Treinamento de Servicos Lg958 Eng Rev1-2010

8/17/2019 Treinamento de Servicos Lg958 Eng Rev1-2010

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Technical Training

LG958 Wheel Loader


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SDLG Information

Linyi – Shandong Area: 650.000 m²

Employees: 2200

Production: 20.000 units /year

Since: 1972

SDLG in China:


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SDLG Information


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In 1972:

• SDLG was built• First ZL40

SDLG Information


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• SDLG Relocation

• Improvement of

production capacity

In 2005:

• In 2006: VolvoCE investment

SDLG Information


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WLO models:

• LG918

• LG933

• LG936

• LG938

• LG956

• LG958

SDLG Information


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Test Track:

• All equipment are tested

• Transmission, Engine, Electric

and Hydraulic functions are proved

• 45° ramp

SDLG Information


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28,155

27,363

21,321

16,708

16,305

9,649

9,079

7,800

8,575

7,457

7,159

5,259

3,300

2,600

1,700

Longgong

Liugong

XGMA

Caterpillar

SDLG

SEM

XCMG

Volvo

Komatsu

Chenggong

Foton

Changlin

CNH

JCB

Kawasaki

SDLG is among the 5

world’s largest wheelloader manufacturers

SDLG Information


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Lingong

WLO

Nominated load

Power train version

L

G9

5

8


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LG 958


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Specifications – Performance

LG 958

• Rated Power: 162kW / 217HP (2200 r/min)

• Travel Speed:

- Forward 1st: 0~12,3 km/h

2st: 0~40,5 km/h

- Reverse 1st: 0~16,1 km/h

• Total Time of the cycle: ≤ 11,3 s

- Lifting Time (full load): ≤ 6,4 s

- Lowering Time (empty bucket):≤

3,6 s- Dumping Time (empty bucket): ≤ 1,3 s


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LG 958

• Operation Weight: 16900 kg

• Rated Load: 5000 kg

• Bucket Capacity: 3,0 m³

• Max Breakout Force: ≥ 180 kN

• Max Traction Force (engine): ≥ 160 kN

• Max Tipping Load: ≥ 110 kN

• Tire Charge Pressure:

- Front: 0,39 ± 0,01 MPa (3,9 ± 0,1 bar)

- Rear: 0,33 ± 0,01 MPa (3,3 ± 0,1 bar)


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LG 958

• Length: 8079 mm

• Width: 3024 mm

• Height: 3382 mm

• Max Dumping Height: 3180 mm

• Max Climbing Angle: 30º

• Dumping Angle:≥

45º• Dumping Space: 1090 mm

• Wheel Track: 2190 mm

• Wheel Base: 3200 mm

• Min Ground Clearence: 457 mm

• Min Turning Radius: 6036 mm

• Level Passing Radius: 6746 mm

• Max Turning Angle: 38º


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Engine Weichai

WD10G.220

Transmission Electric-hydraulic 4WG200

power shift (Forward IV / Reverse III)

Lingong Axle

Specifications

LG 958


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Engine

SDLG Loaders


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Engine WD10G.220

Emission standard

843Max torque (N·m)

228Min. Fuel consumption ratio (g/kW·h)

126/130Bore/stroke (mm)

6Cylinder

10Displacement (L)

2200Rated speed (rpm)

162Rated power (kW)

• Inline water cooling

• Direct injection

• Turbocharged

Type

WD10G.220Model


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Specifications

Engine WD10G.220

• 6 cylinders in line

• Explosion order: 1-5-3-6-2-4

• Compression ratio: 17:1

• Air intake method: turbocharged

• Lubrication method: pressure lubrication

• Rated fuel consumption: ≤ 228 g/kW.h

• Rated oil fuel – consumption ratio: ≤ 0,5 %

• Oil capacity (oil sump): 20 L

• Working oil pressure: 3,5~5,5 bar

• Starting method: electric starting


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Over view right side

Engine WD10G.220

• Turbocharger

• Air filter

• ID plate


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Over view left side

Engine WD10G.220

• Thermostat

• Relief valve

• Fuel water

separator filter

• Fuel filters

• Air

compressor


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Name explanation

Engine WD10G.220

W D 6 10 G .220

Application code (G stands for construction machinery)

Single Cylinder Displacement (10 reffers to 1,0 liters)

Number of Cylinders

Diesel Engine

Water-cooled

Sequence Number


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Construction

Engine WD10G.220

• Cylinder Block • Crankshaft


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Construction

Engine WD10G.220

• Injectionpump gear

• Intermediate

gear

• Crankshaftgear

• Camshaftgear

• Water pump

carapace


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Construction

Engine WD10G.220

• Cone ring

• Ladder ring

• Oil ring

• Piston

• Connectingrod tile

• Connecting

rod

• Connecting

rod bush

• Piston pin


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Construction

Engine WD10G.220

• First ring: trapezoidal ring, “TOP” mark

• Second ring: conical ring, “TOP” mark

• Third ring: assembled oil ring, with spiral ring

• Aluminum casted part

• First and second rings have directions when mounting (“TOP” mark faces up)


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• Connecting rod bolts canbe used only once, otherwise

serious accidents may occur

• Compression piston rings

have top marks for correct

mounting

• Connecting rods have

matching marks

• Connecting rods bolts are

disposable

• Cylinder

sequence mark

• Weight

grouping mark

• Block andhead matching

mark

Construction

Engine WD10G.220


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PTO

Engine WD10G.220


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Valve adjustment

Engine WD10G.220

• Remove valve cover plate

• Remove the plate that give

access to flywheel

• Turn the flywheel positively to

TDC of cylinders 1 and 6

• Put cylinder 1 in overlap


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Valve adjustment

Engine WD10G.220

• Sequence of valve adjusting

• It is possible to reach the requirement by adjusting bolt of the rocker


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Valve adjustment

Engine WD10G.220

Clearance:

- Admission valve: 0,30 mm - Exhaust valve: 0,40 mm


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Lubricant flow

Engine WD10G.220

• Working pressure: 3,0~6,0 bar

• Pressure limiting valve (10 bar)


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Lubricant flow

Engine WD10G.220

• Oil strainer

• Oil pump

• Main passage

relief valve

• Oil filter

• Turbocharger

• Air compressor • Fuel pump

• Oil cooler


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Cooling system

Engine WD10G.220

• Schematic diagram

• This part belongs to the engine (short cycle)


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Cooling system

Engine WD10G.220


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• Water pump

• Centrifugal pump, two water intakes, one connected to radiator and the

other connected to thermostat for minor cycle when water’s temperature is

lower than 71 ºC.

• Water pump is

mounted on the front of

the engine

• Water comes from the

right water tank of the

cylinder block and enters

into the oil cooler

Cooling system

Engine WD10G.220


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Cooling system

Engine WD10G.220

- Starts to open at 71±2 ºC

- Fully open at 82ºC

• Thermostatic valve closed (watergoes directly to water pump – short

cycle)

• Thermostatic valve opened (watergoes to radiator)

• Wax type


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• Tank

• Filters

• Supply Pump

• Injection Pump

• Drain

Fuel supply

Engine WD10G.220


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Engine WD10G.220

Fuel supply

• Injector

assembly

• Connector

• Oil return pipe

• High pressurefuel pumps

• Injectionpump

• Fuel supplying sequence: 1-5-3-6-2-4

• Opening pressure: 225 bar


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1. Fuel from the fuel tank

2. Fuel delivery pump3. Fuel filter

4. Fuel delivery pipe

5. Air-limiting pipe of fume limiter

(only in supercharger)6. Fuel injection pump

7. High pressure fuel pipe

8. Injector

9. Fuel returning pipe of injector

10. Fuel pipe back to the fuel tank

Fuel supply

Engine WD10G.220


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• Fuel injection pump • Fuel pumping system

Engine WD10G.220

Fuel supply


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Engine WD10G.220

Turbocharger


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Transmission

SDLG Loaders


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Transmission system

Specifications

1.4~1.6Gearshift pressure (MPa)

Inside gearboxVariable-speed pump model

4 forward, 3 reverseGears

Fix shaft, electric-hydraulic power

shiftType

ZF 4WG200Model

0.5Outlet oil pressure (MPa)

0.85Inlet oil pressure (MPa)Cycle water coolingOil cooling method

2.55Modulus of converter

Single phase/

3 elements/ HydraulicType


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• Planetary power shift

• Four forward shifts, three reversegear

• Working pressure

• Low pressure warning light in

dashboard: ≤

• Input pressure to toque converter:

• Output pressure from torqueconverter:

Transmission system

Specifications

T i i t


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Transmission system

Specifications – 4WG200 Series

T i i t


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Transmission system

Oil supply flow

T i i t


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Transmission system

Specifications – 4WG200

T i i t


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• Transmission Pump

• Pump input fromtransmission oil

sump

• Pump output to filter

transmission

Transmission system

Pump connections

Transmission system


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• Torque

coverter

• Transmission

oil cooler

• Hydraulic Pump

• Inlet

• Output to

transmission filter

• Inlet to transmission

• To oil cooler

• Control valve

• Transmission Filter

• To transmission

pressure gauge

• Sump

• Engine

radiator

• Inlet to transmission

Transmission system

Pump connections

Transmission system


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• Shift rod

• Transmission Cutoff

(pneumatic)

• Backup switch

• Pressure measure

Transmission system

Functions

Transmission system


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• Pressure

regulation valve

• Shift spool

• Pneumatic

cutoff valve

R1 F2 F1

Transmission system

Gear selector box

Transmission system


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• Gear Shift- F / R 1 – 2 – 3 - 4

• Front

• Neutral• Rear

• Lever Lock

Transmission system

Gear selector box

Transmission system


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Transmission system

Oil check and drain

Transmission system


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Transmission system

Transmission oil filter


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Axle System

SDLG Loaders

Axle system


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Axle system

Main view

Axle system


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Axle system

Main view

Axle system


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Axle system

Main view

• Trunnion system

Axle system


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Axle system

Construction

Axle system


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Axle system

Main view

Axle system


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y

Advanced material


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Hydraulic System

SDLG Loaders

Hydraulic System


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y y

Pressure and connections

MPA BAR

Working Hydraulic Pressure (relief valve) 17,5 175

Working Hydraulic Pressure (safety valve) 17,5 175Safety Valve (ti lt - ) 20,5 200

Safety Valve (ti lt + ) 12 120

Pilot pressure (joystick) 1,8 to 3,2 18 to 32

Steering System working pressure 16 160

Brake (air system) 0,784 7,84Brake (hydraulic system) 14 140

Transmission oil pressure 1,4 to 1,6 14 to 16

Torque converter oil pressure (inlet) 0,85 8,5

Torque converter oil pressure (outlet) 0,5 5

Tyres pressure (Rear/Front) 0,33 / 0,39 3,3 / 3,9

LG958

Hydraulic System


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• Hydraulic pilot control

• Gear main hydraulic pump

• Open center system

• Relief pressure: 175 bars (reliefvalve in MCV)

• Gear servo pump

• Servo pressure: 23 bars

• Hydraulic tank capacity: 210 L

y y

Specifications

Hydraulic System


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y y

Main components - Tank

Hydraulic System


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• Steering Pump• Main HydraulicPump

• Servo Pump

Main components - Pumps


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Hydraulic System


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•Servo Pump

Main components – Pumps

•Steering pump

Model = JHP2100/Gj0010C-XF

Flow = 104,9 ml / rpm

PN = 4120001969

Hydraulic System


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Main components – Main pump

• OUTPUT

• INPUT • PUMP

Model = JHP3160C

Flow = 167,9 ml / rpm

PN = 4120001968

Hydraulic System


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Main components – Oil cooler

•Foto do radiador de oleo

Hydraulic System


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Pumps flow

• Working Pump = 167,9 ml / R

• Servo Pump = 10 ml / R

• Steering Pump = 105 ml / R

• Working / = 4120001968

• Steering / Servo. = 4120001969

Hydraulic System


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• Tilt tubes

• Lift tubes

• Extra function

Main components – MCV

• Return/ drain

Lift spoolTilt spoolExtra spool

Hydraulic System


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Base – 200 bar

Main Safety valve

175 bar


Rod – 120 bar

Hydraulic System


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Hydraulic System


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Diagram

1. Work pump

2. Hydraulic oil tank3. Pressure select valve

• Pilot control

and flowenlarge

hydraulic

system

4. Double units pump

5. Flow enlarge pump6. Steering cylinder

7. Redirector

8. Pilot valve

9. Multi-way valve

10. Lift arm cylinder 11. Bucket cylinder

Hydraulic System


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Diagram


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Steering System

SDLG Loaders

Steering System


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Specifications

Type Loading sensing hydraulic articulatedsteering

Steering pump CBGj2100/Gj0010C-XF

Redirector BZZ6－800

Steering angle ( º) 38º

Steering pressure (MPa) 16

Steering System


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• Load sensing hydraulic system

• When steering, the system

supplies oil rather the steeringhydraulic system than the working

equipment

• Steering hydraulic system

independent from load-sensinghydraulic system

• Open center

• Working pressure 160 bar

Specifications


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Steering System


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Components

Steering System


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• Steering gear pump

Pump

•Obter o flow com a china

Steering System


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OF: to orbitrol

EF: to oil cooler

LS: from orbitrol Drain

From hydraulic

pump

Priority Valve

Steering System


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• Steering cylinders

• Right Cylinder positive side is connected to the Left Cylinder negative side

• Articulation pin

Steering cylinders


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Electrical System

SDLG Loaders

Electrical System•Trocar esta foto


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• 24 V system

• 2 batteries of 12 V in series

• 120 Ah batteries

Specifications

Electrical System


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• Main switch

• Located in the right battery

compartment

• Rotate the anode switch clockwise

to turn on state of power • Never turn off the anode switch with

the engine running

Components

Electrical System

C t


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• 24V Alternator

• 35 Amperes

• Electronic voltage regulator • Voltage cutoff 28,4 V

• Wire to hour meter

Components

Electrical System

C t


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• New auxiliary relay:

protects the starter motor

Components

Electrical System

St t di


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Start diagram

Electrical System

C t


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• Located in the right side of the

steering column

• Three extra switches on the cover

Components

Electrical System

C t


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• Coolant sensor temperature • Engine oil sensor pressure

Components

Electrical System

Components


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• Brake light switch • Neutral switch

Components

Electrical System

Components


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• Torque converter's oil temperature • RPM sensor (over transmission)

Components

Electrical System

Components


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• Air filter indicator • Air pressure sensor • Air pressure switch

Components

Electrical System

Components


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Bucket approach switch

Arm approach switch

Components

Electrical System

Components back up alarm


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Components – back up alarm

Electrical System

Components – levels


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Solenoid in joystick

(when the bucket reachesleveling point, it deactivate the

solenoid)

Components – levels

Electrical System

Components – air monitoring


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Components – air monitoring

Electrical System

Air supply monitoring


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Air supply monitoring

Electrical System

Power system principle


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Power system principle

Electrical System

Advanced material


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Advanced material


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•Link para o diagrama eletrico


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Brakes System

SDLG Loaders

Brakes System

Overview


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• Dry type

• Four wheels caliper disk brake system

• Pneumatic system (pressure oil: 140 bar)

Overview

Brakes System

Components


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• Relief valve

• Max pressure: 7,5 bar

• Low pressure alarm: 4,0 bar

• Air compressor

• Lubrication made from

engine oil main gallery

• Camshaft driven

p

Brakes System

Components – Air intake


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• The air intake for air compressor comes from the air filter p

Brakes System

Components - Booster


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p

Brakes System

Components - Booster


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p


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Brakes System

Components – Air reservoir


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• Pressure switch and

sensor

• Air pressureoutput

• Air pressuremeasurement

connection

• Inlet

Brakes System

Brake diagram – single pedal


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• Brake Lamp

• Air Reservoir

• Brake Booster (rear)

• Brakeconnector

• Brake Booster

(front)

Brakes System

Brake diagram – double pedal


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1.Air booster pump 2. Shuttle valve 3. Air brake valve 4. Air tank

5. Combination valve of oil water separator 5. Air compressor

7. Brake electromagnetic valve 8. Parking brake air chamber

Front axle valve

Rear axle valve

Brake

Brake and

transmissioncutoff

Brakes System

Pads and caliper


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• Four brake calipers for front and

rear axle

Brakes SystemParking brake


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• Two different way:

- Hydraulic clamping discbreaking system

- Hydraulic pin steering

system

• Both systems activated bycompressed air electronically

controlled

Brakes SystemParking brake - safety


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Pneumatic system:

• Activation: Spring

• Deactivation: Air pressure

(when lower than 4,0 bar)

Security issue


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CAB System

SDLG Loaders

• Electric

CAB SystemGeneral overview


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• Pilot control

• Left break

pedal

• Gear shift

Electric

horn • Panel

• Right break

pedal

• Accelerator

2.

CAB SystemPanel and instruments


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1. Transmission Oil Pressure

2. Brake Air Pressure

3. Hour meter

1.

2.

3.

2



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1. Tachometer

2. Information / Warning Lamps

1.

2.

CAB SystemPanel and indicating lamps


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• Pre-heat

indicator

• Oil pressure

alarm

• Charging

indicator

• Power cut

off indicator

• Emergencyturn indicator

• ParkingBrake

• Brake air

Pressure

• High Beam • Computer

Box working

• FuelCoarse Filter



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• Forward and Backward

li ht it h• Water Jet



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lights switches

• Rain Brush Switch



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• Hydraulic functions of the working equipment

CAB SystemPanel and instruments – Air conditioner


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• Avoid setting the temperature control switch on the coolest position and the power

switch on L. The low air flow at this temperature may cause frost the evaporator

• Working

indicator lamp

• Air volume andpower switch

• The switch to

control the

temperature



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• Engine cut off

• Pull up to cut off the engine• Connected to the injection

pump

• Engine turning on

• Rotate the key clockwise toturn on the electrical system

and then the engine



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• A/C

• Parking brake• Engine cut off

• Hydraulic

functions

CAB SystemPanel and controls


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• Gear Shift

- F / R 1 – 2 – 3 - 4

• Front

• Neutral

• Rear • Lever Lock

CAB SystemSEAT


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• German GRAMMER Seat

CAB SystemGeneral overview


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• Four rubber cushion

• Dampening

• More comfort in operation

CAB SystemOptional ROPS & FOPS


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Maintenance Program

SDLG Loaders

MaintenanceLevel – Hydraulic system


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MaintenanceLevel – engine oil


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High

Low


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MaintenanceSpace


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• Lift-up engine hood, convenient in maintenance

MaintenancePreventive Maintenance

Part number Description Qty 100 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000

4110000560008 Filter Oil (Engine) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4110000108003 Filter Air (Engine) 1 1 1 1 1 1

Number of hoursLG918


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4110000108003 Filter Air (Engine) 1 1 1 1 1 1

4110000563002 Filter Fuel (Engine) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4110000563003 Filter Fuel Water Separator (Engine) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4110000508 Filter Oil (Torque converter) 1 1 1 1 1 1

4110000218001 Filter Oil (Transmission) 1 1 1 1 1 129100006611 Filter Oil (Returning Hydraulic) 1 1 1 1 1 1

4120000452 Filter Oil (Hydraulic Tank) 1 1 1 1 1 1

29100006621 Filter Oil (Hydraulic Sucction Line) 1 1 1 1 1 1

4120001954001 Filter Oil (Hydraulic) 1 1 1 1 1 1

15W40 Engine oil 13 liters 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

15W40 Transmission 45 liters 1 1 1 1 1

DOT3 Brake fluid 4 liters 1 1 1 1 180W90 - GL5 Axles oil 16 liters 1 1 1 1 1

ISO46* Hydraulic Oil 100 Liters 1 1

Glicol** Anti Freezing 1 1 1 1

GREASE Base Lithium - Extreme Pressure NLGI 2

Indent Numbers

E1805215A39

E1805215AK6

E1805215AK9

* Temperature from -30º to 40º HVI - ISO46** Usage percentage according O&M

MaintenanceSystem Pressure

MPA BAR

Working Hydraulic Pressure (relief valve) 17 5 175

LG958


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Working Hydraulic Pressure (relief valve) 17,5 175

Working Hydraulic Pressure (safety valve) 17,5 175

Safety Valve (ti lt - ) 20,5 200Safety Valve (ti lt + ) 12 120

Pilot pressure (joystick) 1,8 to 3,2 18 to 32

Steering System working pressure 16 160

Brake (air system) 0,784 7,84

Brake (hydraulic system) 14 140Transmission oil pressure 1,4 to 1,6 14 to 16

Torque converter oil pressure (inlet) 0,85 8,5

Torque converter oil pressure (outlet) 0,5 5

Tyres pressure (Rear/Front) 0,33 / 0,39 3,3 / 3,9

2009 X 2010 Main changes


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2009 X 2010 Main changes

SDLG Loaders

ImprovementsTransmission pressure gauge


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Direct feeling type Inductance typefiltration joint is

added on sensor

which reduces

sensor problems

caused by oil

pollution

ImprovementsSpeedometer X tachometer


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OLD Speedometer New tachometer

ImprovementsNew radio


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OLD New + USB

ImprovementsHour meter


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OLD New

ImprovementsStarting switch


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OLD New

more

fi l

Improvements Approach switch and relays


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firmly

fixedswitch

New auxiliaryrelay,

effective in

avoiding

instand

voltage surge

New auxiliary

ImprovementsBattery relay and starting relay


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New auxiliary

relay, higherin reliabillity

Auxiliary relay,well-fit with

engine,

effictive in

protectingstarting motor.

Reliable VDO

b t

ImprovementsSensors


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barometer

and sensoradopted.

inductive loading fly-wheel diode，

effective in protecting

electrial components

when instand voltage

surge happens

Rotating radiator, more convenient for cleaning and maintenance.

ImprovementsConvenience and maintenance


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Thank you!

[email protected]

Treinamento de Servicos Lg958 Eng Rev1-2010

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Transcript of Treinamento de Servicos Lg958 Eng Rev1-2010