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Version:0000
Safety
Service Manual For LG958L Wheel Loader
CONTENTS
SAFETY .................................................................................................................................. 1
Preface ..................................................................................................................................... 1
EMC Guidelines ..................................................................................................................... 1
Noise Limits ............................................................................................................................ 1
Cab ROPS ............................................................................................................................... 2
Security Involved in Everyone .............................................................................................. 2
Function Checking ................................................................................................................. 3
Safety-related Electrical Systems........................................................................................ 3
Safety When Handling the Loader ....................................................................................... 4
Several Simple Safety Rules ............................................................................................... 5
Measures before Towing ..................................................................................................... 9
Measures after the Towing .................................................................................................. 9
Safety Regulations for Maintenance ..................................................................................... 9
Introduction ......................................................................................................................... 9
Maintenance Position 1 ..................................................................................................... 11
Maintenance Position 2 ..................................................................................................... 12
Working under Elevated Lifting Frame ............................................................................ 13
Fire Prevention Measures .................................................................................................... 13
Notes for Tire ........................................................................................................................ 16
Safety When Lifting and Supporting the Complete Machine .......................................... 18
Methods for Front Axle ..................................................................................................... 18
Methods for Rear Axle ...................................................................................................... 18
The Safety for Operation of the Battery ............................................................................ 19
Starting with a Booster Battery ........................................................................................... 21
Safety When Dealing with Oil and Fuel ............................................................................. 22
Safety When Dealing with Refrigerant .............................................................................. 22
Safety When Operating Accumulator ................................................................................ 25
The Safety of Hydraulic System .......................................................................................... 25
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
SAFETY
Preface
This booklet is part of Service Manual—LG958L
Wheel loader. Please carefully read this part.
Warning
Be sure to read "Safety” part in the manual before
operating
EMC Guidelines
The machine's electronic equipment may disturb other
electronic devices in some cases and may cause security
problems.
Our loaders have passed a special electromagnetic
interference test, and meet the requirements of ISO
13766. If other electronic equipment is installed on this
loader, electromagnetic interference testing should be
carried out on it.
Noise Limits
Noise level near the driver should be in accordance with
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Service Manual For LG958L Wheel Loader
the cab.
Cab ROPS
Never carry out any unauthorized modifications on
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Service Manual For LG958L Wheel Loader
Function Checking
Please check the functions after safety-related electrical
system operation are carried out, to ensure safety.
Drive Brake
Gearbox
Differential lock
Lifting function
Attachment lock
Please refer to the specific content in Part 3 of
Operation and Maintenance Manual—LG958L
Wheel Loader.
Warning
Operation personnel must fully understand and
master the contents of Operation and Maintenance
Manual—LG958L Wheel Loader before operating the
machine.
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
or replace them.
Always face the machine and use pedals and
handrails when climbing on the machine. Always
use the three-point contact, namely two hands and
one foot, or two feet and one hand. Do not jump up
and down!
Before operation
Be sure to read Operation and Maintenance
Manual—LG958L Wheel Loader before
Figure 2 Read Operation and Maintenance operating the machine. Comply with the operating
Manual—LG958L Wheel Loader before instructions, and implement the required actions
operating.
before operating.
Here are some important rules:
Perform all safety inspection measures in
Operation and Maintenance Manual—LG958L
Wheel Loader.
Warning
If you feel tired or influence of alcohol, drugs or
affected by other drugs, do not drive the machine.
Before starting the engine, make sure there is
adequate ventilation. The machine is equipped with
diesel engine and the emission gas is harmful to
your health. Therefore, do ensure adequate
ventilation. If ventilation is insufficient, please
avoid running the engine unless it is absolutely
necessary.
Before operation or maintenance on the machine,
please read all signs and instructions as well as the
contents in Operation and Maintenance
Manual—LG958L Wheel Loader. Each sign
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
right window.
Measures before Towing
See Operation and Maintenance Manual—LG958L
Wheel Loader.
Measures after the Towing
See Operation and Maintenance Manual—LG958L
Wheel Loader.
Introduction
If there is someone else to take over your
maintenance work, ensure the person to get more
information on the progress of work, how much has
been done, and how much needs to be done.
When you use high pressure tap to wash the
machine, do not put the nozzle directly at the
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
Maintenance Position 1
Stop the machine on a level and hard surface, and place
it on the service position 1. (See Figure 6)
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Service Manual For LG958L Wheel Loader
Maintenance Position 2
And the machine on a level hard surface, and place it on
the maintenance position 2. (See Figure 7)
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Service Manual For LG958L Wheel Loader
Figure8 Fix the boom firmly If the support is placed too forward, it will be
overwhelming when the attached tool holder is
tipping.
engine.
Leave the cab.
Disconnect the battery switch.
Start to put out the fire, and call for the fire
department when necessary.
When fill the machine with oil, or when the fuel is
exposed to air, the machine should not be near
Figure 9 When filling the fuel or contacting
with air, should not prevent smoking fireworks.
Diesel fuel is flammable and cannot be used to
clean the machine. Clean the machine with
approved cleaning agent.
Some cleaning agents may cause fire or irritate the
skin. Do avoid absorbing vapors of cleaning agent.
Cleanliness
Cleanness is one of critical factors to keep safe and
reliable operation of the system. Therefore, we
should keep maintenance area clean. Oil and water
will make floors and escalators slippery. Electrical
systems and tools stained with oil and water are
prone to danger. Greasy clothes or clothes soaked
with grease will also be a serious fire hazard.
Make daily inspection of machinery and equipment
to ensure no dust and oil, such as bottom
skateboard of loader body, which may reduce the
risk of fire, and easy to find defective parts or loose
parts.
If cleaning with high pressure water, must be extremely
careful, because the electronic components and cable
insulation may be damaged at a relatively moderate
pressure and water temperature. Please protect the
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Service Manual For LG958L Wheel Loader
cable.
When working the risk of fire hazard, such as in
sawmill, waste disposal sites, etc., do keep the site
clean. In this environment, install the appropriate
equipment in order to reduce the risk of
spontaneous combustion caused by accumulated
material (Such as silencer, radiator screen,
high-power air pre-cleaner, etc.).
Electrical systems
Check whether the cable is scratched, and ensure
that the cable will not suffer such damage. This is
particularly important for the cable without fuse
and the color is red. For example , the cables are
between the following components :
- Battery
- Battery - starter motor
- Alternator - starter motor
- Warm-up coils from cable to the engine.
If the cable without fuse is ever disconnected, do
check whether the wires are connected again, and
make sure wire connections can greatly prevent
from being scratched. The cable without fuse
cannot be close to oil or fuel hoses.
For installing any optional equipment, be sure that
all wires are connected through a fuse and make
sure the layout of wiring and fixing of wire can
avoid being scratched.
Fuel, hydraulic and brake system
Check fuel, hydraulic and brake hoses are not
scratched.
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
without loading.
Spare tire should be inflated only enough to
maintain the rim parts in position.
When the tires are inflated, use a box and a rope or
chain to fix the loose wheels. Before removing the
box, check whether the tire is correctly installed on
the rim.
After inflation, do not adjust the side ring or lock
ring.
If tire pressure installed on the machine is less than
80% of the normal pressure, and wheel rim or tire is
damaged, you should remove the tire.
Install tires and rims
Only trained technicians are allowed to handle the
tires.
Before removing the tire from the rim, you should
deflate tire firstly.
If the tire and the rim do not match with each other,
you cannot install the tire on a rim.
Do not install rims parts with different sizes
together, and do not use damaged and failed
components.
If you use the repaired wheel assembly, be very
careful. Failed or incorrect welding, heating or
fusing may damage the strength of component,
resulting in failure of the future.
Before installing the lock ring, you should confirm
the lock ring inside the rim groove with dirt and
dust.
When installing the tire on the rim, use the
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
of rear axle.
Notice
Before falling down the machine, do not forget to
remove the block.
Machine must be equipped with tooling and jacks with
sufficient support capacity (10-25 tons).
In the case that two wheels are lifted, you can more
easily rotate the hub to set the wheel nut in place.
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Service Manual For LG958L Wheel Loader
Battery charging
Risk of explosion
When charging the battery, it will form an explosive
mixture hydroxide. Short circuit, open flame or sparks
near battery can cause powerful explosion. Before
disconnecting the charging clamps, always turn off the
charging current. Keep it ventilated, especially charging
in an enclosed space battery.
Warning
Serious risk of corrosion!
Corrosive sulfuric acid
Battery electrolyte includes corrosive sulfuric acid. If
electrolyte is splashed on exposed skin, you should
immediately wash it away. Clean the affected area with
soap and plenty of water. If electrolyte gets into your
eyes, or any other sensitive parts of the body,
immediately flush it with water and immediately seek
help for doctor.
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
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Service Manual For LG958L Wheel Loader
Fluoride rubber
Warning
Serious risk of corrosion!
Warning
Heated hydrogen fluoride rubber means that the
accumulation of hydrogen fluoride even at about
320 ° C (610°F) temperature, and it may cause
severe corrosion of the respiratory tract after
breathing this gas.
Some seals are designed to withstand high temperatures
(i.e. the seals in the engine, gearbox, axle, brake,
hydraulic motors and pumps member), which is made
of fluoride rubber, and it will generate hydrogen
fluoride and hydrogen fluoride acids when heating to
high temperature.
Hydrogen fluoride acid is strongly acidic and corrosive,
and it cannot be washed from the skin. And it would
cause very serious burning and corrosion damage, and it
takes a long time to recover. As a general principle, the
injured tissue must be surgically removed.
Hydrofluoric acid will remain parts on the machine
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Service Manual For LG958L Wheel Loader
Environment
Environment Protection for the Future
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Service Manual For LG958L Wheel Loader
Waste Disposal
For the treatment of waste, comply with the following
steps.
If possible, deal with the waste with the recovery
disposal methods.
Re-use is the best from an environmental point of view.
MATERIAL RECYCLING is also a good
environmental choice of means for use of new products.
ENERGY RECOVERY is a good alternative to burn it
as combustible materials.
DESTRUCTION can be used in hazardous waste.
Destruction must be operated in a special venue.
DEPOSITION is the worst way from an environmental
point of view, and should be avoided.
Environmental Method
Always select a most suitable method for environmental
protection, as long as there is the possibility, for
example, use biological oil.
Always comply with national and local environmental
regulations.
All waste should be handed over to authorized waste
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Service Manual For LG958L Wheel Loader
disposal company.
Liquid and oil
Do not reuse the old liquid oil, such as coolant, and
collect it in sealed container and leave it to destroy
department.
Filter
Oil and fuel filter should be drained and then placed in a
sealed container and then leave it to destroy department.
Refrigerant R134a
Refrigerant R134a contains substances affecting
greenhouse effect and should not be released into the
atmosphere. Recover it according to instructions in the
manual of Air conditioning unit.
Battery
Warning
Serious risk of corrosion!
Batteries contain environmentally harmful substances
and corrosive sulfuric acid. And should be handed over
to recycling sector.
Chemicals
Chemicals, paints, adhesives, detergents, etc. , should
be left to deal with recycling sector or destroyed.
Rubber and Plastics
Rubber and plastic parts should not be burned, and
should be handed over to recycling sector.
Tires should be based on special provisions to deal with.
Electronic component
Electrical and electronic waste parts, such as circuit
boards, bulbs, should be handed over to recycling
sector.
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Service Manual For LG958L Wheel Loader
Decontamination
Clean the contamination up as soon as possible. Certain
substances will soon be scattered into the environment.
Clean-up after the leakage/spilling
Use suitable absorbent material to collect leaking oil or
fuel, such as absorbent pads.
Prevent leaked oil/fuel with the rain/flood.
Contaminated soil and materials on the ground must be
removed and collected in a suitable container.
Collect soil and absorbent material should be left to the
destruction department.
Clean-up after the accident
If possible, prevent leakage of the machine.
Use drainage barriers to isolate the leakage site.
Add the absorption material, such as sand or sawdust
water.
Prevent leakage of liquid so that leaked oil/fuel will not
discharge into sewers with the rain/floods.
Collect absorbent material and dirt floating layer in a
sealed container, and leave them to the destruction
department.
Clean up after the fire
First put out fire.
Deal with it in accordance with the post-accident
clean-up measures.
Notice
Be careful of the toxicity of certain substances after
ignited.
34
SERVICE MANUAL
Version:0020
0 GENERAL
Service Manual For LG958L Wheel Loader
CONTENTS
0 GENERAL ........................................................................................................................................... 0-1
01 Introduction....................................................................................................................... 0-1
Ⅰ
Service Manual For LG958L Wheel Loader
0 GENERAL
01 Introduction
Figure 0-1
1 Counterweight 2 Engine hood cover
3 Rear tires 4 Cab
5 Front tires 6 Bucket cylinder
7 Rocker arm 8 Quick-change frame
9 Quick-change bucket
0-1
Service Manual For LG958L Wheel Loader
Table 0-1 Overview
Items Parameters Items Parameters
Min. turning radius (external part
Bucket capacity(m3) 3.0 6039
of rear wheel)(mm)
Moving levelly radius(external
Rated operating load(kg) 5000 6775
part of bucket) (mm)
Max. dragging force
≥160 Max. breakout force(kN) ≥152
(provided by engine) (kN)
Tipping load, Bucket(kN) 100 Max. climbing angle(°) 28
Gears Ⅰ Ⅱ Ⅲ Ⅳ
Speed Forth(km/h) 0~6.8 0~12 0~24 0~36
Back(km/h) 0~7.2 0~12 0~23 ---
0-2
Service Manual For LG958L Wheel Loader
Table 0-4 Transmission
Items Parameter/contents
Type 3-element,single-stage,single-phase
Torque coefficient 2.55
Torque converter Oil cooling type Circulation water cooling
Inlet pressure of converter(MPa) 0.85
Outlet pressure of converter(MPa) 0.5
Model Countershaft and electronic-hydraulic shifting
Shifting gears Front 4 rear 3
Forward Ⅰ 4.278
Forward Ⅱ 2.368
Forward Ⅲ 1.126
Transmission
Forward Ⅳ 0.648
Transmission box ratio
Backward Ⅰ 4.278
Backward Ⅱ 2.368
Backward Ⅲ 1.126
Variable pump model Inner set in the machine
Variable pump working
1.4~1.6
pressure(MPa)
Model Spiral bevel gear
Reduction Gear
Reduction ratio 3.7
Final reduction Model Planetary gear, single reduction
Gear Reduction ratio 6.35
Model Four-wheel-drive
Tire specification 23.5-25
Drive system
Tire pressure Front wheel 0.39±0.01
(MPa) Rear wheel 0.33±0.01
Service brakes Full hydraulic actuated, wet-brakes actuate
Brake system Brake oil pressure(MPa) 5.5MPa
Parking brake Full hydraulic drum brakes
0-3
Service Manual For LG958L Wheel Loader
0-4
Service Manual For LG958L Wheel Loader
Figure 0-2
0-5
Service Manual For LG958L Wheel Loader
02 Specification
Table 0-9 Tightening torque table when the connected piece is made of cast iron or aluminum
0-6
Service Manual For LG958L Wheel Loader
Table 0-10 Tightening torque of connector
Connector with copper washer sealing or screw sealing Connector with O ring
Connector Connector Tightening torque
Tightening torque N·
m
specification specification N·m
M14、G1/4 34±5 M12×1.5 35±3.5
M18、G3/8 73±10 M14×1.5 45±4.5
M20、G1/2 93±10 M16×1.5 55±5.5
M24 142±20 M18×1.5 70±7.0
M27、G3/4 205±30 M20×1.5 80±8.0
M33、G1 421±49 M22×1.5 110±10
M42 872±98 M27×2.0 170±17
M33×2.0 310±31
M36×2.0 310±31
0-7
Service Manual For LG958L Wheel Loader
Conversion of units table
Table 0-13 Length
Unit cm m km inch foot code mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
inch 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
foot 30.48 0.3048 0.000304 12 1 0.3333 0.000189
code 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1mm=01cm 1um=0001mm
0-8
Service Manual For LG958L Wheel Loader
Table 0-17 Pressure
unit KIPS /cm2 bar Pa=N/m2 kPa Lbf /inch2 Lbf /foot2
KIPS /cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 0.001 0.00015 0.02086
2
Pa=N/m 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
2
Lbf /inch 0.07032 0.0689 6894.76 6.89476 1 144
2
Lbf /foot 0.00047 0.00047 47.88028 0.04788 0.00694 1
2
kg/cm =735.56net weight(mm Hg)=096784 atmospheric pressure
0-9
Service Manual For LG958L Wheel Loader
03 Tools
Pliers 1
Diagonal wrench 1
Crowbar 1
0-10
Service Manual For LG958L Wheel Loader
04 Marks
In order to emphasize the significance of safety and quality visually, we design the following
signs as marks.
Table 0-20
Sign Item Note
Tightening
Pay more attention to the tightening torque of assembly parts.
torque
Be careful for the parts where water and oil need to be drained
Draining
and drainage, and judge their volumn.
0-11
Service Manual For LG958L Wheel Loader
1. Never further use the parts which are seriously dump, having fracture and crack, or losing
function.
2. Never further use the oil seals, dust ring, O-ring and seal gasket disassembled owing to
leakage and because of low reliability and short service life in repeated use.
3. Never further use the bolts, nuts, washers, plug screws, pipe joints if they have serious
corrosion, the screw doesn’t work well in tightening operation, or the screw is damaged, worn
out or slipping.
4. Never further use locking steel wire in the connection of bolt after disassembled.
5. Never further use the bearings if they could not be turned smoothly by hand, crack exists on
their components or the ball race is seriously worn.
6. Never further use the gears and the teeth of spline with crack, sheet exfoliation, collision or
over wearing.
7. Never further use the shell with crack, bearing holes with crack, wear, elliptic or sheet
exfoliation, and screw damaged which doesn’t work well in tightening operation.
8. Never further use bearing chock, oil seal pedestal with crack, wear, elliptic, collision or sheet
exfoliation on the mating surface and spigot.
9. Never further use the pins with serious wear, collision or crack.
10 Judge the oil by visual and touching primarily, it should be replaced if hydraulic oil appears
the following situation in the process of use and inspection: present milk white in color,
accompany with acid stink, turn yellow or appear turbidity.
0-12
Service Manual For LG958L Wheel Loader
052 Measure
If it is hard to identify by ocular estimates or hand touching, check it by measurement.
Table 0- 21
Judgment Standard
Oversize
Parts Items Check Items Dimension
Allowable Limit Measures
(Tolerance)
Fitting clearance
Multiple
between valve core >0.02 Replace
valve
Fitting g clearance
Fitting g clearance
Monostable
between valve core >0.02 Replace
valve
and valve hole
Fitting clearance
0-13
Service Manual of RS8160 Road Roller
SERVICE MANUAL
Version:0120
CONTENTS
1 Repair & Maintenance ......................................................................................... 1-1
11 Lubricant, Fuel and Other Liquids ...................................................................... 1-1
111 Lubricant ...................................................................................................... 1-1
112 Fuel .............................................................................................................. 1-1
113 Coolant......................................................................................................... 1-2
114 Selection of Oil ............................................................................................ 1-4
12 Repair................................................................................................................... 1-5
121 Notes before Repair ..................................................................................... 1-5
122 Periodic Maintenance .................................................................................. 1-8
123 Maintenance and Repair ............................................................................ 1-13
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Service Manual for LG958L Wheel Loader
1 Repair &
Maintenance
111 Lubricant
112 Fuel
1-1
Service Manual for LG958L Wheel Loader
113 Coolant
1-3
Service Manual for LG958L Wheel Loader
1-4
Service Manual for LG958L Wheel Loader
12 Repair
1-6
Service Manual for LG958L Wheel Loader
1-7
Service Manual for LG958L Wheel Loader
Fig. 1-1
Every 10 Hours (Daily) Maintenance
1. Check the sealing performance of working
device, steering system and brake system.
2. Check the flexibility and reliability of the
brakes.
3. Check whether the electric circuits are correct
and the electric components are normal.
4. Check the oil level in the fuel tank and the
coolant level in the water tank.
5. Add grease to the engine fan shaft, hinge joints
1-8
Service Manual for LG958L Wheel Loader
1-9
Service Manual for LG958L Wheel Loader
hydraulic tank.
Check if there is leakage in the brake
system.
Every 100 Hours Maintenance
1. Carry out the periodic maintenance of every 10
and 50 hours with this maintenance operation
at the same time.
2. Clean the radiator components.
3. Clean fuel tank filling filter.
4. In addition, do the extra maintenance in the
first 100 hours as follows:
Check and clean the air vent of
transmission box.
Clean transmission oil sump and the oil
absorption filter element therein.
Check and clean filter elements in speed
changer-torque converter assembly oil
line.
Replace transmission oil.
Replace the gear oil in the front and rear
axles.
Every 250 Hours (Monthly) Maintenance
1. Carry out the periodic maintenance of every 10,
50 and 100 hours with this maintenance
operation at the same time.
2. Check the storage battery. Clean surface and
terminals of the battery then coat Vaseline on
them.
3. Check whether connecting bolts of frames and
working devices are loose.
4. Check whether welding seams are cracked.
5. Check whether the connections between front
and rear axles, engine, transmission box and
1-10
Service Manual for LG958L Wheel Loader
1-11
Service Manual for LG958L Wheel Loader
1-12
Service Manual for LG958L Wheel Loader
Brake check
Observe whether its appearance is normal, such as
oil leakage.
Draining of drive axle oil
If you cannot determine whether the fuel is cooled
or not, please wear protective cloth in case of
burning.
Make sure the drain plug is at lowest position,
1
you can rotate the wheel if necessary. (See Fig.
Fig. 1-2
1 Wheel side oil drain plug (keep it at 1-2)
the lowest place while draining)
1-13
Service Manual for LG958L Wheel Loader
1
Fig. 1-3
1 Oil drain plug on axle housing
1
Fig. 1-5
1 Oil drain plug
1-14
Service Manual for LG958L Wheel Loader
1
Fig. 1-6
1 Oil drain plug
1
Fig. 1-7
1 Fine fuel filter
1
Fig. 1-8
1 Engine oil filter
1-15
Service Manual for LG958L Wheel Loader
1
Fig. 1-10
1 Transmission oil filter
1-16
Service Manual for LG958L Wheel Loader
1
Fig. 1-11
1 Oil absorption filter screen location
1
Fig. 1-12
1 Belt
1
Fig. 1-13
1 Engine oil filling port
1-17
Service Manual for LG958L Wheel Loader
1
Fig. 1-15
1 Filling port of transmission oil
1-18
Service Manual for LG958L Wheel Loader
1
Fig. 1-18
1 Feeler lever
1-19
Service Manual for LG958L Wheel Loader
1
Fig. 1-19
1 Hydraulic oil level pointer
1
Fig. 1-20
1 Engine oil dipstick
Checking of battery, cable and connector
Touching the liquid of battery will cause severe
chemical burning.
Wear protective gloves, goggle and clothes when
maintaining the battery.
Open the battery covers. Open one each time.
Check and clean the connectors of cable and
1 terminals and bolts of battery, and coat the
Fig. 1-21
1 Storage battery external surface with grease as anticorrosion,
such as Vaseline. (See Fig. 1-21)
Check the liquid level, and green color means
normal.
1-20
Service Manual for LG958L Wheel Loader
Cleaning of radiator
Open the engine hood and rear window lattice.
Clean the fins of radiator with compressed air
along the traveling direction of the machine.
(See Fig. 1-22)
Install the grille shield.
If not being dealt properly, the fins of radiator may
be damaged.
1
Fig. 1-22
1 Radiator
1-21
Service Manual For LG958L Wheel Loader
Version:0220
Service Manual For LG958L Wheel Loader
CONTENTS
21 Overview ..........................................................................................................................2—1
211 Functions of the Engine .............................................................................................2—1
212 Basic structure of the Engine ....................................................................................2—3
213 Overall Engine Performance Parameters ..................................................................2—6
22 Lubrication System .....................................................................................................2—7
221 Lubrication System Description ................................................................................2—7
23 Fuel System..................................................................................................................2—9
231 Overview ...................................................................................................................2—9
24 Intake and Exhaust System......................................................................................2—14
241 Intake and Exhaust System Description ..................................................................2—14
25 Cooling System ..........................................................................................................2—16
251 Cooling System Description....................................................................................2—16
252 Expansion Tank .......................................................................................................2—17
26 Engine Control ..........................................................................................................2—18
261 Reverse Control, Foot Operation ............................................................................2—18
27 Disassembly and Assembly of Engine ..........................................................................2—19
271 Disassembly of Engine ............................................................................................2—19
272 Assembly of Engine ................................................................................................2—29
273 Disassembly and Assembly of Fuel Tank................................................................2—39
274 Disassembly and Assembly of Water Tank and Oil Radiator ..................................2—44
28 Diagnosis and Solutions for Frequently Asked Questions of Engine System ..........2—52
281 Engine Fails to Start ................................................................................................2—52
282 Engine Power is not Sufficient ................................................................................2—53
283 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke) ...........................2—53
284 Engine Oil Pressure is too High or Too Low ..........................................................2—55
285 Large Consumption of Engine Oil ..........................................................................2—56
Ⅰ
Service Manual For LG958L Wheel Loader
Ⅰ
Service Manual For LG958L Wheel Loader
2 ENGINE SYSTEM
21 Overview
EMS2.
Engine identification
2—1
Service Manual For LG958L Wheel Loader
anti-clockwise.
liner
Crankshaft-flywheel group
6 rigid ring
inertia. It is fixed on the crankshaft rear end
2—4
Service Manual For LG958L Wheel Loader
Valve mechanism
as main component.
8 valve
2—5
Service Manual For LG958L Wheel Loader
Minimum specific
(g/kw.h)
Maximum torque
Rated speed (r/min) 2100 1050
(N.m)
2—6
Service Manual For LG958L Wheel Loader
22 Lubrication System
2—7
Service Manual For LG958L Wheel Loader
4.4 pressure controlled by-pass valve (filter) 18 air compressor outlet oil line
9 camshaft bearing
working temperature.
2—8
Service Manual For LG958L Wheel Loader
23 Fuel System
231 Overview
rail system.
controlled.
2—9
Service Manual For LG958L Wheel Loader
valve (FCV).
filter.
2—10
Service Manual For LG958L Wheel Loader
quantity.
Figure 11 High pressure pumps
2 through high-pressure oil pipe to injectors There are two high-pressure pumps in
3 I/O valve (integrated) fuel system, and they are driven by
4 flow control valve
camshaft through a roller tappet. Its
times).
2—11
Service Manual For LG958L Wheel Loader
Fuel rail
3 “fuel rail” pressure sensor E-ECU will force PRV to open by pressurizing
2—12
Service Manual For LG958L Wheel Loader
overpressure damage.
operating conditions.
Injector
3 armature
injected into the cylinder is
2—13
Service Manual For LG958L Wheel Loader
Intake system
sensor and boost pressure sensor preheating sign on info panel will be lighted.
2—14
Service Manual For LG958L Wheel Loader
Exhaust system
Turbocharger
Figure 16 The exhaust system (schematic diagram)
pressure).
2—15
Service Manual For LG958L Wheel Loader
25 Cooling System
2—16
Service Manual For LG958L Wheel Loader
in the radiator.
Figure 19 Radiator assembly
2 water pipe components parts and cab fan heater through external
4 transmission pipeline components oil is cooled in the radiator and then flows
5 radiator accessories back.
6 jackstay
252 Expansion Tank
and “MAX”.
2—17
Service Manual For LG958L Wheel Loader
26 Engine Control
2—18
Service Manual For LG958L Wheel Loader
These following steps could be referred to disassemble the engine from the machine when the
2—19
Service Manual For LG958L Wheel Loader
1 blocks.
Figure 1-1
1 block ★ Do the operation after the loader cools
1
Figure 1-2
1 water drain valve
3 Open the oil drain plug of engine sump and
vessel.
Engine oil
1 2
Figure 1-3
1 spare oil drain plug 2 oil drain plug
2—20
Service Manual For LG958L Wheel Loader
Engine Hood.
Engine hood
1
Figure 1-4
1 engine hood
1
Figure 1-5
1 hydraulic oil tank
1
Figure 1-6
1 engine wiring harness
2—21
Service Manual For LG958L Wheel Loader
1
Figure 1-7
1 starting motor wiring harness
1
Figure 1-8
1 air compressor wiring harness
1
Figure 1-9
1 air preheater wiring harness
2—22
Service Manual For LG958L Wheel Loader
5) Disconnect the ED
1
Figure 1-10
1 ED connector
1
Figure 1-11
1 wiring harness armor tape
7 Cut off the connection between air conditioning
releasing
1 2
Figure 1-12
1 pressure cooling pipe 2 autoclaved pipe
2—23
Service Manual For LG958L Wheel Loader
1
Figure 1-13
1 oil inlet pipeline
1
Figure 1-14
1 water valve of heater
10 Disconnect the connection between hot-air
1 2
Figure 1-15
1 hot-air water inlet pipe
2 hot-air water inlet valve
2—24
Service Manual For LG958L Wheel Loader
1 2
Figure 1-16
1 turbocharger 2 intake hose
1
Figure 1-17
1 hose
pipes.
1 2
Figure 1-18
1 water outlet pipe 2 water inlet pipe
2—25
Service Manual For LG958L Wheel Loader
1 2 3
Figure 1-19
1 fixing nut 2 gasket 3 fixing bolt
supporting seat
1
Figure 1-20
1 fixing bolt
1
Figure 1-21
1 engine
2—26
Service Manual For LG958L Wheel Loader
1 2
Figure 1-22
1 connecting bolt between the silencer and
exhaust pipe
2 connecting bolt between the silencer and
its support
1
Figure 1-23
1 air filter
1
Figure 1-24
1 fan heater water valve
2—27
Service Manual For LG958L Wheel Loader
1
Figure 1-25
1 compressor
2—28
Service Manual For LG958L Wheel Loader
2—29
Service Manual For LG958L Wheel Loader
1
1) Smear a layer of sealant on the end face of
Figure 1-27 engine. Remove the top cover plate of the speed
1 engine
changer-torque converter assembly. Connect the
1 middle plate.
Figure 1-28
torque converter
2—30
Service Manual For LG958L Wheel Loader
1
Figure 1-29
1 cover plate
120~200Nm
1
Figure 1-30
1 fixing bolt
1
Figure 1-31
1 starting motor wiring harness
2—31
Service Manual For LG958L Wheel Loader
1
Figure 1-32
1 generator wiring harness
harness
1
Figure 1-33
1 air condition compressor wiring harness
1
Figure 1-34
1 air preheater and wiring harness
2—32
Service Manual For LG958L Wheel Loader
5) Connection of ED connector
1
Figure 1-35
1 ED connector
1
Figure 1-36
1 oil inlet pipe
valve.
1
Figure 1-37
1 fan heater water valve
2—33
Service Manual For LG958L Wheel Loader
1 2
Figure 1-38
1 pressure cooling pipe 2 autoclaved pipe
1
Figure 1-39
1 hot-air water inlet pipe
1
Figure 1-40
1 hose
2—34
Service Manual For LG958L Wheel Loader
1
Figure 1-41
1 intake hose
1 2
Figure 1-42
1 water outlet pipe 2 water inlet pipe
1
Figure 1-43
1 hydraulic oil tank
2—35
Service Manual For LG958L Wheel Loader
Engine Hood.
Engine hood
“MAX” stably.
2—36
Service Manual For LG958L Wheel Loader
2 Coat the sealant along the outside screw for one circle. The width of it is about 3~5
circles screw. Be sure the groove is full of sealant and the beginning circle could not be
coated. Coat it just before you want to assemble it. After the assembling, there should be a
whole circle of sealant between the bolt and threaded hole edge.
3 The coated part should be tightened with hand wrench rather than pneumatic impact
wrench.
1)Assemble the fan heater water valve
Coat the valve with Neotec AT545 sealant them
assemble it to the engine.
AT545 sealant
10-12mm.
1
Figure 1-48
2 The hexagon head end of the bolt should
1 compressor
toward outside.
2—37
Service Manual For LG958L Wheel Loader
air pipe to the air filter with T shape hoop; fix the
1
Figure 1-49
1 air filter
1
Figure 1-50
1 silencer
2—38
Service Manual For LG958L Wheel Loader
and drain the oil. Contain the oil with clean vessel
1
Figure 2-3
1 oil level sensor
2—39
Service Manual For LG958L Wheel Loader
1
Figure 2-4
1 oil outlet pipe
1
Figure 2-5
1 oil return pipe
1
Figure 2-6
1 fixing bolt
2—40
Service Manual For LG958L Wheel Loader
1
Figure 2-7
1 fuel tank
1
Figure 2-8
1 rubber pipe connecting port
1
Figure 2-9
1 fuel tank
2—41
Service Manual For LG958L Wheel Loader
Fix the fuel tank on the rear frame with bolts and
gaskets.
1
Figure 2-10
1 fixing bolt
1
Figure 2-11
1 oil outlet pipe
1
Figure 2-12
1 oil return pipe
2—42
Service Manual For LG958L Wheel Loader
of rear frame.
1
Figure 2-13
1 oil level sensor
6 Add fuel.
110L
1
Figure 2-14
1 fuel filling pipe
2—43
Service Manual For LG958L Wheel Loader
cooled.
clean vessel.
Coolant
1
Figure 3-1
1 water draining valve
2 Disassemble the engine rear hood.
1
Figure 3-2
1 engine rear hood
2—44
Service Manual For LG958L Wheel Loader
clean vessel.
1
Figure 3-3
1 transmission oil pipe
1
Figure 3-4
1 oil inlet pipe connection port
Hydraulic oil
2—45
Service Manual For LG958L Wheel Loader
expansion box.
1 2 3
Figure 3-6
1 intercooler hose
2 radiator hose
3 expansion box hose
1 2
Figure 3-7
1 intercooler air inlet hose
2 radiator water return hose
2—46
Service Manual For LG958L Wheel Loader
1 2
Figure 3-8
1 intercooler temperature sensor
2 water temperature sensor
9 Disconnect the cable ties and pull off the plug.
1
Figure 3-9
1 cable ties
1 2
Figure 3-10
1 oil inlet pipe of hydraulic motor
2 oil outlet pipe of hydraulic motor
2—47
Service Manual For LG958L Wheel Loader
1
Figure 3-11
1 fixing bolts
1
Figure 3-12
1 radiator
120±10Nm
1
Figure 3-13
1 fixing bolts
2—48
Service Manual For LG958L Wheel Loader
1 2
Figure 3-14
1 oil inlet pipe of hydraulic motor
2 oil outlet pipe of hydraulic motor
3 Connect the bottom hoses of radiator,
intercooler.
1 2
Figure 3-15
1 intercooler air inlet hose
2 radiator water return hose
4 Connect the hoses of radiator, intercooler and
expansion box.
1 2 3
Figure 3-16
1 intercooler hose
2 radiator hose 3 expansion box hose
2—49
Service Manual For LG958L Wheel Loader
1
Figure 3-17
1 cable ties
1 2
Figure 3-18
1 intercooler temperature sensor
2 water temperature sensor
oil radiator
1 2
Figure 3-19
1 oil inlet pipe 2 oil outlet pipe
2—50
Service Manual For LG958L Wheel Loader
1
Figure 3-20
1 transmission oil pipe
1
Figure 3-21
1 engine rear hood
Coolant
1
Figure 1-45
1 adding port of expansion box
2—51
Service Manual For LG958L Wheel Loader
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
2 Blocking of oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
3 The diesel filter element is particularly dirty.
Adjustment factors
2—52
Service Manual For LG958L Wheel Loader
1 Blockage of fuel filter or fuel pump oil inlet pipe connector filter screen.
Solution: Drain redundant engine oil, and make sure the oil level is within specified range.
2 Diesel flows into oil pan due to oil-fuel injector needle-valve untightly closed or stucked in
open position.
Solution: Clean and adjust the injector or replace the needle valve matching parts.
2—53
Service Manual For LG958L Wheel Loader
3 Damaged fuel pump plunger bushing sealing ring (P pump), or bad sealing between plunger
bushing and pump body, the fuel flows into oil pan along engine oil passage.
Solution: Replace all faulted valves, pipes and oil seal (the oil seal must be replaced once being
disassembled; if the clearance meets the requirements after the valve is replaced, you can spare
the tube).
5 Damaged sealing ring of turbocharger, engine oil burns after enters into the combustion
chamber along air inlet passage.
Solution: Clean the fuel tank and filter, and use qualified diesel oil.
2 Abrasion of cylinder valve.
2—54
Service Manual For LG958L Wheel Loader
Solution: Choose specified brand engine oil, and take preheating action when starting the
machine in winter.
3 Too little gap in force-feed lubricating positions or blocked engine oil filter.
Solution: Readjust the spring force of the valve, so the engine oil pressure can drop to specified
value.
Solution: Check oil capacity, add engine oil and clean the suction filter.
3 Large engine oil leakage.
Solution: Check whether the lubricating pipe is broken; check and adjust the fitting clearance of
2—55
Service Manual For LG958L Wheel Loader
Solution: Check and replace engine oil pressure sensor and pressure gauge.
Solution: Examine the reason for high negative pressure and fix it.
3 Change of rotating speed and operating mode.
Solution: Test showed that with the increase of rotating speed, engine oil consumption rises
Solution: Put the radiating fins back to their original positions with stalloy carefully, after they
return to flat shape, clean them with compressed air or water gun.
3 Wrong indication of water thermometer or warning light.
Solution: Use the water thermometer to measure the temperature of water temperature sensor
area, see whether the measured temperature is consistent with actual value.
4 Low rotating speed of fan, the blades are deformed or installed backwards.
Solution: loosened rubber belt will lead to slipping, which result in low rotating speed of fan.
Adjust the belt if necessary; if the rubber layer aged, damaged or fractured, replace it. If the
2—56
Service Manual For LG958L Wheel Loader
6 Malfunction of thermostat.
2—57
Version:0320
Ⅰ
CONTENTS
3 ELECTRICAL SYSTEM
Battery
1. For checking and repairing the faults in electrical system, please use fully-charged battery
or full-featured battery.
2. Ensure the poles of the battery are connected right when installing the battery.
3. To replace the battery, ensure the capacity is consistent with the used one. These batteries
should be with equal working life, because the charging current will vary with the
increasing of use life.
AC-generator
1. Before any test about AC-generator or regulator, you must check whether the battery and
wires are insulated well, without loosening and corrosion. Check AC-generator belt.
2. Do not disconnect the cable of generator when it is running. Otherwise this may damage the
generator and regulator.
3. You should use secure connections, to prevent sparks and transient change of voltage. If the
cable is disconnected, it will cause damage to the alternator and regulator.
4. If the socket of generator is connected to the chassis, the generator and the regulator will be
damaged.
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Service Manual For LG958L Wheel Loader
Electrical components
Attention! Electronic equipment is sensitive to electromagnetic or susceptible to or
damaged by static electricity from the human body or the tools. Therefore, when carrying out
the operation about the electronic components, you must comply with the following
instructions:
1. When an electronic component is powered, connection leading to the unit must not be cut
off. If disconnected, it may damage the electronic components.
2. Before the maintenance of the electrical system, the tool should be in contact with a metal
mechanical part on the frame to discharge the static electricity on the tools.
3. Do not touch the plug on electronic components.
4. When maintaining electrical systems, avoid touching the circuit board. If you have to touch
it, you only grasp the edge of the circuit board.
5. Do not touch a single electronic component.
6. When replacing units, make sure the ground wire is securely connected.
Welding
1. Disconnect the terminals of battery to prevent explosion of battery.
2. After the repair is completed, be sure to install the wire connectors of the computer control
panel, otherwise the machine will not start and move.
3. For welding, sparks may fall directly on rubber hoses, wires or pressure pipe, and these pipes
may suddenly rupture, wire insulation may be damaged, so these pipes should be covered.
Electrical system includes battery, starter motor, AD generator, bucket automatic leveling
control system, gauges, switches, lighting, air conditioning circuits and other electrical
equipment.
Machine system voltage is DC 24V, containing two batteries 12V in series, located in the left
side of the rear frame. Negative pole is grounded, and the line applies single system. As to the
relationship and working principle between electrical equipment, please carefully read the
electrical system circuit diagram.
Battery power switch is located on the left side. When the switch turns to " " position, the
3-2
Service Manual For LG958L Wheel Loader
vehicle power is off; when the switch turns to " " position, the vehicle power is turned on. For
parking vehicles for a long term, turn off the power switch. Relays and fuses are mainly located
in the distribution box behind operator's seat, after the cover of distribution box is removed, you
can see the relays in distribution boxes can be interchanged.
Connectors of components were all marked with CN + digital + letter format, which is different
from other connections. A is representative of the plug, and B represents the slot. For example,
I-ECU has two connection units, CN6 and CN7, CN6-A represents plug, and CN6-B represents
the corresponding slot.
The current of AD generator alternator is 80A and its normal charging voltage is 28.3V, and it
contains a built-in charger.
When the engine is turned off, the battery usually provides a voltage of about 24V, depending
on the charging status. When the engine is running, the battery is usually charged by AD
generator, because the charging voltage of AD generator is higher than the normal battery
voltage.
If the battery is not charging, the charging voltage of the alternator may be not correct.
The power switch is used to disconnect the connection between electrical system and battery
voltage on the condition that the machine is not used.
Power switch is located inside the battery box; battery cut-off switch is connected with the
battery negative pole (24V).
3-3
Service Manual For LG958L Wheel Loader
Fig. 3-2 power switch diagnosis system that facilitates fault detection. If
1. Gauge control unit I-ECU
there is an electrical fault, the operator will get the
2. Engine control unit E-ECU
fault code on gauge panel.
Gauge control unit I-ECUis located on gauge panel, including the warning lights and the
control lights. This unit receives information from the other control units via the data bus.
Transmission control unit is located beside distribution box behind the operator seat, and is
used to control the transmission range switching while sends part of the signal to the I-ECU for
display.
Engine control unit E-ECU is located on front left of
the engine, including software used for controlling the
functions of engine. The engine control unit receives
data from engine own sensors and information from
data bus. The control unit also sends information to
other control units through data bus.
1
Fig. 3-3 power switch
1. Engine control unit E-ECU
3-4
Service Manual For LG958L Wheel Loader
warning lights.
2. Engine speed, fuel level, torque converter oil temperature, engine temperature are shown in
the measure table one gauge panel.
3. Display the working time, and display the fault code.
3-5
Service Manual For LG958L Wheel Loader
3-6
Service Manual For LG958L Wheel Loader
316 Battery
Battery electrolyte contains sulfuric acid, and battery can produce hydrogen and oxygen when
charging. Therefore, the wrong handling of the battery may result in serious injury or fire.
Therefore, comply with the following precautions:
1. The battery contains sulfuric acid liquid with a strong corrosive, please keep it away from
children. The user should wear protective glasses and rubber gloves when operating the
battery. Once sulfuric acid splashes on the eyes, skin or clothes, rinse immediately with
plenty of water, go to hospital for treatment if necessary.
2. Turn the engine off before doing any operation that related to the battery.
3. Connect the positive terminal of the battery and positive terminal of the engine, and then
connect the negative terminal of the battery and negative of the engine. When removing the
battery, first disconnect the negative pole (ground side). If the battery electrolyte is close to
the “low level”, fill distilled water, but be sure not exceed “high level”.
4. The battery may not be reversed and laid down, and shall not be subjected to any
mechanical shock and stress.
5. The battery will produce hydrogen and oxygen when charging. In case of fire or vent
blockage, it may cause an explosion, so the battery should stay away from open flames ,
and avoid the short circuit caused by touching metal objects ( such as tools ).
6. When cleaning the top surface of the battery, use cloth to wipe it. Do not use gasoline,
solvents and any other organic solvents or detergents. Battery case is flammable and should
stay away from open flame.
7. The battery should be stored at 5 ~ 25 ℃ in a dry, clean and well-ventilated environment,
and it should be free from direct sunlight. The battery should be at least more than 2m
away from the heat source. Too high ambient temperature will cause a great impact on the
performance of the battery. It can be stored at room temperature for six months, and it can
be used within six months without charging. The battery can still be used with charging
after being stored for more than six months. Installed battery should be removed from the
vehicle when it is not in use for the long-term (generally more than 15 days) and it should
be stored in dry and ventilated place. Charge the battery every 3 to 6 months (depending on
whether the indicator is black).
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Service Manual For LG958L Wheel Loader
8. When replacing the battery, be sure to use the rubber pads to protect the battery and fix it
firmly with a fixed plate and, and install shield guards on it.
3-8
Service Manual For LG958L Wheel Loader
3-8
Service Manual For LG958L Wheel Loader
Engine tachometer
This gauge shows the rotation speed of the engine.
3-9
Service Manual For LG958L Wheel Loader
Low brake air pressure alarm lamp: This lamp will be on if the
brake air pressure lower than 0.4MPa.
Fuel coarse filtering indicator lamp: If the lamp is on, it means that
the fuel coarse filter blocked and it should be cleaned or replaced.
Low fuel level indicator lamp: If fuel level is too low, the lamp will
be on and buzzer will ring.
Air filter blocking alarm lamp: When the engine is running, this
lamp is on and it means that the air filter is blocked. Clean or replace
it.
3-10
Service Manual For LG958L Wheel Loader
When the LED is just powered, it will not display anything and for
working condition is as follows:
Mode Note
Normal LED displays in two rows and the too row shows shifts
and the bottom row shows working hours.
Funnel-shaped timing figure flashes every 2.5S, hours
is not stored and only read the ECU data via CAN.
Fault LED displays in two rows, the first row is fault code
and the second row shows warning and hour timing
(WARNING)
Fault diagnosis information should meet the demands
of J1939.
3-11
Service Manual For LG958L Wheel Loader
32 Diagrams
321 Connectors
85
87
86
87a 30
A10 A1 B11 B1
3-12
Service Manual For LG958L Wheel Loader
Name Type
Radio connector
3-13
Service Manual For LG958L Wheel Loader
Name Type
Connector between rear frame
harness and stopping brake harness
CN80-A
E-ECU
3-14
Service Manual For LG958L Wheel Loader
322 Circuit
WD1 ECU
Fig. 3-10
3-15
Service Manual For LG958L Wheel Loader
Component positions
I-ECU
HMIM
M
Fig. 3-11
3-16
Service Manual For LG958L Wheel Loader
WD2 Preheating
Preheating relay
Preheat relay
Fig. 3-12
Component positions
Pre-heater
Battery Power switch
E-ECU
Preheating relay
Fig. 3-13
3-17
Service Manual For LG958L Wheel Loader
Accelerator pedal
Fig. 3-14
Component positions
Fig. 3-15
3-18
Service Manual For LG958L Wheel Loader
Parking brake
indicator switch
Left
Lefttail
taillamp
lamp Right
Righttail
taillamp
lamp
Transmission
Gear shiftcontrol
unit control unit
Fig. 3-16
3-19
Service Manual For LG958L Wheel Loader
Component positions
Fig. 3-17
3-20
Service Manual For LG958L Wheel Loader
Fig. 3-18
3-21
Service Manual For LG958L Wheel Loader
Component positions
Fig. 3-19
3-22
Service Manual For LG958L Wheel Loader
WD6 Fuel level sensor, Converter oil temperature sensor, gearbox transmission oil
pressure sensor
Fuel Oil
gauge temperature
gauge
Fig. 3-20
3-23
Service Manual For LG958L Wheel Loader
Component positions
I-ECU
Fig. 3-21
3-24
Service Manual For LG958L Wheel Loader
Hydraulic motor
rotation switch
Independent
radiator
controller
Rotation direction
solenoid valve
Fig. 3-22
3-25
Service Manual For LG958L Wheel Loader
Component positions
Fig. 3-23
3-26
Service Manual For LG958L Wheel Loader
Bucket valve
Boom valve
Floating valve
Fig. 3-24
3-27
Service Manual For LG958L Wheel Loader
Component positions
Bucket relay
Boom relay
Fig. 3-25
3-28
Service Manual For LG958L Wheel Loader
Quick-change switch
Buzzer
Quick-change
solenoid valve
Quick-change
solenoid valve
Buzzer
Fig. 3-26
3-29
Service Manual For LG958L Wheel Loader
Component positions
Fig. 3-27
3-30
Service Manual For LG958L Wheel Loader
WD10 wiper
Spraying switch
Spraying motor
Fig.3-28
3-31
Service Manual For LG958L Wheel Loader
Component positions
front wiper Water spraying
rocker switch switch
Spraying motor
Front wiper
Fig. 3-29
3-32
Service Manual For LG958L Wheel Loader
WD11 radio
Left horn
Right horn
Radio
Fig. 3-30
3-33
Service Manual For LG958L Wheel Loader
Component positions
Radio Horn
Fig.3-31
3-34
Service Manual For LG958L Wheel Loader
switch switch
Relay
Fig.3-32
3-35
Service Manual For LG958L Wheel Loader
Component positions
Rear light
Rear working lamp rocker switch
I-ECU
Fig.3-33
3-36
Service Manual For LG958L Wheel Loader
Indoor lamp
Fig. 3-34
3-37
Service Manual For LG958L Wheel Loader
Component positions
Indoor lamp
Fig. 3-35
3-38
Service Manual For LG958L Wheel Loader
Combination switch
Relay
A B C
Fig. 3-36
A:Backing relay
B: Headlight short beam relay
C: Headlight long beam relay
3-39
Service Manual For LG958L Wheel Loader
Component positions
Back relay
Combination switch
Headlight Headlight
Front combination lamp
long beam short beam
relay relay
继电器
Fig. 3-37
3-40
Service Manual For LG958L Wheel Loader
Fig. 3-38
Component positions
Fig. 3-39
3-41
Service Manual For LG958L Wheel Loader
Cigarette lighter
Fig. 3-40
Component positions
Figure 3-43
Cigarette lighter
DC-DC
CONVERTER
Fig. 3-41
3-42
Service Manual For LG958L Wheel Loader
Fig. 3-42
3-43
Service Manual For LG958L Wheel Loader
Component positions
Fig. 3-43
3-44
Service Manual For LG958L Wheel Loader
Start auto
protection
Transmission
control unit
AD
Start switch
generator
Start motor
Battery
Fig. 3-44
3-45
Service Manual For LG958L Wheel Loader
Component positions
HMIM Battery
Fig. 3-45
3-46
Service Manual For LG958L Wheel Loader
Component positions
AD generator
Start motor assembly
3-47
Service Manual For LG958L Wheel Loader
WD18 Horn
Horn
Horn switch
Horn assembly
Fig. 3-47
3-48
Service Manual For LG958L Wheel Loader
Component positions
Horn relay
Horn switch
Horn
Fig. 3-48
3-49
Service Manual For LG958L Wheel Loader
33 Troubleshooting
3-51
Service Manual For LG958L Wheel Loader
34 Repair Instructions
Fig. 3-49
Fig. 3-50
3. Replace with new I-ECU. Plug the connector
correctly and ensure good contact.
Fig. 3-51
3-52
Service Manual For LG958L Wheel Loader
Fig. 3-52
342 Replace E-ECU
Fig. 3-53
3. Remove four fixing bolts.
Fig. 3-54
3-53
Service Manual For LG958L Wheel Loader
Fig. 3-56
3-54
Service Manual For LG958L Wheel Loader
Fig. 3-57
Fig. 3-58
Fig. 3-59
3-55
Service Manual For LG958L Wheel Loader
Fig. 3-61
Fig. 3-62
3-56
Service Manual For LG958L Wheel Loader
Fig. 3-63
Assembly of battery
Fig. 3-64
1. Put the battery on required place and Assemble
clamps.
Fig. 3-65
3-57
Service Manual For LG958L Wheel Loader
Fig. 3-66
Fig. 3-67
3-58
Service Manual of RS8160 Road Roller
SERVICE MANUAL
Version:0420
4 Transmission System
Service Manual for LG958L Wheel Loader
CONTENTS
4 Transmission System ........................................................................................... 4-1
41 Transmission Box System ................................................................................... 4-1
411 General......................................................................................................... 4-1
412 Composition and Structure of Transmission ............................................... 4-2
413 Disassembly and Assembly of Transmission System ................................. 4-6
414 Troubleshooting of Transmission box System .......................................... 4-18
42 Transmission Shaft System ............................................................................... 4-22
421 Overview of Transmission Shaft ............................................................... 4-22
422 Disassembly and assembly of Transmission Shafts .................................. 4-23
43 Drive Axle System............................................................................................. 4-28
431 Overview of Drive Axle .......................................................................... 4-28
432 Maintenance of Drive Axle ..................................................................... 4-28
433 Disassembly and Assembly of Drive Axle................................................ 4-29
44 Pressure Measuring Methods and Standards of Transmission System ............. 4-37
45 Diagnosis and Solutions for Common Faults of Transmission System ............ 4-39
451 Fault Diagnosis and Solutions for Transmission box ............................... 4-39
452 Fault Diagnosis and Solutions for Drive Axle .......................................... 4-40
I
Service Manual for LG958L Wheel Loader
4 Transmission System
LG958L transmission system is composed of transmission box, transmission shaft, front and rear
drive axles and wheels. The principle diagram of transmission system is shown in Fig. 4-1.
Rear axle
Tire
411 General
4WG200 (4 forward gears, maximum transmission power 200kw) power shift transmission box is
composed of hydraulic torque converter and rear fixed axis type transmission box with a multi-disc
friction clutch. The transmission box the loader used is forward-4-reverse-3 type. Since full
four-wheel drive is adopted and large center distance between input and output shaft is provided,
4WG200 transmission box has been widely used in domestic manufacturing industries, such as wheel
loaders, bulldozers, graders, scrapers, etc.
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Service Manual for LG958L Wheel Loader
Table 4-1
Items Parameter/contents
Single-stage three-element
Type
single-turbine hydraulic torque converter
Torque
converter Inlet pressure of converter (MPa) 0.85
Outlet pressure of converter
0.5
(MPa)
Type Fixed shaft electro-hydraulic shift
Fig. 4-2
1 Torque converter housing 2 Transmission control valve 3 Oil filter 4 Lifting eye
5 Main PTO 6 Auxiliary PTO 7 Speed sensor 8 Parking brake
9 Oil absorption pipe 10 Transmission box oil outlet port
11 Torque converter oil temperature measuring port
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Service Manual for LG958L Wheel Loader
Fig. 4-3
1 Intermediate shaft assembly 2 KRK2 clutch assembly 3 K3K4 clutch assembly
4 Output shaft assembly 5 KR clutch oil pipe 6 K2 clutch oil pipe
7 K4 clutch oil pipe 8 K3 clutch oil pipe 9 KVK1 clutch assembly
10 KV clutch oil pipe 11 K1 clutch oil pipe
Fig. 4-4
1 Gear shift valve 4 2 Pressure control valve 3 Control pressure valve 4 Reversing valve
5 Second-stage pressure control valve 6 Set valve 7 Oil draining valve
8 Gear shift valve 3 9 Gear shift valve 5 10 Gear shift valve 1 11 Gear shift valve 2
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Service Manual for LG958L Wheel Loader
The corresponding working condition of electromagnetic valves and clutches in each gear are
shown in Table 4-2.
Table 4-2
M1 ● ● ●
M2 ● ● ●
M3 ● ● ●
M4 ● ● ● ● ● ●
M5 ●
Clutch KV KV KV K4 KR KR KR K3
Clutch K1 K2 K3 K3 K1 K2 K3
4-4
Service Manual for LG958L Wheel Loader
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Service Manual for LG958L Wheel Loader
Fig. 4-6
ATTENTION
The pipe joints should be bound up to avoid
foreign matters entering.
Fig. 4-7
ATTENTION
The pipe joints should be bound up to avoid
foreign matters entering.
1
Fig. 4-8
1 Oil return pipe from radiator to
transmission box
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Service Manual for LG958L Wheel Loader
ATTENTION
The pipe joints should be bound up to avoid
foreign matters entering.
1
Fig. 4-9
1 Oil inlet pipe of radiator (from
radiator to transmission box)
1
Fig. 4-10
1 Connecting socket
1
Fig. 4-11
1 Output shaft speed sensor
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Service Manual for LG958L Wheel Loader
1
Fig. 4-12
1 Transmission box pressure sensor
1
Fig. 4-13
1 Torque converter oil temperature
sensor
1 2
Fig. 4-14
1 Hexagon bolt
2 Intermediate transmission shaft
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Service Manual for LG958L Wheel Loader
1 2
Fig. 4-15
1 Rear transmission shaft
2 Hexagon bolt
1
Fig. 4-16
1 Oil drain plug
1 2
Fig. 4-17
1 Oil filling pipe 2 Bolt
4-10
Service Manual for LG958L Wheel Loader
1 2
Fig. 4-18
1 Parking brake cylinder
2 Connecting pin
1
Fig. 4-19
1 Nut
1
Fig. 4-20
1 Connecting bolt
4-11
Service Manual for LG958L Wheel Loader
ATTENTION
Lift the transmission box smoothly and do
1 not tilt to prevent the torque converter
Fig. 4-21
1 Bolt slipping.
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Service Manual for LG958L Wheel Loader
ATTENTION
Be careful to avoid nuts and washers falling
into the flywheel housing.
1
Fig. 4-23
1 Connecting bolt
1
Fig. 4-24
1 Bolt
4-13
Service Manual for LG958L Wheel Loader
1
Fig. 4-25
1 Nut
ATTENTION
Check the O-shape ring in pipe joint before
installing.
Fig. 4-26
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Service Manual for LG958L Wheel Loader
1 2
Fig. 4-28
1 Rear transmission shaft
2 Hexagon bolt
1
Fig. 4-29
1 Oil return pipe from radiator to
transmission box
1
Fig. 4-30
1 Oil inlet pipe of radiator (from
radiator to transmission box)
4-15
Service Manual for LG958L Wheel Loader
4-16
Service Manual for LG958L Wheel Loader
1
Fig. 4-33
1 Output shaft speed sensor
1 2
Fig. 4-34
1 Connecting socket
2 Transmission control valve
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Service Manual for LG958L Wheel Loader
Table 4-3
Problems Causes Solutions
Check whether the gear shifting handle is in
Shift neutral gear.
neutral position.
Whether the connection between EST
The wheel Press the plug, and there will be a
electronic control box and the electric plug
loader is sound of click.
is loose.
unable to start.
Whether the battery power is enough. Charge or replace the battery
Whether the starting circuit has faults; Restore the circuit back to
Whether starting fuse burnt out. normal.
Whether the transmission box is enough,
Adjust the oil level to normal.
check cold and hot machine oil level.
Check whether the electric plug of
Tighten the plug.
transmission control valve is tightened.
Whether the connection between EST
Push the plug, and there will be a
electronic control box and the electric plug
sound of click.
is loose.
Check whether the electric plug that
The wheel connected with gear shifting selector cable Insert the plug tight.
loader is able is loose.
to start, but is Whether the neutral locking switch of Turn on the neutral locking
unable to shifting selector is on. switch.
travel.
Whether the parking brake is removed. Remove the parking brake.
Check whether the gear shifting oil pressure
Check the oil pressure gauge.
on the dashboard is normal.
Check whether the ventilated valve on the Clean up the ventilated valve.
transmission box is blocked and whether Check whether the oil is too
there is oil overflow. much or too little.
Check whether the speed sensor plug is
Tighten the plug; wrap or replace
loose; check whether the speed sensor cable
the cable.
is severely worn.
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Service Manual for LG958L Wheel Loader
output speed sensors and the gear shifting handle. If the speed difference is too large, the computer
can command the magnetic valve to let the transmission box shift to a workable minimum speed
gear, then shift to the preselected gear by the cycle of 2.5 seconds. For example, when you shift
from gear I to gear III, after the computer receives electrical signals from the gear shifting handle,
then the computer recognizes the speed signals of the speed sensor, judges whether the speed
reaches the preselected gear, if not, automatically passes electrical signals to the magnetic valve
shifting the gear II firstly, when the loader speed reaches 14km/h, then it will shift the gear III
automatically, which can reduce the impact.
Examples of general faults:
a) When maintaining the loader, after washing the loader with water and find that the loader
cannot shift a gear and couldn’t start. After checking, the circuit connection of electronic
control system is normal, and there is no mechanical failure. Originally when you splash water
to wash the loader, the electronic control box gets damp; after drying, the loader can travel
normally. Therefore, when washing the loader with water, pay attention to waterproof
protection of electronic control box and the handles.
b) The loader was working normally, and after parking to refuel, found that the engine can start,
but the loader couldn’t travel. After checking, the circuit connection of electronic control
system is normal, and gear shifting oil pressure is within the normal range. Later found that the
plug on bottom of electronic control box is not inserted in place. Since on the electronic control
box there is a clamp spring that used to fix the electronic control box’s plug, only when
inserting one end of the wire plug into the pin, there should be a sound of "click" after inserting
the other end, which means the clamp spring has clamped the plug in position. Otherwise when
the loader is running, vibration will cause the plug cannot be inserted tight.
1 2
Fig. 4-35
1 Plug socket 2 Electronic control box
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Service Manual for LG958L Wheel Loader
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Service Manual for LG958L Wheel Loader
After changing the transmission box oil, the loader starts travelling about 20 meters and then
couldn’t run. Shut down and restart the loader, it only can travel 10~20 meters again. After checking,
the circuit of electronic control system is normal and there is no mechanical failure. Later found out
that after changing oil, the user didn’t check the oil level follow the regulations, which results in a
seriously shortage of transmission box oil. After add oil to normal level, the loader can run
normally.
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Service Manual for LG958L Wheel Loader
Fig. 4-36
1 Front transmission shaft 2 Intermediate support 3 Intermediate transmission shaft
4 Rear transmission shaft
Since the axes of the loader transmission box output shaft and drive axle input shaft are difficult to
be aligned in line; moreover, during the loader operation process, due to the unfairness road and
work place, the relative position of the two axes changes frequently. So we can’t apply rigid
connection between the output shaft of the transmission box and the input shaft of the drive axle,
while we must adopt the universal transmission device, which is made of two cross universal joints
and a drive shaft.
The function of the universal transmission device is to solve the uncoaxiality between the
transmission box and the drive axle, to meet the needs of angle changing between the transmission
box and the drive axle, and pass the power of transmission box to the drive axle.
2. Structure and characteristic of transmission shaft
The transmission shaft is an important part of the universal transmission device, usually used for the
connection between the transmission box and drive axle. Generally speaking, the transmission shaft
is composed of pipe sleeve fork assembly, universal joint fork and spline shaft assembly, etc.
During the operation of the loader, the relative position of the transmission box and drive axle
changes constantly, in order to avoid the movement interference, the transmission shaft has sliding
splined connection parts, which consisting of sliding fork and spline shaft, so that, to realize the
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Service Manual for LG958L Wheel Loader
change of the length of the transmission shaft. In order to reduce abrasion, the transmission shaft is
equipped with filling grease oil cup, oil seal and spline sheath, etc. Make sure the lubrication of the
spline shaft in the sleeve fork, and prevent water and dust entering into the sliding spline.
ATTENTION
Put the loader in maintenance position
before the disassembly.
Press down the parking brake switch.
1 2
Fig. 4-37
1 Intermediate support
2 Front transmission shaft
1 2
Fig. 4-38
1 Front drive axle 2 Hexagon bolt
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Service Manual for LG958L Wheel Loader
1 2
Fig. 4-39
1 Hexagon bolt
2 Front transmission shaft
4. Connect front transmission shaft assembly to
intermediate support.
90±15Nm
1 2
Fig. 4-40
1 Intermediate support
2 Front transmission shaft
Replacement of intermediate transmission shaft
assembly
1. Disconnect the intermediate transmission shaft
assembly from transmission box
1 2
Fig. 4-41
1 Intermediate transmission shaft
2 Hexagon bolt
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Service Manual for LG958L Wheel Loader
1 2 3
Fig. 4-42
1 Intermediate support
2 Hexagon bolt
3 Intermediate transmission shaft
1 2 3
Fig. 4-43
1 Intermediate transmission shaft
2 Hexagon bolt
3 Intermediate support
ATTENTION
Align the orientation arrows on spline shaft
and bushing when assembling.
90±15Nm
1 2
Fig. 4-44
1 Hexagon bolt
2 Intermediate transmission shaft
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Service Manual for LG958L Wheel Loader
1 2
Fig. 4-45
1 Hexagon bolt
2 Rear transmission shaft
2. Disconnect rear transmission shaft assembly
from rear drive axle.
1 2
Fig. 4-46
1 Rear transmission shaft
2 Hexagon bolt
3. Replace the transmission shaft with a new one.
Connect the new rear transmission shaft
assembly to rear drive axle.
ATTENTION
Align the orientation arrows on spline shaft
and bushing when assembling.
90±15Nm
1 2
Fig. 4-47
1 Rear transmission shaft
2 Hexagon bolt
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Service Manual for LG958L Wheel Loader
1 2
Fig. 4-48
1 Hexagon bolt
2 Rear transmission shaft
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Service Manual for LG958L Wheel Loader
Drive axle locates at the end of wheel loader transmission system and it is a general term that
describes all the transmission mechanisms between transmission shaft and driving wheel. Drive
axle is mainly used to transmit the torque of transmission shaft to driving wheels, make the rotate
speed of transmission output reduce and torque increase, and it also works as a differential to realize
differential speed of left side and right side wheels. Moreover, drive axle shell also plays a role of
load-bearing and stress-passing.
Fig. 4-49
Oil lever of the drive axle: Oil level is subject to overflow of plug hole or the oil filling port.
——Check: After a few minutes, if the oil level drops, add oil, until the oil level reaches to the
regulation lever and remains unchanged.
Check oil level once a month.
2. Change oil
After the new loader running 500 hours, replace the drive axle oil for the first time, since then
change the oil every 1,000 working hours, and oil should be change at least once a year.
If any of the following case is involved, we recommend you to replace the drive axle oil every 500
hours or at least once every six months.
Frequent operating brake or poor working conditions.
Ambient temperature of operating conditions exceeds 40oC.
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Service Manual for LG958L Wheel Loader
1 2
Fig. 4-50
1 Lifting rope
2 Tire
1 2
Fig. 4-51
1 Rear transmission shaft
2 Hexagon bolt
4. Remove the brake oil pipe(s) from the
T-junction.
ATTENTION
Put a vessel under the axle to contain the
hydraulic oil. Make good protection of the
joint after disassembling.
1
Fig. 4-52
1 Brake oil pipe
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Service Manual for LG958L Wheel Loader
1
Fig. 4-53
1 Grease pipe
1 2
Fig. 4-54
1 Rear drive axle
2 Lifting rope
1
Fig. 4-55
1 Connecting bolt
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Service Manual for LG958L Wheel Loader
Fig. 4-56
ATTENTION
Since there is no axial poisoning when
1 2 installing the swing frame to rear drive axle,
Fig. 4-57
bind the swing frame and rear drive axle
1 Swing frame 2 Drive axle
with two ropes before lifting to prevent
falling off.
1 2
Fig. 4-58
1 Rear drive axle
2 Lifting rope
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Service Manual for LG958L Wheel Loader
1
Fig. 4-59
1 Connecting bolt
1
Fig. 4-60
1 Grease pipe
1
Fig. 4-61
1 Brake oil pipe
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Service Manual for LG958L Wheel Loader
ATTENTION
Align the orientation arrows on spline shaft
and bushing when assembling.
90±15Nm
1
Fig. 4-63
1 Deflating valve
1
Fig. 4-64
1 Front tire
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Service Manual for LG958L Wheel Loader
1
Fig. 4-65
1 Hexagon bolt
ATTENTION
Put a vessel under the axle to contain the
hydraulic oil. Make good protection of the
joint after disassembling.
1
Fig. 4-66
1 Brake oil pipe
4-34
Service Manual for LG958L Wheel Loader
1
Fig. 4-68
1 Brake oil pipe
1 2
Fig. 4-69
1 Lifting rope 2 Front drive axle
1 2
Fig. 4-70
1 Bolt
2 Front drive axle
4-35
Service Manual for LG958L Wheel Loader
1
Fig. 4-71
1 Brake oil pipe
ATTENTION
Align the orientation arrows on spline shaft
and bushing when assembling.
90±15Nm
1
Fig. 4-73
1 Deflating valve
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Service Manual for LG958L Wheel Loader
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Service Manual for LG958L Wheel Loader
5) After the measuring, repeat step 1 and install the pressure switch to the transmission
control valve, and wipe off the spilled transmission oil.
2. Reference pressure
Gear shifting
Items Gear I/II Gear III/IV
pressure
Pressure (MPa) 1.6~1.8 1.6~1.8 1.6~1.8
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Service Manual for LG958L Wheel Loader
Solutions: Re-adjust or change the spring; fill oil to specified level; clean or dredge; repair or
replace the seal ring.
c) Oil temperature is too high
Fault analysis: Operating time is too long; the oil is insufficient or overmuch; the clutch discs
sliding; the clutch couldn’t be disengaged.
Solutions: Stop the loader or idle running for a period of time; fill oil to overflow; check the oil
pressure and seal ring; check the clutch control oil passage or the position of operating handle.
d) Shifting oil pressure of a certain gear is low
Fault analysis: Damaged piston or seal ring of this gear; blockage or leakage of oil passage.
Solutions: Replace the seal ring; Check, clean and eliminate the problem.
e) Disordered gears
Fault analysis: Leakage of the shaft end seal ring
Solutions: Replace the seal ring.
f) System leakage
Fault analysis: Loose pipe joints; damaged seal ring.
Solutions: Tighten the joints; replace the seal ring.
g) The oil level of transmission box oil sump automatically rises
The reason for this phenomenon is that steering pump or working pump input shaft seal is damaged,
the oil of the hydraulic system flows through the torque converter gearbox to the transmission box
sump, leading to oil level rise. Replace the oil seal if necessary.
Since different parts in different states produce the sound with different intensity and characteristic,
you can base on the abnormal sound producing conditions and parts to estimate the sound source
and find out the sound reason.
One reason is that the noise is produced by the loose connections and damaged parts, and this
kind of sound is much belong to the abnormal friction and collision between the parts, so the
sound is clear; The other is that the noise is produced by the abnormality of the bearing fit and
gear engagement.
The abnormality of the gear engagement is that meshing clearance is too small or too large,
meshing position is not correct, meshing area is insufficient. At this time the gear can produce
continuous and clear sound, which increasing with the increase of rotational speed. The
abnormality of the bearing fit is that bearing clearance is too large or too small. When the
clearance is too large, the bearings can produce continuous sound, which increasing with the
increase of the speed.
When the rear axle housing produces sound, in addition to checking whether the parts loose or
not, you should first check whether the meshing area of the main transmission bevel gear is
correct or not.
2. Drive axle is overheating
a) The phenomena and its harm
The drive axle overheating is that after the drive axle mechanically works a period of time, its
temperature exceeds the permissible normal temperature range. Generally speaking, when checking
by hand touch, you will have a hot feeling. The overheating mainly produces in the place of drive
axle housing (except the main drive and differential) and wheel reducer. The drive axle overheating
is the same as the abnormal reflection of technical state of the drive axle parts, or cooperative
relationship, or lubrication. You should promptly identify the reasons and eliminate them, in order
to avoid damaging the relevant parts.
b) The causes for drive axle overheating fault and solutions
Causes: produce more heat; the heat can’t be dissipated in time.
The heat source of the wheel drive axle mainly is friction heat, and that the friction heat can
only be caused by the too small fit clearance of the relative motion parts. The matching parts of
the drive axle have two categories: one is the bearing, the other is the gear. So the fundamental
cause of the overheating drive axle is too small clearance of bearing fit or of gear engagement.
The main reason for heat dissipation problem of the drive axle is that the drive axle (and the
wheel reducer) is lack of lubricating oil or the oil is inferior oil. Lack of lubricating oil or
inferior oil not only makes the friction heat generated by the drive axle cannot be dissipated in
4-41
Service Manual for LG958L Wheel Loader
time, but also can make the relative movement parts are in a dry friction state, which makes the
friction heat increase greatly.
When the drive axle is overheating, we can base on the overheating position to determine the
causes of overheating. If the bearing is overheating, we can ascertain that the fault is caused by
the bearing; when the whole drive axle housing is overheating, the reason may be caused by the
abnormal gear engagement or lubricating oil shortage; you should fill the specific lubricants
timely.
3. Oil leakage of drive axle
a) The phenomena and its harm
The oil leakage of the drive axle occurs mostly in the axle housing and wheel reducer, and mostly
leaking through the seal and the fitting surface.
b) The causes for oil leakage of drive axle and solutions
The oil leakage of the drive axle mainly is caused by the damaged sealing elements and sealing
gaskets, for the former: such as the oil leakage caused by damaged final drive’s oil sealing; for
the latter: such as the oil leakage of the rear axle housing and wheel reducer fitting surface.
Check the whether oil sealing is aged, cracked or damaged or not; don't widen the oil seal too
fiercely, to avoid the plastic deformation; try to warm the oil sealing with liquid that has the
same temperature as operating temperature, and then install it with special tools.
4-42
SERVICE MANUAL
Version:0520
5 Brakes
CONTENTS
5 Brakes ..................................................................................................................................................... 5-1
511 Composition of Travel Brake System and Working Principle ...................................................... 5-2
5-1
Service Manual For LG958L Wheel Loader
Pilot system
51 Travel Brake
Oil filling
Oil tank Front axle brake cliper
valve
Accumulator
5-3
Service Manual For LG958L Wheel Loader
WARNING
When operating or driving in flat
terrain, power off function can be used
to reduce the load on the brake and
transmission. However, you can not use
power off function when operating on
slope to avoid slip, in order to ensure
traffic safety.
Technical Descriptions
5-4
Service Manual For LG958L Wheel Loader
Filter
Capsule accumulator
Capsule brake is used to store pressure oil for
Fig. 5-6 Filter
braking. Its principle is to store the pressure
liquid and capsule with pressure in a sealed
housing and it is used to brake by absorbing and
releasing the liquid due to the changing
pressure. Brake pump is working, and inject the
pressure fluid into accumulator through prefill
valve to store energy. Then, the gas is
compressed in the capsule, so that the pressure
5-6
Service Manual For LG958L Wheel Loader
5-7
Service Manual For LG958L Wheel Loader
Main Components
1 2
pedal valve.
Fig. 5-11
★ Notice
1 P2 port connection pipe
2 P1 port connection pipe When disassemble the hydraulic connections,
5-8
Service Manual For LG958L Wheel Loader
1 2
Fig. 5-12
1 A1 port connection pipe
2 A2 port connection pipe
1 2
Fig. 5-13
1 T1 port connection pipe
2 T2 port connection pipe
5-9
Service Manual For LG958L Wheel Loader
Figure 5-14
1transition plate
Fig. 5-15
1 2
Fig. 5-16
1 transition plate
2 straight joint
5-10
Service Manual For LG958L Wheel Loader
1 2
Fig. 5-17
1 transition plate
2 straight joint
1 2
Fig. 5-19
1 T1port connection pipe
2 T2port connection pipe
5-11
Service Manual For LG958L Wheel Loader
1 2
Fig. 5-20
1 A1 port connection pipe
2 A2 port connection pipe
1 2
Fig. 5-21
1 P1port connection pipe
2 P2port connection pipe
Disassembly of accumulator
1 Remove the guard plate of accumulator.
2 Remove the bent plate assembly of
accumulator guard hood.
1 2
Figure 5-22
1 guard bent plate assembly
2 guard direct plate
5-12
Service Manual For LG958L Wheel Loader
5-13
Service Manual For LG958L Wheel Loader
Assembly of accumulator
1 2
Fig. 5-26
1 guard bent plate assembly
2 guard direct plate
5-14
Service Manual For LG958L Wheel Loader
Oil tank
Accumulator
Working Principle
Notice
5-16
Service Manual For LG958L Wheel Loader
5-17
Service Manual For LG958L Wheel Loader
5-18
Service Manual For LG958L Wheel Loader
5-19
Service Manual For LG958L Wheel Loader
Table 5-1
5-20
Service Manual For LG958L Wheel Loader
5-21
Service Manual For LG958L Wheel Loader
Cycle filling
1 Pressure of accumulator 1 Check the air pressure in
rate is too fast
4 capsules is too low. the accumulator capsules.
for prefill
2 Prefill valve does not work. 2 Replace prefill valve.
valve
1 The clearance between
brake drum and brake shoe
Power of is too large. 1 Readjust it as required.
5 parking brake 2 There is oil on the brake 2 Clean brake shoe.
is not enough. shoe 3 Check the brake cylinder.
3 The spring force of the
brake cylinder is not enough
1 Check the oil level in the
1 There is no oil or oil level is
tank.
too low
Accumulator 2 Check the pump pressure or
6 2 Pump is too old to work
charging fails flow.
3 There is air in accumulator.
3 Drain the air.
4 Prefill valve does not work
4 Replace the prefill valve.
1 Pump is too old to work and
1 Check the pressure or flow
can not convey all flow or
Accumulator of pump.
pressure
7 charging time 2 Replace the prefill valve.
2 Prefill valve does not work
is too long 3 Remove, check or replace
3 Capsules are damaged and
capsules.
nitrogen leaks
Detect whether the maximum
pressure of brake valve outlet is
normal. If the maximum
No inching
8 Brake valve fails pressure of export is much
braking
greater than required system
pressure, replace the brake
valve.
5-22
Service Manual For LG958L Wheel Loader
Travel brake
1 System pressure is
low pressure 1 Please wait that the alarm
inadequate, in the short time
alarm lamp or will stop automatically if
of starting loader.
emergency system oil pressure is
9 2 There are system faults in
brake low sufficient.
the working process of
pressure 2 Stop the machine to check
loader and oil pressure
warning lamp it.
decreased.
are on.
1 The brake light is damaged.
2 There are system faults in 1 Check the brake lights.
The brake
10 the working process of 2 Stop the machine to check
lamp is off.
loader and oil pressure is it.
decreasing.
5-23
SERVICE MANUAL
Version:0620
6 Steering System
CONTENTS
6 STEERING SYSTEM
6.1 Overview
1 2 3 4
6-1
Service Manual For LG958L Wheel Loader
Steering
Priority
valve
Main safety
valve
Filter
Steering pimp
Oil tank
Figure 6-2
6-2
Service Manual For LG958L Wheel Loader
When steering
When relative angular displacement is produced
between the valve spool and valve bush of steering gear
and the displacement increases to a suitable quantity,
neutral position throttling orifice will be closed
completely. Hydraulic oil flows through the variable
orifice of steering gear and result in pressure loss
(smaller than neutral position throttling orifice). The
two ends pressure of steering variable orifice pass to
two ends of priority valve spool, force the spool to find
a new equilibrium position. If increase the rotating
speed of steering wheel, at the moment of change, the
flow valve in the steering gear is less than the product
of steering wheel rotating speed times steering gear
displacement; rotating speed of valve bush droved by
metering mechanism is lower than rotating speed of
spool droved by steering wheel, so angular
displacement of spool to valve bush increases and
opening degree of variable orifice increases. At this
point, larger flow is needed to produce the same
differential pressure as the one before the change
between two ends of the variable orifice to force the
priority valve spool left. So CF port opening degree of
priority valve increases with the increase the increase
6-3
Service Manual For LG958L Wheel Loader
Steering gear
Priority
valve
Steering
Filter pimp
Oil tank
Figure 6-3
Figure 6-4
6-5
Service Manual For LG958L Wheel Loader
Figure 6-6
1 inlet check valve 2 bi-directional overload valve 3 bi-directional oil compensation valve
Figure 6-7oil lines in steering gear
6-6
Service Manual For LG958L Wheel Loader
6-7
Service Manual For LG958L Wheel Loader
Figure 6-10
1 2
1L port connecting pipe
2R port connecting pipe
Figure 6-12
6-8
Service Manual For LG958L Wheel Loader
1 2
1T port connecting pipe
2P port connecting pipe
Figure 6-13
1 2 3
1screw 2bolt 3 cover plate
Figure 6-14
1
1connecting bolt between steering gear
and steering column
Figure 6-15
6-9
Service Manual For LG958L Wheel Loader
1
1straight joint
Figure 6-16
1 2
1protective element
2straight joint
Figure 6-17
Figure 6-18
6-10
Service Manual For LG958L Wheel Loader
1
1straight joint
Figure 6-19
1 2
1protective element
2straight joint
Figure 6-20
1
1connecting bolt between steering gear
and steering column
Figure 6-21
6-11
Service Manual For LG958L Wheel Loader
1 2 3
1screw 2bolt 3 cover plate
Figure 6-14
6-12
Service Manual For LG958L Wheel Loader
1
1LS port connecting pipe
Figure 6-25
Figure 6-27
6-13
Service Manual For LG958L Wheel Loader
1
1piston-side oil inlet pipe
Figure 6-29
Figure 6-30
6-14
Service Manual For LG958L Wheel Loader
Figure 6-31
Figure 6-32
Figure 6-33
6-15
Service Manual For LG958L Wheel Loader
Figure 6-34
Figure 6-35
6-16
Service Manual For LG958L Wheel Loader
Figure 6-38
1
1piston-side oil inlet pipe
Figure 6-39
6-17
Service Manual For LG958L Wheel Loader
1
1rod-side oil inlet pipe
Figure 6-40
Figure 6-41
Figure 6-42
6-18
Service Manual For LG958L Wheel Loader
Figure 6-43
Figure 6-44
6-19
Service Manual For LG958L Wheel Loader
1
1CF port connecting pipe
Figure 6-46
1
1EF port connecting pipe
Figure 6-47
1
1steering pump outlet pipe
Figure 6-48
6-20
Service Manual For LG958L Wheel Loader
Figure 6-49
Figure 6-50
Figure 6-51
6-21
Service Manual For LG958L Wheel Loader
Figure 6-52
1
1steering pump outlet pipe
Figure 6-53
1
1EF port connecting pipe
Figure 6-54
6-22
Service Manual For LG958L Wheel Loader
1
1CF port connecting pipe
Figure 6-55
1
1feedback oil pipe of steering gearFigure
6-56
1
1oil inlet pipe of priority valve
Figure 6-57
6-23
Service Manual For LG958L Wheel Loader
Figure 6-58
6-24
Service Manual For LG958L Wheel Loader
Table 6-1
6-25
Service Manual For LG958L Wheel Loader
6-26
SERVICE MANUAL
Version:0720
I
Service Manual For LG958L Wheel Loader
71 Introduction
1
Figure 7-2
1 swaying bracket
1 2 3
Figure 7-3
1 connecting rod 2 rocker arm
3 lifting arm
7-1
Service Manual For LG958L Wheel Loader
1
Figure 7-4
1 lifting eye (on both sides of the lifting
position, in the tool box and battery box)
2 Middle of the Balance Weight (middle
lifting position)
1
2. Disassemble the four balance weight bolts. (Figure
7-5)
3. Low the balance weight, and disassemble it from
the machine. Then lift and remove it.
7-2
Service Manual For LG958L Wheel Loader
7-3
Service Manual For LG958L Wheel Loader
1
Figure 7-9
1 position for installing pin-pulling tools 731 Lower Frame Junction
17. Mark the position of bearing cover. Remove spacer
ring and upper and lower bearing covers and the
adjusting gaskets under bearings. Remove sealing
elements and clear bearing cover, and do not wash
away the marks. (Figure 7-10)
18. Install the tools and disassemble lower bearing
race.
19. Mount the lower bearing race at the junction of
Figure 7-10 lower frame. Strike it into until the bearing race
edge is 4mm (0.16inch) from junction of lower
frame. Mount two ball bearings. Use the same
method to mount bearing braces until it is 5mm
(0.2 inch) from junction of lower frame.
20. Mount lower and upper bearing races using bolts
and nuts. Put four gaskets (thickness about 3mm
(0.12 inch)) between upper cover and frame.
Tighten the bolts symmetrically until the lower
race is 4mm (0.16 inch) from lower frame junction.
1 2 3 21. Remove four gaskets. Mount pin and bear
Figure 7-11
1 gasket 2 lower pin 3 sealing ring temporarily. When rolling resistance reaches to
13-17 Nm (10-13 lb-ft), stop tightening.
22. Use clearance gauge measures the clearances
between bearing cover and frame at random points
23. Remove bearing pin.
7-4
Service Manual For LG958L Wheel Loader
7-5
Service Manual For LG958L Wheel Loader
7-6
Service Manual For LG958L Wheel Loader
7-7
Service Manual For LG958L Wheel Loader
Figure 7-13 2. Put jack under balance weight. Lift the machine,
and put specialized tool under balance weight.
Remove jack.
3. Loosen wheel nuts.
4. Mount wheel forklift tool and fix the wheel.
Remove wheel nuts and wheel.
7-8
Service Manual For LG958L Wheel Loader
Figure 7-15
4. Lift the machine with specialized tool. Keep the
front wheel off the ground. (Figure 7-16)
5. Loosen wheel nuts
Notice
Before the shaft fixed, don’t disassemble the
wheel nuts.
6. Mount wheel forklift tool and fix the wheel
1
7. Remove wheel nuts and wheel.
Figure 7-16
1 specialized tool (similar to that of rear 744 Assembly Front Wheel
frame, there are baffles at the two support
positions to stop the frame moving) 1. Clear the contact surface of rim and hub. Make
sure the thread of the hub clean and no damage.
2. Mount the wheel.
Mount the wheel, install the four wheel nuts.
Tighten the nuts directly.
Notice
Tighten the nuts clockwise, screw into a little
every time to avoid the wheel tilt.
1
Remove the forklift.
Figure 7-17 Install the rest of the wheel nuts.
1 wheel Forklift Instrument
Tighten torque: 480~580Nm
3. Lower the machine.
4. Recover the machine, check and affirm there is no
wrong information.
5. Check and make sure all functions are normal.
7-9
Service Manual For LG958L Wheel Loader
75 Disassembly of Linkage
1
Figure 7-19
1 lifting position
4. Disassemble the fixing bolt of connecting pin
between connecting rod and rocker arm. (Figure
7-20)
1
Figure 7-20
1 fixing Bolt 5. Predict the motion trail of connecting rod to avoid
hurting people or ground, remove the pin using soft
hammer and lift away the connecting rod.
Figure 7-21
7-10
Service Manual For LG958L Wheel Loader
1
Figure 7-22
1 lifting rope crosses through the linkage
hole (the hole connecting quick-change and
linkage)
1
scraper seals.
Figure 7-23 6. Adjust the connecting rod and operate the tilt
1 O-shape scraper seal
cylinder to align the connecting rod with
quick-change frame.
7. Use a pin to connect the quick-change frame and
connecting rod assembly, use a bolt and gasket to
fix the pin.
Tighten torque: 78~104 N·m
8. Fill in proper volume grease to pin connection with
grease gun.
7-11
Service Manual For LG958L Wheel Loader
1
Figure 7-24
1 lifting position
3. Lift the tilt cylinder and put a block at the bottom
of tilt cylinder to support it.
1
Figure 7-25
1 reliable support
7-12
Service Manual For LG958L Wheel Loader
7-13
Service Manual For LG958L Wheel Loader
1
Figure 7-28
1 position for blocks
7-14
Service Manual For LG958L Wheel Loader
1
Figure 7-30
1 blocks
7-15
Service Manual For LG958L Wheel Loader
1
Figure 7-31
1 lift the pin position of both side of
quick-change frame
1
Figure 7-32
1 pin
Figure 7-33
7-16
Service Manual For LG958L Wheel Loader
Figure 7-35
7-17
Service Manual For LG958L Wheel Loader
77 Replacement of Quick-change
Bucket
Figure 7-36
1 2
Figure 7-37
1 alignment
2 connecting base of quick-change bucket
3. Approach slowly and adjust the height of quick
attachment. Align the pin of quick attachment with
the set of holes in the middle of quick-change
bucket. (Figure 7-38)
1
Figure 7-38
1 hinge pin of quick-change frame
7-18
Service Manual For LG958L Wheel Loader
1 2
Figure 7-39
1 alignment 2 stop block
1
Figure 7-40
1 quick-change power switch
7-19
Service Manual For LG958L Wheel Loader
7-20
SERVICE MANUAL
Version:0820
II
Service Manual For LG958L Wheel Loader
81 Cab Description
1
Figure 8-1
1 cab
Figure 8-1 2. LG958L use four silicone oil dampers to connect
the cab to the frame. The dampers can reduce the
noise and vibration, and prevent them from
spreading to the cab. The cab has well-designed
frame structure, which would not be crushed when
the loader roll over.
1 2
1 2
Figure 8-2
1 silicone oil damper
2 damping bolt
8-1
Service Manual For LG958L Wheel Loader
1
Figure 8-3
1 ROPS bolt
8-2
Service Manual For LG958L Wheel Loader
8-3
Service Manual For LG958L Wheel Loader
8-4
Service Manual For LG958L Wheel Loader
8-5
Service Manual For LG958L Wheel Loader
1
be on, push it to the OFF position, it will go out.
Figure 8-10 When driving, the top light must be closed.
1 top light switch
8. Parking brake switch
Parking brake: when the loader stops working, this
switch can prevent its movement because of the
slant of the road or external force.
9. Rocker switch
· Headlamp switch
Press the low end of the switch, the headlamps on the
1 top of the cab will be on; press the upper end, they go
Figure 8-11 out.
1 parking brake switch
8-6
Service Manual For LG958L Wheel Loader
8-7
Service Manual For LG958L Wheel Loader
Press the upper end of the switch, at the same time step
the brake pedal, power won’t cut off.
· Quick-change switch
Press the low end of the switch, at the same time
operate the quick-change button of the operating handle,
the working device can be changed quickly.
Press the upper end of the switch, at the same time
operate the quick-change button of the operating handle,
the function of quick-change is locked.
· Positive & negative rotation switch
Pressing this switch, the fan rotates reversely for
degusting. This switch is self-locking. Under normal
condition, it is locked. When using this switch, push the
lock catch on the switch to unlock it.
Warning
This switch can only be used when the engine is in
the flameout status.
· Safety lock switch
Pressing this switch, pilot operating handle will be
locked.
· Horn button
1 2
Figure 8-15
Press the button in the middle of the steering wheel, the
1 steering wheel horn sounds; release it, the horn stops sounding.
2 horn button
10. Cigarette lighter
Insert the cigarette lighter and press it until locked up,
then the electric heater band of the cigarette lighter
contacts with the socket, the heating process starts.
When the heating wire of the cigarette lighter reaches
the required temperature, the clamp spring deforms
because of the high temperature and pops the cigarette
lighter up. Then the cigarette lighter can be used for
1
Figure 8-16
lighting the cigarette. After finished, insert it back.
1 cigarette lighter 11. Working device operating handle
8-8
Service Manual For LG958L Wheel Loader
This handle can control the bucket and boom. There are
four gear modes in the front-rear direction, controlling
the lift, neutral position, lower and float of the boom,
respectively; there are three gear modes in the left-right
direction, controlling the forward tilt, neutral position
and backward tilt of the bucket respectively.
· Bucket
Backward tilt: retract the bucket
Neutral position: keep the bucket in a certain position
Float Forward tilt: unload
Lower Forward · Boom
tilt
Neutral position: keep the boom in a certain position
Lower: lower the boom.
Backward Lift
tilt · Float
the boom moves freely under the action of external
forces.
· Quick-change button
Left: quick-change disassemble button
1 2
Figure 8-17 Right: quick-change assemble button
1 quick-change button
12. Emergency exit
2 working device operating handle
The cab has two emergency exits: the door and the rear
window. No matter the stationary type or slide type of
the rear window is, when emergency occurs, use the
emergency hammer hanging on the left rear side of the
cab to break the window and escape from the cab
Notice
Emergency exits can only be used in case of an
emergency.
13. Seat
1
Figure 8-18 · Weight adjustment
1 safety hammer
The weight adjustment knob is in the middle of seat
bottom. Turn the knob anticlockwise to reduce the
damping stiffness and turn it clockwise to increase the
8-9
Service Manual For LG958L Wheel Loader
8-10
Service Manual For LG958L Wheel Loader
1 2
Figure 8-21
1 engine
2 compressor
8-11
Service Manual For LG958L Wheel Loader
1 2
Figure 8-22
1 receiver-drier
2 condenser
8-12
Service Manual──LG958L Wheel Loader
8- 13
Service Manual──LG958L Wheel Loader
Notice
When refrigerating in summer, please close the hot water valve. When heating in winter, please
close the temperature control switch.
The refrigerant of LG958L is R-134a (Freon-free environmentally friendly refrigerant). It
possesses the properties as follows: strong heat absorptivity and easily liquefied; non-flammable
and non-explosive; chemical composition stable; non-toxic; non-corrosive.
8- 14
Service Manual──LG958L Wheel Loader
1
Figure 8-26
1 pilot operating handle
5. Disassemble evaporator assembly. Refer to 86
Disassembly and Assembly of Air Conditioning
System.
1
Figure 8-27
1 evaporator assembly
8-15
Service Manual──LG958L Wheel Loader
1 2
Figure 8-28
1 platform
2 hoisting rope
7. Disassemble left hydraulic oil tank shield.
1
Figure 8-29
1 bolt
8-16
Service Manual──LG958L Wheel Loader
1 2
Figure 8-30
1 cab
2 rear platform wire harness
9. Pull up the yellow plug of the rear frame wire
harness (as shown in Figure 8-31).
1
Figure 8-31
1 rear platform wire harness
10. Disconnect the radiating valve wire harness in the
engine hood (left inside).
1
Figure 8-32
1 radiating valve wire harness
8-17
Service Manual──LG958L Wheel Loader
1
Figure 8-33
1 output shaft speed sensor
12. Disconnect the gang socket wire harness on the
gearbox.
1
Figure 8-34
1 gang socket wire harness
13. Disassemble the damper connecting nuts.
1
Figure 8-35
1 damper nut
8-18
Service Manual──LG958L Wheel Loader
1
Figure 8-36
1 ROPS bolt
15. Hang down the cab with hoisting rope and put it on
the cab support.
Notices:
During hoisting, don’t run the cab part into the
hydraulic tank and wire harness. When putting
down the cab, keep it stable.
1
Figure 8-37
1 cab
8-19
Service Manual──LG958L Wheel Loader
1
Figure 8-38
1 cab
2. Assemble ROPS connecting bolts
1
Figure 8-39
1 ROPS bolt
3. Assemble damper connecting nuts
1
Figure 8-40
1 damper nut
8-20
Service Manual──LG958L Wheel Loader
1
Figure 8-41
1 gang socket wire harness
5. Connecting the speed sensor wire harness on the
gearbox
1
Figure 8-42
1 output shaft speed sensor
1
Figure 8-43
1 radiating valve wire harness
8-21
Service Manual──LG958L Wheel Loader
1 2
Figure 8-44
1 cab 2 rear frame wire harness
1
Figure 8-45
1 rear platform wire harness
9. Assemble the frame, for details refer to 85
Disassembly and Assembly of Left and Right
Platforms.
1 2
Figure 8-46
1 platform 2 hoisting rope
8-22
Service Manual──LG958L Wheel Loader
1
Figure 8-47
1 evaporator assembly
11. Assemble steering gear hydraulic pipeline. For
details, refer to 622 Assembly of Steering Gear.
12. Assemble brake valve hydraulic pipeline. For
details refer to corresponding section in 514
Disassembly and Assembly of Main Components
1 2
Figure 8-48
1 steering gear
2 foot brake valve
13. Assemble operating handle pilot hydraulic pipeline,
for details refer to 948 Disassembly and Assembly
of Pilot Operating Valve Assembly.
1
Figure 8-49
1 pilot operating handle
8-23
Service Manual──LG958L Wheel Loader
1
Figure 8-50
1 bolt
2. Hang the seat out of the cab with hoisting rope.
1
Figure 8-51
1 seat
3. Replace the old seat with new one and fix it with
bolts
1
Figure 8-50
1 bolt
8-24
Service Manual──LG958L Wheel Loader
1
Figure 8-53
1 bolt
2. Disassemble the peripheral shield. And
disassemble the bolts shown in Figure 8-54.
1
Figure 8-54
1 bolt
1
Figure 8-55
1 bolt
8-25
Service Manual──LG958L Wheel Loader
1 2
Figure 8-56
1 maneuvering welding assembly
2 bolt
5. Disassemble the fixed pilot valve and fixing blots
of the small pilot valve.
1 2
Figure 8-57
1 pilot valve bolt
2 small pilot valve bolt
6. Disassemble the roof fixed on the maneuvering
welding assembly.
1 2
Figure 8-58
1 bolt
2 roof assembly
8-26
Service Manual──LG958L Wheel Loader
1 2
Figure8-59
1 bolt
2 maneuvering box welding assembly
1 2
Figure8-60
1 bolt
2 maneuvering box welding assembly
2. Fix the roof assembly to the maneuvering box
welding assembly with bolts.
1 2
Figure 8-61
1 bolt 2 roof assembly
8-27
Service Manual──LG958L Wheel Loader
1 2
Figure 8-62
1 pilot valve bolt
2 small pilot valve bolt
4. Assemble the pipe clamp of the pilot pipeline and
sponge.
1 2
Figure8-63
1 maneuvering welding assembly
2 bolt
5. Fasten the cover using bolt and gasket.
1
Figure 8-64
1 bolt
8-28
Service Manual──LG958L Wheel Loader
1
Figure 8-65
1 bolt
7. Reset the seat and mount the rear fixing bolts
1
Figure 8-66
1 seat
8-29
Service Manual──LG958L Wheel Loader
1 2
Figure 8-67
1 rear cover
2 engine hood
841 Disassembly of Rear Cover
1
Figure 8-68
1 window lattice
8-30
Service Manual──LG958L Wheel Loader
1 2
Figure 8-69
1 rear lamp wire harness
2 back-up buzzer wire harness
4. Disassemble the four connecting bolts between
rear cover and rear frame.
1
Figure 8-70
1 rear cover bolt
5. Disassemble the connecting two bolts between rear
cover and engine hood.
1
Figure 8-71
1 rear cover bolt
8-31
Service Manual──LG958L Wheel Loader
1 2
Figure 8-72
1 rear cover
2 hoisting rope
7. If the rear cover is not easy to lift up, disassemble
the bolts on both side of the radiator first. After
hanging the rear cover, mount the bolts.
1
Figure 8-73
1 bolt
8-32
Service Manual──LG958L Wheel Loader
1 2 3 4
Figure 8-74
1 bolt 2 prefilter
3 tail pipe 4 bolt
3. Disconnect the liquid level monitor wire harness
connecting to the expansion box.
4. Disassemble the connect rubber hose 2 which
connecting the expansion box and engine body
5. Disassemble the filling water pipe 3 connecting to
exhalent siphon of the radiator
1 2 3 4
Figure 8-75
1 expansion box
2 rubber hose
3 filling water pipe
4 monitor wire harness
8-33
Service Manual──LG958L Wheel Loader
1
Figure 8-76
1 water draining valve
7. Disassemble the hose clamp of the pre-filter.
1 2
Figure 8-77
1 air prefilter 2 hose clamp
8. Disassemble the connecting bolts between the right
and left panels and press plate and engine hood.
1 2 3 4
Figure 8-78
1 left panel 2 right panel
3 press plate 4 bolt
8-34
Service Manual──LG958L Wheel Loader
1
Figure 8-79
1 bolt
10. Disassemble the connecting clamps between
radiator water inlet hose and engine hood and
radiator.
1 2 3 4
Figure 8-80
1 hose clamp 2 engine hood
3 radiator water inlet 4 radiator assembly
11. Disassemble the connecting V-shape hoops
between intercooler exit pipe and radiator and
engine hood.
1 2 3 4
Figure 8-81
1 radiator 2 intercooler exit pipe
3 V-shape hoop 4 engine hood
8-35
Service Manual──LG958L Wheel Loader
1
Figure 8-82
1 engine hood
8-36
Service Manual──LG958L Wheel Loader
1 2 3 4
Figure 8-84
1 radiator 2 intercooler exit pipe
3 V-shape hoop 4 engine hood
3. Assemble the hose clamp connection of the
radiator water inlet and engine hood and radiator.
1 2 3 4
Figure 8-85
1 hose clamp 2 engine hood
3 radiator water inlet 4 radiator assembly
8-37
Service Manual──LG958L Wheel Loader
1
Figure 8-86
1 bolt
5. Assemble the left and right panel and press plate to
the engine hood.
1 2 3 4
Figure 8-87
1 left panel 2 right panel
3 press plate 4 bolt
6. Assemble the air pre-filter and hose clamp.
1 2
Figure 8-88
1 air prefilter
2 hose clamp
8-38
Service Manual──LG958L Wheel Loader
1 2 3 4
Figure 8-89
1 expansion box 2 rubber hose
3 water filling pipe 4 monitor wire harness
10. Mount the fixed bolts of air pre-filter and hose
clamp.
11. Mount the fixed bolts of the tail pipe.
12. Fill coolant, for details refer to 272 Assembly of
Engine.
1 2 3 4
Figure 8-90
1 bolt 2 prefilter
3 tail pipe 4 bolt
8-39
Service Manual──LG958L Wheel Loader
1 2
Figure 8-91
1 rear cover 2 hoisting rope
2. Mount the connecting bolts between rear cover and
engine hood.
1
Figure 8-92
1 rear cover bolt
3. Mount the four bolts connecting rear cover and
rear frame.
1
Figure 8-93
1 rear cover bolt
8-40
Service Manual──LG958L Wheel Loader
1 2
Figure 8-94
1 rear lamp wire harness
2 Back-up buzzer wire harness
5. Close the window lattice.
6. Recover the machine.
1
Figure 8-95
1 window lattice
8-41
Service Manual──LG958L Wheel Loader
1 2 3
Figure 8-96
1 right platform 2 ladder stand
3 hoisting rope
2. Disassemble the bolts connecting left and right
platform and hydraulic oil tank stand.
1
Figure 8-97
1 bolt
8-42
Service Manual──LG958L Wheel Loader
1
Figure 8-98
1 bolts
4. Disassemble the bolts connecting platform and
ladder stand.
1
Figure 8-99
1 bolt
5. Lift the right platform and put it on the cushion.
Notice
Keep the platform stable.
1 2
Figure 8-100
1 hoisting Rope
2 right platforms
8-43
Service Manual──LG958L Wheel Loader
1 2 3
Figure 8-101
1 ladder stand 2 condenser support
3 bolts
8-44
Service Manual──LG958L Wheel Loader
1 2
Figure 8-103
1 hoisting Rope
2 platforms
3. Mount the connecting bolts between platform and
ladder stand.
1
Figure 8-104
1 bolt
8-45
Service Manual──LG958L Wheel Loader
1
Figure 8-105
1 bolts
5. Mount the connecting bolts between platform and
oil tank support. After finished, remove hoisting
rope.
1
Figure 8-106
1 bolt
8-46
Service Manual──LG958L Wheel Loader
1
Figure 8-107
1 lockpin
3. Disassemble the filter and its cover.
4. Disconnect the wire harness connection between
temperature control panel and fresh air damper
motor.
1 2
Figure 8-108
1 filter cover
2 damper motor wire harness
8-47
Service Manual──LG958L Wheel Loader
1 2 3
Figure 8-109
1 power source wire harness
2 temperature controller panel wire harness
3 temperature control panel
6. Disconnect the hose clamp connection between
engine heater pipe and evaporator.
7. Disassemble the bolts connecting evaporator and
cab.
1 2
Figure 8-110
1 hose clamp
2 bolts
8. Disconnect the bolts connecting the right interior
trim panel in cab and evaporator assembly.
1 2
Figure 8-111
1 interior trim panel
2 bolt hole
8-48
Service Manual──LG958L Wheel Loader
1
Figure 8-112
1 evaporator assembly
1
Figure 8-113
1 evaporator assembly
3. Connect the hose clamp between engine heater
pipe and evaporator.
4. Mount the bolts connecting evaporator and cab.
1 2
Figure 8-114
1 hose clamp 2 bolts
8-49
Service Manual──LG958L Wheel Loader
1 2 3
Figure 8-115
1 power source wire harness
2 temperature controller panel wire harness
3 temperature control panel
7. Mount the bolts connecting cab interior trim panel
and evaporator.
1 2
Figure 8-116
1 interior trim panel
2 bolt hole
8. Connect the wire harness between temperature
controller panel and fresh air damper.
9. Fix the filter cover with bolts
1 2
Figure 8-117
1 filter cover
2 damper motor wire harness
8-50
Service Manual──LG958L Wheel Loader
1
Figure 8-118
1 lockpin
1 2
Figure 8-119
1 evaporator
2 fixing plate
8-51
Service Manual──LG958L Wheel Loader
1
Figure 8-120
1 clamp
4. Take down the heating unit and replace it.
5. Reinstall the cover, and fix all of the clamps.
Notice
Check whether the fan is assembled in the right
position.
6. Reinstall climate unit, refer to 862 Assembly of
Climate Unit.
1
Figure 8-121
1 heating unit
Replacement of air blower
1. Disassemble the evaporator from the machine, and
put in on the platform, refer to 861 Disassembly of
Climate Unit.
2. Disassemble the fixing plate on the right of the
evaporator.
1 2
Figure 8-122
1 evaporator
2 fixing plate
8-52
Service Manual──LG958L Wheel Loader
1
Figure 8-123
1 clamp
4. Disconnect the wire harness connection, lift out the
air blower and replace with a new one.
5. Reinstall the cover, and fix all the clamps.
Notice
Check whether the fan is assembled in the right
position.
6. Reinstall climate unit, refer to 862Assembly of
1 Climate Unit.
Figure 8-124
1 air blower
Replacement of expansion valve
Warning
Oil is harmful, avoid it contacting with
unprotected skin. Use protective gloves.
1. Drain all refrigerant in the system. Refer to 867
Draining and Filling of Refrigerant.
2. Disassemble filter cover and filter, disconnect wire
harness connection between temperature control
panel and fresh air damper motor.
1 2
Figure 8-125
1 filter cover
2 damper motor wire harness
8-53
Service Manual──LG958L Wheel Loader
1 2
Figure 8-126
1 fixing plate
2 pressure sensor connector
4. Disconnect the pipeline and disassemble the
expansion valve. Plug the connector.
5. Remove the plug and mount new expansion valve.
Notice
Keep the lumen clean and use the compressor
oil to lubricate the seal ring.
6. Connect the expansion valve pipeline.
1
Figure 8-127
1 expansion valve
1 2
Figure 8-128
1 fixing plate
2 pressure sensor connector
8-54
Service Manual──LG958L Wheel Loader
1 2
Figure 8-129
1 filter cover
2 damper motor wire harness
1 2
Figure 8-130
1 evaporator
2 fixing plate
3. Disassemble the clamps of the evaporator
assembly, and remove the shell.
1
Figure 8-131
1 clamp
8-55
Service Manual──LG958L Wheel Loader
1 2
Figure 8-132
1 heating unit
2 refrigeration unit
5. Assemble evaporator assembly shell and right
fixing plate.
1
Figure 8-133
1 fixing plate
6. Mount filter cover and damper motor wire harness.
7. Close the air condition cover lockpin.
8. Recover the machine.
1 2
Figure 8-134
1 filter cover
2 damper motor Wire Harness
8-56
Service Manual──LG958L Wheel Loader
Replacement of evaporator
Warning
Oil is harmful, avoid it contacting with unprotected
skin. Use protective gloves.
1. Open the evaporator assembly cover.
Drain all refrigerant fluid in the system, refer to
867 Draining and Filling of Refrigerant.
2. Disassemble filter and filter cover.
3. Disconnect the wire harness connection between
damper motor and temperature control panel.
1 2
Figure 8-135
1 filter cover
2 damper motor Wire Harness
1
Figure 8-136
1 fixing plate
6. Disassemble shell clamps, take evaporator out and
move it one side.
7. Loose bolts and mount new evaporator.
Notices:
Keep the inner chamber of evaporator clean
and use the compressor oil lubricate the seal
ring.
8. Insert temperature sensor.
1
Figure 8-137 9. Mount evaporator cover.。
1 evaporator
8-57
Service Manual──LG958L Wheel Loader
1
Figure 8-138
1 fixing plate
11. Assemble filter cover, filter and damper motor
wire harness.
1 2
Figure 8-139
1 filter cover
2 damper motor wire harness
12. Use vacuum pump to fill system with refrigerant.
Refer to 867 Draining and Filling of Refrigerant.
13. Recover machine.
1
Figure 8-140
1 filling hose
8-58
Service Manual──LG958L Wheel Loader
1
Figure 8-141
1 bolt*8
3. Loose the four connecting bolts of condenser fan.
Notice
Pay attention to nuts inside.
4. After replacing with new fan, fasten the four
connecting bolts.
Notice
When assemble new fan, put the fan wire
harness on the upper right position.
1 2
5. Assemble condenser cover and fan to the
Figure 8-142
1 condenser fan bolt condenser.
2 fan wire harness
6. Recover machine.
8-59
Service Manual──LG958L Wheel Loader
8-60
Service Manual──LG958L Wheel Loader
8-61
Service Manual──LG958L Wheel Loader
8-62
Service Manual──LG958L Wheel Loader
8-63
Service Manual──LG958L Wheel Loader
8-64
Service Manual──LG958L Wheel Loader
8-65
Service Manual──LG958L Wheel Loader
16. Open the red and blue valves through the machine
connector and check the pressure at the speed of
the 1800rpm.
17. Disconnect the red and blue hoses from the
machine.
1 2
Figure 8-154
1 red hose
2 blue hose
8-66
Service Manual──LG958L Wheel Loader
When check and maintain the failures of the air condition system, you must according to the
abnormal phenomena to find out the reasons, and then take measures. The common failures of
air conditioning system are non-refrigeration, non-heating, insufficient refrigeration capacity and
so on.
8-66
Service Manual──LG958L Wheel Loader
8-67
Service Manual──LG958L Wheel Loader
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Service Manual──LG958L Wheel Loader
6. After replaced air condition components, connect the pipeline connectors. Tighten them in
accordance with required tightening torque as shown in Table 8-8.
Table 8-8 Tightening torque
Thread size Tightening torque
5/8-18UNF, M16×1.5 16~20Nm
8-69
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SERVICE MANUAL
Version:0920
9 Hydraulic System
CONTENTS
Ⅰ
Service Manual For LG958L Wheel Loader
9 Working Hydraulics
91 Working Hydraulics, Component
Positions
Figure 9-1
1 bucket cylinder 2 boom cylinders
3 multiway valve 4 pilot handle
5 steering radiating double pump 6 hydraulic oil tank
7 working pilot double pump 8 radiator
9-1
Service Manual For LG958L Wheel Loader
9-2
Service Manual For LG958L Wheel Loader
9-3
Service Manual For LG958L Wheel Loader
9-4
Service Manual For LG958L Wheel Loader
9-6
Service Manual For LG958L Wheel Loader
Figure 9-6
9-7
Service Manual For LG958L Wheel Loader
Technical parameters
Rated speed 2200 r/min
Rated pressure 200 Bar
Pilot pump displacement 16 ml/r
Steering pump displacement 100 ml/r
Radiating pump displacement 40 ml/r
Figure 9-7
1 pilot pump 2 steering pump
3 radiating pump 4 working pump
Figure 9-8
1 oil filling port 2 ventilation filter
3 oil return filter 4 oil level viewer 9-8
Service Manual For LG958L Wheel Loader
9-9
Service Manual For LG958L Wheel Loader
Reserved part Bucket slide valve part Boom slide valve part
Figure 9-9 Interior oil way of multiway valve
Figure 9-10
1 reserved part 2 bucket slide valve part 3 boom slide valve part
4 main relief valve 5 check valve 6 overload valve for bucket cylinder rod side chamber
7 overload valve for bucket cylinder piston side chamber 8 logical valve
9-10
Service Manual For LG958L Wheel Loader
Figure 9-11
1 control lifting of boom, a2 2 control backward tilt of bucket, a1
3 control the reserved part, a3 4 connect rod side chamber of bucket cylinder, B1
5 connect piston side chamber of bucket cylinder, A1
6 connect rod side chamber of the reserved part, B3
7 connect piston side chamber of the reserved part, A3
8 oil inlet port of multiway valve, P 9 control the reserved part, B3
10 control forward tilt of bucket, B1 11 control falling of boom, B2
12 oil outlet port of multiway valve, T 13 connect piston side chamber of boom cylinder, A2
14 connect rod side chamber of boom cylinder, B2
9-11
Service Manual For LG958L Wheel Loader
Figure 9-12
1 operate to lower the boom
2 operate to retract the bucket
3 operate pilot valve to return oil
4 operate to lift the boom
5 operate pilot valve to supply
6 floating port
7 operate the bucket to unload
4 a2 A2 lifting
Boom operating
part 1 b2 B2 falling
6 k A2, B2 floating
9-12
Service Manual For LG958L Wheel Loader
Figure 9-13
1 operate to lower the boom 2 operate to retract the bucket
3 operate pilot valve to return oil 4 operate to lift the boom
5 operate pilot valve to supply 6 floating port 7 operate the bucket to unload
Figure 9-14
1 oil outlet port, T 2 oil inlet port, P
3 connect to b3 port in multiway valve
4 connect to a3 port in multiway valve
9-13
Service Manual For LG958L Wheel Loader
Figure 9-17
9-14
Service Manual For LG958L Wheel Loader
Figure 9-18
1
Figure 9-19
1 maintenance cover plate
1
1 working pump oil outlet rubber pipe
Figure 9-21
1
Figure 9-22
1 flange joint
1
Figure 9-23
1 bolt
9-16
Service Manual For LG958L Wheel Loader
★ Notice
When disassemble the hydraulic connections, do not
1
Figure 9-26 loosen the connection bolts rashly and completely to
1 working pump oil outlet rubber pipe
avoid oil bursting out. Loosen them off slightly until
there is oil spills out, and then disconnect them
completely.
9-17
Service Manual For LG958L Wheel Loader
★ Notice
During the processes of hydraulic pipes disassembly,
1
Figure 9-27 all the pipelines and ports should be protected to
1 flange joint
avoid the debris entering into the pipelines.
1
Figure 9-28
1 working pump oil suction steel pipe
1
Figure 9-29
1 maintenance cover plate
9-18
Service Manual For LG958L Wheel Loader
Figure 9-32
9-19
Service Manual For LG958L Wheel Loader
Figure 9-33
Figure 9-34
1
Figure 9-35
1 maintenance cover plate
9-20
Service Manual For LG958L Wheel Loader
1
Figure 9-37
1 steering pump oil outlet rubber pipe
1 2
Figure 9-38
1 pilot pump oil outlet rubber pipe
2 joint
9-21
Service Manual For LG958L Wheel Loader
1
Figure 9-39
1 connecting bolts between steering pump
and gearbox Assembly of the Steering Pump
1. Assemble the steering pump to end face of gearbox
with four M12 nuts and washers and sealing
gasket.
1
Figure 9-40
1 connecting bolts between steering pump
and gearbox
1
Figure 9-41
1 steering pump oil outlet rubber pipe
9-22
Service Manual For LG958L Wheel Loader
1 2
Figure 9-42
1 pilot pump oil outlet rubber pipe
2 joint
1
Figure 9-43
1 steering pump oil suction steel pipe
1
Figure 9-44
1 maintenance cover plate
9-23
Service Manual For LG958L Wheel Loader
1 2 3
Figure 9-48
1 upper right guard board
2 lower right guard board
3 right stage
Figure 9-49
1
Figure 9-50
1 connecting bolt between silencer and
bellows
9-25
Service Manual For LG958L Wheel Loader
1
Figure 9-51
1 T-shape hold hoop
1
Figure 9-52
1 hose clamps
9-26
Service Manual For LG958L Wheel Loader
1 2
Figure 9-54
1 oil return rubber pipe of radiator
2 oil return rubber pipe of multiway valve
1 2 3
Figure 9-55
1 oil return rubber pipe of radiator motor
2 three-port joint
3 straight joint
9. Disassemble the hose clamps back-down side of
hydraulic oil tank.
1
Figure 9-56
1 hose clamp
9-27
Service Manual For LG958L Wheel Loader
1
Figure 9-57
1 ECU
1 2
Figure 9-58
1 hose clamp
2 oil-water separator
1
Figure 9-59
1 bolts
9-28
Service Manual For LG958L Wheel Loader
1
Figure 9-60
1 bolts
Assembly of Hydraulic Oil Tank
1. Assemble the tank on tank support with bolts.
1
Figure 9-61
1 bolts
1
Figure 9-62
1 bolts
9-29
Service Manual For LG958L Wheel Loader
1 2
Figure 9-63
1 hose clamp
2 oil-water separator
1
Figure 9-64
1 ECU
5. Fix the air filter inlet rubber pipe on the filter with
a T-shape hold hoop.
1
Figure 9-65
1 T-shape hold hoop
9-30
Service Manual For LG958L Wheel Loader
1
Figure 9-66
1 connecting bolt between silencer and
bellows
1
Figure 9-67
1 hose clamps
1 2 3
Figure 9-68
1 oil return rubber pipe of series pedal valve
2 oil return pipe of priority valve
3 oil return valve of prefill valve
9-31
Service Manual For LG958L Wheel Loader
1 2
Figure 9-69
1 oil return rubber pipe of radiator
2 oil return rubber pipe of multiway valve
1 2 3
Figure 9-70
1 oil return rubber pipe of radiator motor
2 three-port joint
3 straight joint
9. Assemble the hose clamps back-down side of
hydraulic oil tank.
1
Figure 9-71
1 hose clamp
9-32
Service Manual For LG958L Wheel Loader
Figure 9-72
11. Assemble the fixing bolts of oil tank left and right
guard boards; assemble the fixing bolts between
left and right stages and the tank support.
9-33
Service Manual For LG958L Wheel Loader
Figure 9-75
Figure 9-76
Figure 9-77
1
Figure 9-78 9-34
Service Manual For LG958L Wheel Loader
1 2 3
Figure 9-80
1 pilot control oil pipe for falling of the
boom
2 pilot control oil pipe for forward tilt of
bucket
3 pilot control oil pipe for reserved part
9-35
Service Manual For LG958L Wheel Loader
1 2
Figure 9-81
1 connect to boom cylinder rod side chamber
2 connect to boom cylinder piston side chamber
1 2 3 4
Figure 9-82
1 reserved part rod side rubber pipe
2 reserved part piston side rubber pipe
3 bucket slide valve part rod side steel
pipe
4 bucket slide valve part piston side steel
pipe
1 2
Figure 9-83
1 multiway valve oil inlet pipe
2 multiway valve oil outlet pipe
9-36
Service Manual For LG958L Wheel Loader
1
Figure 9-84
1 U-shape fixing bolts
12. Loosen the U-shape fixing bolts of bucket slide
valve part rod side and piston side steel pipes.
(Doesn’t need to be removed).
1
Figure 9-85
1 U-shape fixing bolt
1
Figure 9-86
1 U-shape fixing bolts
9-37
Service Manual For LG958L Wheel Loader
1
Figure 9-87
1 bolt Assembly of the Multiway Valve
1. Assemble straight joints in relevant oil port of
multiway valve, and then lift the valve on front
frame, insert two M12×165 and two M12×145
bolts from top to down, use gaskets and nuts to
fasten them.
1 Multiway valve
Figure 9-88
1 bolt
★ Notice
1 2
Figure 9-89 The O-ring side of transition body assembly should
1 multiway valve oil inlet pipe
2 multiway valve oil outlet pipe face down.
9-38
Service Manual For LG958L Wheel Loader
★ Notice
Adjust the direction of rubber pipe, keep it
1 2 3 4
Figure 9-90 horizontal.
1 reserved part rod side rubber pipe
2 reserved part piston side rubber pipe
3 bucket slide valve part rod side steel
pipe
4 bucket slide valve part piston side steel
pipe
1 2
Figure 9-91
1 connect to boom cylinder rod side chamber
2 connect to boom cylinder piston side chamber
9-39
Service Manual For LG958L Wheel Loader
1 2 3 4
Figure 9-92
1 pilot control oil pipe for reserved part
2 pilot control oil pipe for backward tilt of
bucket
3 pilot control oil pipe for floating of the
boom
4 pilot control oil pipe for lifting of the
boom
1 2 3
Figure 9-93
1 pilot control oil pipe for falling of the
boom
2 pilot control oil pipe for forward tilt of
bucket
3 pilot control oil pipe for reserved part
9-40
Service Manual For LG958L Wheel Loader
1
Figure 9-94
1 U-shape fixing bolts
1
Figure 9-95
1 U-shape fixing bolt
1
Figure 9-96
1 U-shape fixing bolts
9-41
Service Manual For LG958L Wheel Loader
1
Figure 9-97
Figure 9-98
Figure 9-99
9-42
Service Manual For LG958L Wheel Loader
Figure 9-100
Figure 9-101
Figure 9-102
9-43
Service Manual For LG958L Wheel Loader
Figure 9-104
1
Figure 9-105
1 boom cylinder front pin
9-44
Service Manual For LG958L Wheel Loader
Figure 9-106
1
Figure 9-107
1 front fender
1
Figure 9-108
1 boom cylinder rear pin
9-45
Service Manual For LG958L Wheel Loader
Figure 9-109
1
Figure 9-110
1 U-shape fixing bolts
1
Figure 9-111
1 fixing plate
9-46
Service Manual For LG958L Wheel Loader
1
Figure 9-112
1 boom cylinder rod side steel pipe
1
Figure 9-113
1 boom cylinder piston side steel pipe
Figure 9-114
9-47
Service Manual For LG958L Wheel Loader
1
Figure 9-115
1 boom cylinder piston side steel pipe
1
Figure 9-116
1 boom cylinder rod side steel pipe
1
Figure 9-117
1 fixing plate
9-48
Service Manual For LG958L Wheel Loader
1
Figure 9-118
1 U-shape fixing bolts
Boom cylinder
Figure 9-119
1
Figure 9-120
1 pin
9-49
Service Manual For LG958L Wheel Loader
1
Figure 9-121
1 boom cylinder rear pin
1 2
Figure 9-122
1 boom cylinder rod side rubber pipe
2 boom cylinder piston side rubber pipe
9. Smear some grease on boom cylinder front pin,
add a gasket, and then start the engine. Operate
pilot handle to adjust stroke of boom cylinder
piston rod, keep its connecting hole aligned with
the pin joint hole on boom, and connect them with
pin.
★ Notice
Be careful when assembling the boom cylinder,
1 the screw base on piston rod head should be on
Figure 9-123
1 pin outside; use proper numbers of gaskets to
ensure the clearance between piston rod head
end face and boom is within 0.5~1.5mm.
9-50
Service Manual For LG958L Wheel Loader
1
Figure 9-124
1 boom cylinder front pin
1
Figure 9-125
1 front fender
Figure 9-126
9-51
Service Manual For LG958L Wheel Loader
Figure 9-129
9-52
Service Manual For LG958L Wheel Loader
Figure 9-130
Figure 9-131
1
Figure 9-132
1 flat fender
9-53
Service Manual For LG958L Wheel Loader
1
Figure 9-133
1 limiting lay-flat holder
1
Figure 9-135
1 bucket cylinder rod side rubber pipe
9-54
Service Manual For LG958L Wheel Loader
1
Figure 9-136
1 pin
Figure 9-137
1
Figure 9-138
1 pin
9-55
Service Manual For LG958L Wheel Loader
1
Figure 9-139
1 bucket cylinder piston side oil inlet steel pipe
Assembly of the Bucket Cylinder
1. Put O-ring in O-ring groove of bucket cylinder
piston side steel pipe, and fix the pipe on piston
side oil port with two M10×50 and two M10×55
bolts and gaskets separately.
1
Figure 9-140
1 bucket cylinder piston side oil inlet steel pipe
9-56
Service Manual For LG958L Wheel Loader
Figure 9-142
1 2
Figure 9-143
1 bucket cylinder rod side rubber pipe
2 bucket cylinder piston side rubber pipe
1
Figure 9-144
1 pin
9-57
Service Manual For LG958L Wheel Loader
1
Figure 9-145
1 flat fender
8. Assemble the connecting bolts between limiting
lay-flat holder and bucket cylinder.
1
Figure 9-146
1 limiting lay-flat holder
Figure 9-147
9-58
Service Manual For LG958L Wheel Loader
Figure 9-148
947 Disassembly and Assembly of
Quick-change Cylinder
Disassembly of Quick-change Cylinder
1. Operate pilot handle to separate quick-change
device from bucket. Stop the machine and load off
brake system by stepping brake pedal again and
again.
2. Put clean vessel under the cylinder to contain oil.
Figure 9-149
1
Figure 9-150
1 cover plate
9-59
Service Manual For LG958L Wheel Loader
★ Notice
When disassemble the hydraulic connections, do not
loosen the connection bolts rashly and completely to
avoid oil bursting out. Loosen them off slightly until
there is oil spills out, and then disconnect them
completely.
During the processes of hydraulic pipes disassembly,
1 2 all the pipelines and ports should be protected to
Figure 9-151
1 rubber pipe avoid the debris entering into the pipelines.
2 rubber pipe
1
Figure 9-152
1 slip shaft
1 2
Figure 9-153
1 bolts
2 support
9-60
Service Manual For LG958L Wheel Loader
1
Figure 9-154
1 slip shaft
Figure 9-155
Figure 9-156
9-61
Service Manual For LG958L Wheel Loader
Figure 9-157
2. Put the cylinder in the support, the end with rubber
pipe connector should towards right. Connect the
cylinder left to slip shaft with a pin, and then
assemble the ring.
1
Figure 9-158
1 slip shaft
1 2
Figure 9-159
1 bolts
2 support
9-62
Service Manual For LG958L Wheel Loader
1
Figure 9-160
1 slip shaft
5. Assemble rubber pipe 1 and 2.
1 2
Figure 9-161
1 rubber pipe
2 rubber pipe
1
Figure 9-162
1 cover plate
9-63
Service Manual For LG958L Wheel Loader
Figure 9-165
9-64
Service Manual For LG958L Wheel Loader
Figure 9-166
1
Figure 9-167
1 shell plate
1
Figure 9-168
1 upper cover
9-65
Service Manual For LG958L Wheel Loader
★ Notice
When disassemble the hydraulic connections,
do not loosen the connection bolts rashly and
completely to avoid oil bursting out. Loosen
them off slightly until there is oil spills out, and
then disconnect them completely.
Figure 9-169 During the processes of hydraulic pipes
disassembly, all the pipelines and ports should
be protected to avoid the debris entering into
the pipelines.
Figure 9-170
1
Figure 9-171
1 bolt
9-66
Service Manual For LG958L Wheel Loader
Figure 9-173
1
Figure 9-174
1 bolt
9-67
Service Manual For LG958L Wheel Loader
★ Notice
Straighten out the pipes, avoid interference and
do not distort them.
Figure 9-175
Figure 9-176
1
Figure 9-177
1 upper cover
9-68
Service Manual For LG958L Wheel Loader
1
Figure 9-178
1 shell plate
9-69
Service Manual For LG958L Wheel Loader
Figure 9-181
1
Figure 9-183
1 shell plate
1
Figure 9-184
1 upper cover
9-70
Service Manual For LG958L Wheel Loader
1
Figure 9-185
1 bolt
7. Disconnect the two lateral oil pipes of triple
operating valve control handle assembly, and then
take down the pipes, bolts and gaskets.
★ Notice
When disassemble the hydraulic connections,
do not loosen the connection bolts rashly and
completely to avoid oil bursting out. Loosen
them off slightly until there is oil spills out, and
then disconnect them completely.
1 2
Figure 9-186 During the processes of hydraulic pipes
1 oil return pipe of triple operating valve disassembly, all the pipelines and ports should
2 oil inlet pipe of triple operating valve
be protected to avoid the debris entering into
the pipelines.
1 2
Figure 9-187
1 connect to multiway valve control oil port
2 connect to multiway valve control oil port
9-71
Service Manual For LG958L Wheel Loader
1
Figure 9-188
1 bolt
1
Figure 9-189
1 straight joint
1
Figure 9-190
1 straight joint
9-72
Service Manual For LG958L Wheel Loader
1
Figure 9-191
1 bolt
1 2
Figure 9-192
1 connect to multiway valve control oil port
2 connect to multiway valve control oil port
Tightening torque: 70 ~ 85 Nm
1 2
Figure 9-193
1 oil return pipe of triple operating valve
2 oil inlet pipe of triple operating valve
9-73
Service Manual For LG958L Wheel Loader
1
Figure 9-194
1 bolt
6. Assemble fixing bolts of operation box upper
cover.
1
Figure 9-195
1 upper cover
7. Assemble fixing bolts of operation box shell plate.
1
Figure 9-196
1 shell plate
9-74
Service Manual──LG958L Wheel Loader
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Service Manual──LG958L Wheel Loader
chamber to multiway valve to find out whether there are obvious external leakage phenomena
exist.
2. If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multiway valve bucket slide vale part. At this point, if the unexpected
forward tilt phenomenon disappeared, then we can come to a conclusion that the fault is caused
by pilot valve, which causes multiway valve bucket slide vale part fails to go back to neutral
position. Disassemble and clean the pilot valve or replace it. Otherwise, check the third
situation.
3. For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lower the boom to lowest position, and retract the bucket to its extreme position, and
then shut down the engine, disconnect bucket cylinder piston side rubber pipe and diver it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to backward tilt the
bucket, observe whether there is oil comes out from piston side oil port continually. If there is,
which means server inner leakage exists in bucket cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth and fifth situations.
4. For the fourth and fifth situations, method of pressure detection can be used: Connect a
0-250Bar pressure gauge to gauge port of bucket cylinder piston side chamber. Start the
machine and operate pilot valve handle to extend the bucket to its extreme position; step on the
gas and operate pilot valve handle to lift the boom, at the same time, check whether the reading
on the gauge reach the design value when the boom is lifting. If not, either situation
mentioned in the first place is possible, the overload valve or oil compensation valve for bucket
cylinder piston side chamber need to be checked and cleaned.
5. If situation 1 to situation 5 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multiway valve bucket slide valve
part, look through the valve rod, valve opening and their fitting situation.
6. Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
9-77
Service Manual──LG958L Wheel Loader
Fault analysis: When the boom is lifted and stays in a certain height, the boom cylinder piston side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston side
chamber, the boom will fall automatically.
Six situations can cause the leakage in piston side chamber of boom cylinder:
1. Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston side
chamber to multiway valve.
2. Multiway valve boom slide vale part fails to go back to neutral position (due to valve rod gets
stuck, valve element of pilot valve cannot reset or there are defects exist in the valve body, such
as sand holes and grooves), which cause boom cylinder rod side chamber connect to pump, or
piston side chamber connect to oil return port.
3. While inner leakage exists in boom cylinder, leakage also exists from rod side chamber to oil
outlet port.
4. Malfunctioned selector valve of control oil combination valve, (may caused by machining
defects, jammed valve element, inner leakage of pilot valve or defects exist in the valve body,
such as sand holes and grooves), which make selector valve element fail to cut off the channel
between boom cylinder piston side chamber and combination valve and pilot valve, result in
leakage in piston side chamber of boom cylinder.
5. Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
Diagnosis and solutions:
1. Six situations that cause leakage are listed above and the simplest and easiest to diagnose is the
first one: Start the machine and lift the boom to a certain height, and then observe the pipelines,
joints and fitting surfaces from the piston side chamber to multiway valve to find out whether
there are obvious external leakage phenomena exist.
2. If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multiway valve bucket slide vale part. At this point, if the boom
sinking phenomenon disappeared, then we can come to a conclusion that the fault is caused by
pilot valve, which causes multiway valve boom slide vale part fails to go back to neutral
position. Disassemble and clean the pilot valve or replace it. Otherwise, check the third
situation.
3. For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lift the boom to highest position, and retract the bucket to its extreme position, and
9-78
Service Manual──LG958L Wheel Loader
then shut down the engine, disconnect boom cylinder piston side rubber pipe and divert it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to lower the boom,
observe whether there is oil comes out from piston side oil port continually. If there is, which
means server inner leakage exists in boom cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth situation.
4. For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lift the boom to highest position, and then shut down the engine. Open pilot valve oil
return port, observe whether there is oil comes out. If there is, which means inner leakage of
pilot valve causes the fault, the pilot valve needs to be repaired or replaced. Otherwise; If there
is not, then open combination valve oil return port and check whether there is oil comes out, if
there is, which means inner leakage of combination valve causes the fault, the combination
valve needs to be repaired or replaced.
5. If situation 1 to situation 4 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multiway valve boom slide valve
part, look through the valve rod, valve opening and their fitting situation.
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7. Low adjusting pressure of multiway valve main safety valve (may caused by damaged pressure
adjusting spring, valve element stuck in open position, or there are defects exist in the valve
body, such as sand holes and grooves that connect to oil return chamber).
8. Severe inner leakage exists between oil inlet channel an oil return channel of multiway valve
body (caused by sand hole or breakage of valve body).
9. Excessive wear of selector valve rod or valve opening of multiway valve boom slide valve part,
which result in fit clearance between valve body and valve element is far more than design
value.
10. Insufficient opening of multiway valve (due to selector valve rod gets stuck, valve element of
boom cylinder piston side pilot valve cannot reset or there are sand holes and grooves exist in
the valve body, or low setting pressure of combination valve that result in insufficient pilot
pressure).
Diagnosis and solutions:
1. For all situations mentioned above, firstly, we should start the machine and lift the boom, check
out whether there is obvious external leakage exists in pipelines, joints and fitting surfaces from
working pump to boom cylinder piston side chamber.
2. If there is no severe external leakage, then basic inspection should be done: Whether the
hydraulic oil level is above “LOW” level, whether there is too much bubble in hydraulic oil or
the oil turns black. Add hydraulic oil if necessary; if the oil turns bad, clean the tank and the
whole hydraulic system, and then replace the oil.
3. If the hydraulic oil is good, then start the machine and operate pilot handle to retract the bucket,
at the same time, listen carefully and check whether there is screaming in working pump. If
there is, which means the pump have severe oil suction problem, check and clean oil suction
filter and rubber pipes.
4. If there is no screaming phenomenon, check the forth situation: Start the machine, operate the
pilot valve to load the pump for 1-2 minutes, then shut down the engine; carefully touch the
shell of working pump, if it feels too hot, then we can come to a conclusion that severe inner
leakage exist in working pump, which causes the oil shortage problem.
5. For the fifth to ninth situations, we need to do some simple tests first: Connect a 0-25Bar
pressure gauge to gauge port of multiway valve P port. Start the machine and operate pilot
valve handle to pressurize the hydraulic system, at the same time, check whether the reading on
the gauge reach the design value. If not, check situation 5 to 9 one by one.
6. For the fifth situation, start the machine and operate pilot valve handle to lower the boom to
lowest position, and retract the bucket to its extreme position, and then shut down the engine,
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disconnect boom cylinder piston side rubber pipe and divert it to hydraulic oil tank. Start the
machine again, operate the pilot valve handle to lower the boom, observe whether there is oil
comes out from piston side oil port continually. If there is, which means server inner leakage
exists in boom cylinder, the cylinder needs to be repaired or replaced.
7. For situation 6: Shut down the engine and operate pilot valve handle to lower the boom to
lowest position, then reverse the check valve between boom cylinder piston side chamber and
combination valve.
8. For situation 7: Check and clean main safety valve, if there is irreparable damage for valve
element or valve body, please replace the safety valve.
9. If situation 5 to 7 are being excluded and the system pressure still fails to reach design value,
then focus on situation 8 and 9. Disassemble multiway valve boom slide valve part, look
through the valve rod, valve opening and their fitting situation.
10. If the hydraulic system pressure reaches design value but the boom still lifting slow, check the
tenth situation:
a) Operate pilot valve handle to lower the boom and bucket to their lowest positions, and then
open the spring-free end cover(the one with short axial dimension) of multiway valve
boom slide valve part, force the valve rod to do axial movement, check whether the rod can
get to the right positions, whether it can return to neutral position smoothly.
b) Exchange control oil pilot pipes of bucket slide valve part and boom slide valve part, then
start the machine and operate pilot valve, check whether the boom can be lifted normally.
If it turns normal, check and clean pilot valve of multiway valve boom slide valve part.
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3. Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element ).
4. Severe inner leakage exists between oil inlet channel an oil return channel of multiway valve
body (caused by sand hole or breakage of valve body), due to that the system cannot build up
pressure or the system pressure cannot reach design value.
Diagnosis and solutions:
Focus on the four reasons mentioned above and refer to 9.5.3 Boom Lifting Slow for
troubleshooting.
Symbols Explanations
Pipelines
Pipeline joints
Inserted joints
Restraint unit
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Symbols Explanations
Accumulator
Heat exchanger
Control equipment
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Symbols Explanations
Hydraulic control
Pneumatic control
Power source
Electric motor
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Symbols Explanations
Pump
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Motor
Symbols Explanations
Hydraulic cylinder
Valve
Shuttle valve
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Symbols Explanations
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Application
The symbols above show line connection, flow channel
and the components’ function, but they don’t indicate the
component structure.
In hydraulic symbols, the valve always pictured in neutral
Valve symbol
position.
Valve symbol
Square is the basic element for valve symbol. A square
represents a position that valve moveable part (sliding part
valve body
Closed valve
Neutral position
The moveable part of the valve is centered in neutral
position by spring force, the inlet ports are connected to
outlet ports through the moveable part.
1 oil inlet port of the valve
2 oil outlet port of the valve
Figure 9-197 Neutral position
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