Technical Training LG958 Wheel Loader
SDLG Information SDLG in China: Linyi – Shandong Area: 650.000 m² Employees: 2200 Production: 20.000 units /year Since: 1972
SDLG Information
SDLG Information In 1972: • SDLG was built • First ZL40
SDLG Information In 2005: • SDLG Relocation • Improvement of production capacity
• In 2006: VolvoCE investment
SDLG Information WLO models: • LG918 • LG933 • LG936 • LG938 • LG956 • LG958
SDLG Information Test Track: • All equipment are tested • Transmission, Engine, Electric and Hydraulic functions are proved • 45° ramp
SDLG Information 28,155
Liugong Longgong XGMA Caterpillar SDLG XCMG Chenggong
27,363 21,321 16,708 16,305 9,649 9,079
Volvo
7,800
Komatsu
8,575
SEM Foton Changlin CNH
7,457 7,159 5,259 3,300
JCB 2,600 Kawasaki 1,700
SDLG is among the 5 world’s largest wheel loader manufacturers
L G
Lingong
9
WLO
5
Nominated load
8
Power train version
LG 958
LG 958 Specifications – Performance • Rated Power: 162kW / 217HP (2200 r/min) • Travel Speed: - Forward Æ 1st: 0~12,3 km/h Æ 2st: 0~40,5 km/h - Reverse Æ 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
LG 958 Specifications – Performance
• 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)
LG 958 Specifications – Performance • 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
LG 958 Specifications
Engine Weichai WD10G.220
Lingong Axle
Transmission Electric-hydraulic 4WG200 power shift (Forward IV / Reverse III)
Engine SDLG Loaders
Engine WD10G.220 Model
WD10G.220
Type
• Inline water cooling • Direct injection • Turbocharged
Rated power (kW)
162
Rated speed (rpm)
2200
Displacement (L)
10
Cylinder
6
Bore/stroke (mm)
126/130
Min. Fuel consumption ratio (g/kW·h)
228
Max torque (N·m)
843
Emission standard
Engine WD10G.220 Specifications • 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
Engine WD10G.220 Over view right side
• Air filter
• Turbocharger
• ID plate
Engine WD10G.220 Over view left side
• Air compressor
• Fuel water separator filter
• Thermostat
• Relief valve
• Fuel filters
Engine WD10G.220 Name explanation
W D 6 10 G .220 Sequence Number Application code (G stands for construction machinery) Single Cylinder Displacement (10 reffers to 1,0 liters) Number of Cylinders Diesel Engine Water-cooled
Engine WD10G.220 Construction
• Cylinder Block
• Crankshaft
Engine WD10G.220 Construction • Injection pump gear
• Water pump carapace
• Camshaft gear • Intermediate gear • Crankshaft gear
Engine WD10G.220 Construction • Ladder ring • Cone ring
• Piston pin
• Oil ring
• Piston
• Connecting rod bush • Connecting rod
• Connecting rod tile
Engine WD10G.220 Construction • Aluminum casted part • First and second rings have directions when mounting (“TOP” mark faces up) • First ring: trapezoidal ring, “TOP” mark • Second ring: conical ring, “TOP” mark • Third ring: assembled oil ring, with spiral ring
Engine WD10G.220 Construction • Connecting rod bolts can be used only once, otherwise serious accidents may occur
• Cylinder sequence mark • Weight grouping mark
• Block and head matching mark
• Compression piston rings have top marks for correct mounting • Connecting rods have matching marks • Connecting rods bolts are disposable
Engine WD10G.220 PTO
Engine WD10G.220 Valve adjustment
• 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
Engine WD10G.220 Valve adjustment • Sequence of valve adjusting
• It is possible to reach the requirement by adjusting bolt of the rocker
Engine WD10G.220 Valve adjustment Clearance: - Admission valve: 0,30 mm
- Exhaust valve: 0,40 mm
Engine WD10G.220 Lubricant flow • Working pressure: 3,0~6,0 bar • Pressure limiting valve (10 bar)
Engine WD10G.220 Lubricant flow • Main passage relief valve
• Oil strainer
• Oil filter
• Oil pump
• Turbocharger
• Fuel pump
• Oil cooler
• Air compressor
Engine WD10G.220 Cooling system • Schematic diagram
• This part belongs to the engine (short cycle)
Engine WD10G.220 Cooling system
Engine WD10G.220 Cooling system • 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
Engine WD10G.220 Cooling system • Wax type • Thermostatic valve closed (water goes directly to water pump – short cycle) - Starts to open at 71±2 ºC - Fully open at 82ºC
• Thermostatic valve opened (water goes to radiator)
Engine WD10G.220 Fuel supply • Tank • Filters • Supply Pump • Injection Pump • Drain
Engine WD10G.220 Fuel supply • Fuel supplying sequence: 1-5-3-6-2-4 • Opening pressure: 225 bar
• High pressure fuel pumps
• Injection pump
• Oil return pipe
• Injector assembly • Connector
Engine WD10G.220 Fuel supply 1. Fuel from the fuel tank 2. Fuel delivery pump 3. 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
Engine WD10G.220 Fuel supply
• Fuel injection pump
• Fuel pumping system
Engine WD10G.220 Turbocharger
Transmission SDLG Loaders
Transmission system Specifications Model
ZF 4WG200
Type
Fix shaft, electric-hydraulic power shift
Gears
4 forward, 3 reverse
Variable-speed pump model Gearshift pressure (MPa) Type Modulus of converter Oil cooling method
Inside gearbox 1.4~1.6 Single phase/ 3 elements/ Hydraulic 2.55 Cycle water cooling
Inlet oil pressure (MPa)
0.85
Outlet oil pressure (MPa)
0.5
Transmission system Specifications •
Planetary power shift
•
Four forward shifts, three reverse gear
•
Working pressure
•
Low pressure warning light in dashboard: ≤
•
Input pressure to toque converter:
•
Output pressure from torque converter:
Transmission system Specifications – 4WG200 Series
Transmission system Oil supply flow
Transmission system Specifications – 4WG200
Transmission system Pump connections • Pump output to filter transmission
• Pump input from transmission oil sump
• Transmission Pump
Transmission system Pump connections • Inlet to transmission
• Output to transmission filter
• Hydraulic Pump • To transmission pressure gauge
• Torque coverter • Engine radiator
• Control valve
• Inlet
• Transmission oil cooler • Transmission Filter • Inlet to transmission
• To oil cooler
• Sump
Transmission system Functions • Transmission Cutoff (pneumatic)
• Pressure measure
• Backup switch • Shift rod
Transmission system Gear selector box • Pressure regulation valve • Pneumatic cutoff valve
• Shift spool
R1
F2
F1
Transmission system Gear selector box
• Gear Shift -F/R1–2–3-4
• Front • Neutral • Rear • Lever Lock
Transmission system Oil check and drain
Transmission system Transmission oil filter
Axle System SDLG Loaders
Axle system Main view
Axle system Main view
Axle system Main view
• Trunnion system
Axle system Construction
Axle system Main view
Axle system Advanced material
Hydraulic System SDLG Loaders
Hydraulic System Pressure and connections LG958 Working Hydraulic Pressure (relief valve) Working Hydraulic Pressure (safety valve) Safety Valve (tilt - ) Safety Valve (tilt + ) Pilot pressure (joystick) Steering System working pressure Brake (air system) Brake (hydraulic system) Transmission oil pressure Torque converter oil pressure (inlet) Torque converter oil pressure (outlet) Tyres pressure (Rear/Front)
MPA 17,5 17,5 20,5 12 1,8 to 3,2 16 0,784 14 1,4 to 1,6 0,85 0,5 0,33 / 0,39
BAR 175 175 200 120 18 to 32 160 7,84 140 14 to 16 8,5 5 3,3 / 3,9
Hydraulic System Specifications •
Hydraulic pilot control
•
Gear main hydraulic pump
•
Open center system
•
Relief pressure: 175 bars (relief valve in MCV)
•
Gear servo pump
•
Servo pressure: 23 bars
•
Hydraulic tank capacity: 210 L
Hydraulic System Main components - Tank
Hydraulic System Main components - Pumps • Main Hydraulic Pump
• Servo Pump
• Steering Pump
Hydraulic System Main components – Servo pump
Hydraulic System Main components – Pumps Model = JHP2100/Gj0010C-XF Flow = 104,9 ml / rpm PN = 4120001969 •Steering pump
•Servo Pump
Hydraulic System Main components – Main pump • INPUT
• PUMP
Model = JHP3160C Flow = 167,9 ml / rpm PN = 4120001968
• OUTPUT
Hydraulic System Main components – Oil cooler
•Foto do radiador de oleo
Hydraulic System 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 Main components – MCV • Tilt tubes • Return/ drain
• Extra function
• Lift tubes
Extra spool
Tilt spool
Lift spool
Hydraulic System Main components – MCV Main Safety valve 175 bar
Base – 200 bar Rod – 120 bar
Hydraulic System Main components – MCV
Hydraulic System Diagram • Pilot control and flow enlarge hydraulic system
1. Work pump
4. Double units pump
9. Multi-way valve
2. Hydraulic oil tank
5. Flow enlarge pump
10. Lift arm cylinder
3. Pressure select valve
6. Steering cylinder
11. Bucket cylinder
7. Redirector 8. Pilot valve
Hydraulic System Diagram
Steering System SDLG Loaders
Steering System Specifications
Type Steering pump Redirector
Loading sensing hydraulic articulated steering CBGj2100/Gj0010C-XF BZZ6－800
Steering angle ( º)
38º
Steering pressure (MPa)
16
Steering System Specifications • Load sensing hydraulic system • When steering, the system supplies oil rather the steering hydraulic system than the working equipment • Steering hydraulic system independent from load-sensing hydraulic system • Open center • Working pressure 160 bar
Steering System Specifications • Send the oil pressure to the correct steering cylinder • 1 inlet port • 2 outlet ports (Left and Right steering) • 1 return port
Steering System Components
Steering System Pump • Steering gear pump
•Obter o flow com a china
Steering System Priority Valve LS: from orbitrol
Drain
EF: to oil cooler
From hydraulic pump OF: to orbitrol
Steering System Steering cylinders
• Steering cylinders
• Articulation pin
• Right Cylinder positive side is connected to the Left Cylinder negative side
Electrical System SDLG Loaders
•Trocar esta foto
Electrical System Specifications
• 24 V system • 2 batteries of 12 V in series • 120 Ah batteries
Electrical System Components
• 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
Electrical System Components
• 24V Alternator • 35 Amperes • Electronic voltage regulator • Voltage cutoff 28,4 V • Wire to hour meter
Electrical System Components
• New auxiliary relay: protects the starter motor
Electrical System Start diagram
Electrical System Components • Located in the right side of the steering column
• Three extra switches on the cover
Electrical System Components
• Coolant sensor temperature
• Engine oil sensor pressure
Electrical System Components
• Brake light switch
• Neutral switch
Electrical System Components
• Torque converter's oil temperature
• RPM sensor (over transmission)
Electrical System Components
• Air filter indicator
• Air pressure sensor • Air pressure switch
Electrical System Components Bucket approach switch
Arm approach switch
Electrical System Components – back up alarm
Electrical System Components – levels
Solenoid in joystick (when the bucket reaches leveling point, it deactivate the solenoid)
Electrical System Components – air monitoring
Electrical System Air supply monitoring
Electrical System Power system principle
Electrical System Advanced material
•Link para o diagrama eletrico
Brakes System SDLG Loaders
Brakes System Overview
• Dry type • Four wheels caliper disk brake system • Pneumatic system (pressure oil: 140 bar)
Brakes System Components
• Air compressor • Lubrication made from engine oil main gallery • Camshaft driven
• Relief valve • Max pressure: 7,5 bar • Low pressure alarm: 4,0 bar
Brakes System Components – Air intake • The air intake for air compressor comes from the air filter
Brakes System Components - Booster
Brakes System Components - Booster
Brakes System Components
Brakes System Components – Air reservoir
• Air pressure output
• Inlet • Pressure switch and sensor
• Air pressure measurement connection
Brakes System Brake diagram – single pedal
• Brake connector
• Air Reservoir • Brake Booster (front)
• Brake Lamp
• Brake Booster (rear)
Brakes System Brake diagram – double pedal Brake Front axle valve
Rear axle valve
Brake and transmission cutoff
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
Brakes System Pads and caliper
• Four brake calipers for front and rear axle
Brakes System Parking brake • Two different way: - Hydraulic clamping disc breaking system - Hydraulic pin steering system • Both systems activated by compressed air electronically controlled
Brakes System Parking brake - safety
Pneumatic system: • Activation: Spring • Deactivation: Air pressure (when lower than 4,0 bar)
Security issue
CAB System SDLG Loaders
CAB System General overview • Electric horn
• Panel
• Right break pedal • Accelerator
• Gear shift
• Left break pedal • Pilot control
CAB System Panel and instruments 2. 1. Transmission Oil Pressure 2. Brake Air Pressure 3. Hour meter
1.
3.
CAB System Panel and instruments 2. 1. Tachometer 2. Information / Warning Lamps
1.
CAB System Panel and indicating lamps • Oil pressure alarm
• Charging indicator
• Power cut off indicator • Emergency turn indicator
• Pre-heat indicator
• Fuel Coarse Filter
• Parking Brake • Brake air Pressure
• High Beam
• Computer Box working
CAB System Panel and instruments
CAB System Panel and instruments • Forward and Backward lights switches
• Water Jet
• Rain Brush Switch
CAB System Panel and instruments
• Hydraulic functions of the working equipment
CAB System Panel and instruments – Air conditioner
• Working indicator lamp • The switch to control the temperature • Air volume and power switch
• 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
CAB System Panel and instruments
• Engine turning on • Rotate the key clockwise to turn on the electrical system and then the engine
• Engine cut off • Pull up to cut off the engine • Connected to the injection pump
CAB System Panel and instruments • A/C • Hydraulic functions
• Engine cut off
• Parking brake
CAB System Panel and controls
• Gear Shift -F/R1–2–3-4
• Front • Neutral • Rear • Lever Lock
CAB System SEAT
• German GRAMMER Seat
CAB System General overview • Four rubber cushion • Dampening • More comfort in operation
CAB System Optional ROPS & FOPS
Maintenance Program SDLG Loaders
Maintenance Level – Hydraulic system
Maintenance Level – engine oil
High Low
Maintenance Level – fuel
• Fuel level gauge in the panel
Maintenance Space
• Lift-up engine hood, convenient in maintenance
Maintenance Preventive Maintenance Part number 4110000560008 4110000108003 4110000563002 4110000563003 4110000508 4110000218001 29100006611 4120000452 29100006621 4120001954001
LG918 Description Filter Oil (Engine) Filter Air (Engine) Filter Fuel (Engine) Filter Fuel Water Separator (Engine) Filter Oil (Torque converter) Filter Oil (Transmission) Filter Oil (Returning Hydraulic) Filter Oil (Hydraulic Tank) Filter Oil (Hydraulic Sucction Line) Filter Oil (Hydraulic)
15W40 15W40 DOT3 80W90 - GL5 ISO46* Glicol**
Engine oil 13 liters Transmission 45 liters Brake fluid 4 liters Axles oil 16 liters Hydraulic Oil 100 Liters Anti Freezing
GREASE
Base Lithium - Extreme Pressure NLGI 2 Indent Numbers E1805215A39 E1805215AK6 E1805215AK9 * Temperature from -30º to 40º HVI - ISO46 ** Usage percentage according O&M
Qty 1 1 1 1 1 1 1 1 1 1
100 1 1 1 1 1 1 1 1 1 1
250 1
500 1
750 1
1 1
1 1
1 1
1 1 1 1
1
1
1
1000 1 1 1 1 1 1 1 1 1 1
1250 1
1500 1
1 1
1 1
1 1 1 1
1
1
1
Number of hours 1750 2000 2250 2500 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
1 1 1 1 1 1
1
1
2750 1 1 1
1
3000 1 1 1 1 1 1 1 1 1 1
3250 1
3500 1
3750 1
1 1
1 1
1 1
1 1 1 1
1
1
1
1
4000 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1
Maintenance System Pressure LG958 Working Hydraulic Pressure (relief valve) Working Hydraulic Pressure (safety valve) Safety Valve (tilt - ) Safety Valve (tilt + ) Pilot pressure (joystick) Steering System working pressure Brake (air system) Brake (hydraulic system) Transmission oil pressure Torque converter oil pressure (inlet) Torque converter oil pressure (outlet) Tyres pressure (Rear/Front)
MPA 17,5 17,5 20,5 12 1,8 to 3,2 16 0,784 14 1,4 to 1,6 0,85 0,5 0,33 / 0,39
BAR 175 175 200 120 18 to 32 160 7,84 140 14 to 16 8,5 5 3,3 / 3,9
2009 X 2010 Main changes SDLG Loaders
Improvements Transmission pressure gauge
Direct feeling type
Inductance type
filtration joint is added on sensor which reduces sensor problems caused by oil pollution
Improvements Speedometer X tachometer
OLD Speedometer
New tachometer
Improvements New radio
OLD
New + USB
Improvements Hour meter
OLD
New
Improvements Starting switch
OLD
New
Improvements Approach switch and relays more firmly fixed switch
New auxiliary relay, effective in avoiding instand voltage surge
Improvements Battery relay and starting relay New auxiliary relay, higher in reliabillity
Auxiliary relay, well-fit with engine, effictive in protecting starting motor.
Improvements Sensors Reliable VDO barometer and sensor adopted.
inductive loading flywheel diode， effective in protecting electrial components when instand voltage surge happens
Improvements Convenience and maintenance Rotating radiator, more convenient for cleaning and maintenance.
Thank you!
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