add to specified level. is within 8~12.
11. Add lubricating oil or grease to all lubricating points, including all artic ulated points
of working device, fan shaft, frame articulated points, and drive shaft. RELIABILITY 91 IN ACTION
Adding method of lubricating grease:
(1) Remove oil dirt from vicinity of lubricating points.
(2) Connect grease gun to the grease nipple and operate the grease gun to add th e
lubricating grease. Observe the articulated surfaces, till the used grease is completely squeezed out and the new grease just overflows.
(3) Remove over-flown used grease and properly protect the grease nipple with a small
12. Conduct the maintenance for the diesel engine strictly as per the requiremen ts of
Operation and Maintenance Manual of Diesel Engine. 12.1 Maintenance of air cleaner
RELIABILITY 92 IN ACTION
Main cleaner Auxiliary cleaner
(1) Replace or clean once every 2,000 hours or when the maintenance indicator tu rns red.
(2) The main cleaner must be replaced after being cleaned for up to 6 times and the
auxiliary cleaner is a one-off part.
(3) If the maintenance indicator is still red after the cleaning, make sure to r eplace the
cleaner.
(4) The damaged cleaner shall be replaced as well.
(5) The interval for replace of cleaner depends on the working environment. The worse the
Cleaning and checking method of main cleaner: (1) Mechanical cleaning:
Lean against the surface of a soft and clean object and slap the end of main cleaner lightly. (2) Clean with compressed air:
. Blow clean the cleaner from inside to outside along the wrinkles of the cleaner.
. Use clean and dry compressed air with pressure no more than 500kPa.
. Maintain at least 3~5cm spacing between nozzle and cleaner.
(3) Check the cleaner. RELIABILITY 93 IN ACTION
. Check the cleaner by illumination method. Place a light source within the cleaner. If the lighting is visible from the outside, replace the cleaner. . Upon detection of pinhole, scratch, cracking or other damage, make sure to replace the cleaner.
. At the replacement of the main cleaner, make sure to replace the auxiliary cleaner.
. If the filter indicator lights up though the main cleaner is replaced or ever cleaned, it indicates that the auxiliary cleaner is blocked.
12.2 Replace the engine oil filter. Engine oil filter
RELIABILITY 94 94 IN ACTION
(1) Remove the impurities and oil dirt from the vicinity of the filter and place an oil container beneath the filter.
(2) Disassemble the used filter and place properly. Apply a small amount of engine oil to the seal ring of new filter and install to the filter seat. (3) Clean the splashed oil dirt.
12.3 Replace the engine oil Filler
port H L
RELIABILITY 95 IN ACTION
(1) Place an oil container beneath the oil drainage port of the engine, disassem ble the
oil drainage plug to fully drain the oil from oil sump, and then install the oil drainage plug.
(2) Open the filler cap and add engine oil to the engine. The filling amount sha ll be
between L and H of the oil dipstick. Please refer to the Checking of Engine Oil Level
in Checking before Start for specific operation method.
(3) Install the filler cap, clean the splashed oil dirt, and properly dispose th e used oil.
12.3 Replace fuel-water separator element. Fuel-water separator
element
RELIABILITY 96 IN ACTION
(1) Remove the dirt form the vicinity of the separator element, place an contain er beneath the
separator element, and use wrench to disassemble the separator element along wit h fuel
cup.
(2) Disassemble the fuel cup from the used element and install to new element. T op up new
element with fuel, apply a film of fuel uniformly to the seal ring of element, a nd install the
element to the element seat.
12.4 Replace fuel filter element. Fuel filter element
RELIABILITY 97 IN ACTION
(1) Clean the dirt from the vicinity of the fuel filter and place a container beneath the fuel filter.
(2) Disassemble the used filter and place properly. Apply fuel uniformly to the seal ring of new filter and install to the filter seat.
12.5 Check the engine belt tension. (1) Push the belt with a
10kg force after the belt is tensioned. The vertical deflection shall be approximate
5~8mm. If the deflection exceeds
RELIABILITY 98 IN ACTION 15mm, please adjust the tensioner or replace with new belt.
(2) Check the belt once every 250h or when the belt noise is high.
13. Replace the filter element in the torque converter transmission oil line system.
(1) Remove the oil dirt and foreign material from the vicinity of the filter and place an oil container beneath the transmission.
(2) Disassemble the used filter element, apply uniformly a film of lubricating oil to RELIABILITY 99 IN ACTION the seal ring of new filter element, and install new filter element to the transmission.
(3) Clean the oil dirt splashed on the transmission.
14. Replace transmission oil. (1) Remove the oil dirt from the vicinity of the oil drainage plug, place an oil container beneath the oil drainage port, and disassemble the oil drainage plug to drain the used oil. Thoroughly remove the oil dirt from the oil drainage plug, housing sealing surface, and
transmission body and install RELIABILITY 100 IN ACTION Oil drainage plug Filler port
the oil drainage plug with new seal ring.
(2) Add transmission oil into the transmission through filler
port to the specified level and install the oil dipstick. (3) Clean the splashed oil dirt.
15. Replace the gear oil of front and rear axles. RELIABILITY 101 IN ACTION
Replace the gear oil of wheel reducer:
(1) While parking the machine, adjust the oil drainage plug of wheel reducer to the lowest position, place an oil container beneath the oil drainage port, and disassemble the oil drainage plug to fully drain the used oil. Then install the oil drainage plug.
(2) Disassemble the oil filler plug, add gear oil into the wheel reducer till th e
gear oil overflows from the filler port, and then install the oil filler plug. (3) Clean the splashed gear oil.
Axle housing oil filler plug Axle housing oil drainage plug
RELIABILITY 102 IN ACTION
Replace the axle housing gear oil:
(1) Place an oil container beneath the oil drainage plug, disassemble the oil dr ainage
plug to fully drain the used oil, and then install the oil drainage plug.
(2) Disassemble the oil filler plug, add gear oil to the axle housing till the g ear oil
overflows from the filler port, and then install the oil filler plug. (3) Clean the over-flown gear oil.
16. Check the battery, clean the battery surfaces and wiring terminals, and apply a film of Vaseline to the surfaces of wiring terminals.
RELIABILITY 103 IN ACTION
(1) Remove the foreign materials from the surfaces of the battery. (2) Check the cables and wiring posts for secure connections and timely tighten any loose connection.
(2) Uniformly apply a film of Vaseline to the surfaces of wiring posts and install the fire-proof caps.
17. Check and fasten the connecting bolts between front and rear axles, diesel engine, transmission, and the frame.
Check the connecting bolts between the front and rear axles, diesel engine, and transmission and the frame for presence of looseness and timely tighten any loos e
bolt to specified torque. RELIABILITYINACTION104
18. Check the working device and frame for cracked welds and loose connecting bolts.
RELIABILITY 105 IN ACTION
(1) Check the welds of structural parts, such as working device and frame, for presence of cracking and, upon detection of cracking, repair timely. (2) Check the fastening bolts of all portions for presence of looseness and, upon detection of any loose bolt, tighten to specified torque.
19. Check and adjust the braking gap of the handbrake system. Adjustment nut
Linked with brake
RELIABILITY 106 IN ACTION
(1) Park the vehicle on a level ground, start the engine, release the parking br ake, and
adjust the adjustment nut to a moderate gap between brake shoe and brake drum. (2) Checking criterion: Park the vehicle with properly adjusted gap on a slope w ith 1/4
gradient, stop the engine, and apply the parking brake. If the vehicle can hold on
the slope, it indicates that the gap is moderately adjusted. If not, the re-adju stment
20. Check the wear status of the brake disc and frication plate of the foot brake system and when necessary replace.
RELIABILITY 107 IN ACTION
Check the wear status of brake disc and friction plate. If the braking effect is impaired due to serious wear, the replacement is required.
21. Open the water drainage valve of the air reservoir to drain the water. Water
drainage plug
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(1) Open the water drainage valve of the air reservoir to drain the water. (2) Close the water drainage plug after the water in the air reservoir is fully drained.
22. Replace the brake fluid. Air bleeding
valve
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(1) Drive the loader to a level ground, shift the gearshift operating lever to neutral gear (N) , stop the loader, and push down the parking brake
switch to guard the loader against movement. Open the air bleeding
valves of all brake calipers with open-end wrench to fully drain the used brake fluid into a container.
(2) Add new brake fluid, start the engine, apply the braking for several times to flush the entire system pipeline with new brake fluid, and then drain the brake fluid.
(3) Close the air bleeding valves of rear axle brake and front axle left brake a nd top up
the oil cup with brake fluid. Filler port Oil cup Brake pedal RELIABILITY 110 IN ACTION
(4) Apply the braking for several times (ensure that the air reservoir has suffi cient
pressure. In event of pressure alarm, slightly depress the throttle pedal furthe r till
the pressure is normal, before the application of braking) , till the brake flui d flows
continually at the air bleeding valve.
(5) While maintaining the oil level of booster pump oil cup, depress and hold th e brake
pedal. When the brake fluid flows out continually under spurting state, close th e air
bleeding valve of front axle right brake.
(6) Repeat above step to bleed the air from the front axle left brake, rear axle left brake,
and rear axle right brake respectively.
(7) Top up the booster pump oil cup with oil, apply the braking for several time s, and
Brake pedal Brake pressure
RELIABILITY 111 IN ACTION
(6) Repeat above step to bleed the air from the front axle left brake, rear axle left
brake, and rear axle right brake respectively.
(7) Top up the booster pump oil cup with oil, apply the braking for several time s,
23. Replace the hydraulic oil tank return filter element and suction filter element and clean the breather port of hydraulic oil tank.
(1) Remove the dirt from vicinity of return flange, disassemble the return Suction flange
cap
Filler cap Return flange cap Breather cap
Breather filter
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flange, take out the return filter element, properly install new filter element, clean the flange mounting surface, and properly install the flange.
(2) Remove the dirt from vicinity of suction flange, disassemble the suction flange, take out the suction filter element, properly install new suction filter element, clean the flange mounting surface, and properly install the flange.
(3) Disassemble and clean the breather cap and reinstall to original position.
24. Replace pilot oil filter element. RELIABILITY 113 IN ACTION
(1) Remove the dirt from the pilot filter housing and place an oil container beneath.
(2) Disassemble the filter housing, take out the used filter element, replace with new filter element, and install the filter housing.
(3) Clean the splashed hydraulic oil and properly dispose the used filter element.
25. Check the gap and wear status between hinge pin and sleeve at all articulated points.
RELIABILITY 114 IN ACTION
(1) Check the gap between hinge pin and sleeve. If over-sized, repair timely. (2) Check for looseness and gap between bushing and structural part and
Section III Checking of Complete Machine I. Safety precautions
1. The operator shall understand and abide by the governing national and local s afety regulations.
2. Most of the accidents are caused by the failure of abiding by the operation a nd maintenance
regulations of the machine. To prevent the accidents, before the operations, ple ase read,
understand, and abide by all warnings and precautions in the operation and maint enance manual
and on the machine.
3. Pay attention to the safety during the testing, in order to prevent harming y ourself or others.
4. While adjusting the working pressure of hydraulic system, make sure to stop t he engine, operate
the operating lever to lower the boom, and wait for the hydraulic system to unlo ad before the
pressure adjustment.
5. During the pressure measurement, do not directly conduct the pressure adjustm ent when the
pressure reading is low, or it will easily lead to over-high pressure of hydraul ic system and cause
RELIABILITY 115 IN ACTION danger.
6. During the testing, make sure to hang a label of NO OPERATION on the working de vice
operating lever of the loader or appoint a special person to guard the machine, in order to
prevent the operation errors of the non-testing personnel from causing danger. 7. As it s impossible to forecast all possible dangers, the safety instructions in this manual and on
the machine can't include all safety precautions. While using the procedures and operations not
recommended in this manual, ensure the safety of yourself and other persons and make sure not
to damage the machine. If it s unsure of the safety of certain operations, please consult with our
company. We company will not be liable for any safety obligations for the safety accidents arising
from the improper operations and the safety obligations for such operations will be solely borne
II. Instructions of Testing Tools and Applications 1. List of testing tools
No. Code Name Specification and model Application 1 6900000436 One-off packing carton Packing carton 2 4030000369 Pressure gauge
213.53.063/60G1/4 0 6MPa For measurement of pilot pressure and gearshift pressure
3 4030000370 Pressure gauge
213.53.063/400G1/4 0 40MPa For measurement of system pressure (working/steering)
4 4030000368 Testing hose SMS20/M1/4-3000A Assorted with pressure gauge
5 6430000379 Pressure gauge 213.53.063/600G1/4 For measurement of road roller vibration pressure
6 6430000205 Tire pressure gauge 0 0.6MPa For measurement of tire pressure 7 6430000423 Tire pressure gauge extension rod Assorted with tire pressure gauge 8 6430000204 Infrared thermometer Infrared thermometer Non-contact infrared ther mometer
9 6430000206 Multimeter For measurement of all kinds of electric units and circuits
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Note: The actual storage places of the testing connectors and pressure gauges wi thin the toolbox may differ
from the places shown in the figure. Please carefully observe at the choice of t esting tools, in order to prevent
the use of wrong tool.
10 6430000203 Battery tester HBV200 For measurement of battery voltage and discharging
11 6410004204 Measuring connector smk20-
m14*1.5-PE smk20-m14*1.5-PE Assorted with pressure gauge 12 6410003035 Measuring connector smk20-
m14*1.5-pc smk20-m14*1.5-pc Assorted with pressure gauge
13 4120002381 Testing connector SMK20-G1/4-PC smk20-G1/4-PC Assorted with pressu re gauge
14 6430000556 Tachometer DT-207L For measurement of engine speed or related speeds
III. Testing Method
1. Operation Method of Pressure Gauge
1.1 Testing specification of pressure gauges:
(1) Pay attention to maintain the cleanliness during testing, in order to prevent the ingress of dirt into the hydraulic system.
(2) While switching from one testing medium to another testing medium, pay attention to thoroughly clean the connectors of testing hoses, in order to prevent contaminating the oil or fluid to be tested.
RELIABILITY 118 IN ACTION
(3) Use pressure gauge of appropriate measuring range strictly as per the requirements.
1.2 Measure the pressure of working hydraulic system.
(1) Park the loader on a level and solid ground, lower the working device onto t he ground, apply the
parking brake, place an oil container beneath the pressure measurement port, and connect the Multi-way valve Pressure measurement port RELIABILITY 119 119 IN ACTION
pressure measurement pipeline, on which the pressure gauge is already connected, to the pressure
measurement port. Choose the measuring range of 40MPa for the pressure gage (The rated pressure
of the working hydraulic system for LG958L is 17.5MPa and the working hydraulic system may contain
reserved pressure. Pay attention to the safety while connecting the pressure mea surement pipeline and
loosen the pressure measurement port firstly to relieve the pressure) .
(2) Start the engine and operate the working device for a while. After the oil t emperature reaches
approximate 60ºC~90ºC, operate the throttle pedal to run the engine at rated speed a nd operate the
boom cylinder to the end of rodless chamber. Under the system overflow status, r ead the reading of
pressure gauge (The boom cylinder is at the end of rod chamber and the bucket cy linder may at the
end of rodless or rod chamber) .
(3) After the measurement, park steadily the machine, stop the engine, disassemb le the measuring tools,
1.3 Measure the pressure of steering hydraulic system. Oil inlet pipe B
of steering cylinder
Oil inlet pipe A of steering cylinder Pressure measurement port
Measuring connector Testing result RELIABILITY 120 IN ACTION
(1) Park the loader on a level and solid ground, lower the working device onto t he ground, apply the
parking brake, place an oil container beneath the pressure measurement port, and connect the
pressure measurement pipeline, on which the pressure gauge is already connected, to the pressure
measurement port. Choose the measuring range of 40MPa for the pressure gage (The rated
pressure of the steering hydraulic system for LG958L is 16MPa and the steering h ydraulic system
may contain reserved pressure. Pay attention to the safety while connecting the pressure
measurement pipeline and loosen the pressure measurement port firstly to relieve the pressure) .
(2) Start the engine and operate the working device for a while. After the oil t emperature reaches
approximate 60ºC~90ºC, operate the throttle pedal to run the engine at rated speed, rotate the
steering to one limit position, and read the reading of pressure gauge.
(3) After the measurement, park steadily the machine, stop the engine, disassemb le the measuring
2. Operation of battery tester 2.1 Structural characteristics:
This product is composed of the DC voltmeter, load resistors, circuits, and switches, casing made of imported steel, and copper plated clamps. There is battery capacity status indicator on the instrument panel.
2.2 Technical Specification:
Testing range: The battery is 6V and 12V in rated voltage, 32~500A in rated capacity, and 100~120A in discharging current.
Indication method: Indicated by surface colors and characters. RELIABILITY 121 IN ACTION
Measurement method: Manual momentary contact type, with testing time no more than 5s each time.
Accuracy of gauge outfit: With grade 2.0 gauge outfit and 0~16V measuring limit, the delivery products meet the enterprise standard (Q/ILPW-02-98) . Measure the open-circuit voltage of battery before the testing. If the voltage i s
=12.4V, the test can be conducted. If the voltage is <12.4V, charge the battery firstly and then conduct the testing and judgment. The loading time of battery shall not exceed 10s.
2.3 Test the battery. RELIABILITY 122 IN ACTION Load switch
(1) While testing the battery, test in a ventilated place. No smoking is allowed for the operator and no
open fire is allowed in the surrounding area. Clean the testing terminals of the battery and check the
battery casing for presence of rupture and destruction.
(2) Check whether the pointer of the tester is at the zero position on the left side of the dial. If not,
rotate the zero setter in the rear cap hole to adjust the pointer to straight ze ro position.
(3) Clamp the testing clamps to the wiring posts of the battery. If the surface indicator lights up, it
indicates the positive pole. The test may be conducted disregarding the positive and negative poles.
If the indicator fails to light up, check whether the clamps are securely connec ted.
(4) Depress the load switch, till the pointer is stable. The testing time is not allowed to last for 10s.
Observe the surface pointer and the test result is good if within green zone, lo w if within red zone,
2.3 Test the charging system.
(1) Connect the tester as per the method for measurement of battery.
(2) Start the engine and run the engine, till the normal working temperature is reached.
(3) Increase the engine speed to 1,200~1,500r/min. Pay attention to keep clean t he
engine and at the same time do not depress the load switch.
(4) If the pointer is within red zone, it indicates that the charging system is malfunctioned and the battery will be insufficiently charged. If the pointer is within green zone, it indicates that the charging system is normal and the battery can be charged.
2.4 Measure the missing cell of battery: RELIABILITY 123 IN ACTION
(1) Connect the red rubber clamp of the battery tester to the positive post of battery. Note: It's absolutely prohibited to use the black rubber clamp, in orde r
to prevent danger.
(2) Insert the wire testing probe into the lower socket of the gauge body to tes t
the missing cell in turn. If there is no reaction in surface indicator for one c ell
(ensure the good contact during testing) , it indicates that the battery has missing cell.
(3) The conventional testing is 2V per cell, which indicates that the battery is normal.