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
Liugong 28,155
Longgong 27,363
XGMA 21,321 SDLG is among the 5
Caterpillar 16,708 world’s largest wheel
SDLG 16,305
loader manufacturers
XCMG 9,649
Chenggong 9,079
Volvo 7,800
Komatsu 8,575
SEM 7,457
Foton 7,159
Changlin 5,259
CNH 3,300
JCB 2,600
Kawasaki 1,700
L
Lingong
G
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
Lingong Axle
WD10G.220

Transmission Electric-hydraulic 4WG200

power shift (Forward IV / Reverse III)
 Engine

SDLG Loaders
 Engine WD10G.220
Model WD10G.220
• Inline water cooling
Type • 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

• Fuel filters
• Relief valve
 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
• Water pump
carapace
• Injection
pump gear

• Camshaft
gear
• Intermediate
gear

• Crankshaft
gear
 Engine WD10G.220
Construction
• Ladder ring
• Cone ring
• Oil ring

• Piston pin • Piston

• Connecting
• Connecting
rod bush
rod tile

• Connecting
rod
 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
• Compression piston rings
• Block and have top marks for correct
head matching mounting
• Cylinder mark
sequence mark • Connecting rods have
• Weight matching marks
grouping mark
• 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 • Oil strainer

relief valve

• Oil filter • Oil pump

• Turbocharger • Oil cooler

• Fuel pump • 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 • Thermostatic valve opened (water

goes directly to water pump – short goes to radiator)
cycle)
- Starts to open at 71±2 ºC
- Fully open at 82ºC
 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

• Injector
• Oil return pipe 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
Fix shaft, electric-hydraulic power
Type
shift
Gears 4 forward, 3 reverse
Variable-speed pump model Inside gearbox
Gearshift pressure (MPa) 1.4~1.6
Single phase/
Type 3 elements/ Hydraulic
Modulus of converter 2.55
Oil cooling method 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
transmission

• Pump input from

transmission oil
sump
 Transmission system
Pump connections
• Hydraulic Pump
• Inlet to transmission • Output to
transmission filter • To transmission
pressure gauge

• Torque
coverter
• Engine • Control valve
radiator

• Transmission • Inlet
oil cooler

• Transmission Filter • Sump

• To oil cooler

• Inlet to transmission
 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

• Front
• Gear Shift
• Neutral
-F/R1–2–3-4
• 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
MPA BAR
Working Hydraulic Pressure (relief valve) 17,5 175
Working Hydraulic Pressure (safety valve) 17,5 175
Safety Valve (tilt - ) 20,5 200
Safety Valve (tilt + ) 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) 14 140
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
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
• Steering Pump
Pump

• Servo 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

• Extra function • Return/ drain

• 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

Loading sensing hydraulic articulated

Type
steering

Steering pump CBGj2100/Gj0010C-XF

Redirector 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
 Electrical System
•Trocar esta foto
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 • Relief valve

• Lubrication made from • Max pressure: 7,5 bar
engine oil main gallery • Low pressure alarm: 4,0 bar
• Camshaft driven
 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 • Brake Booster

connector (rear)
• Air Reservoir
• Brake Booster • Brake Lamp
(front)
 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

• Gear shift • Accelerator

• 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 • Charging • Power cut

alarm indicator off indicator
• Emergency
• Pre-heat turn indicator
indicator

• Fuel
• Parking
Coarse Filter
Brake

• Brake air • High Beam • Computer

Pressure Box working
 CAB System
Panel and instruments
 CAB System
Panel and instruments
• Forward and Backward
• Water Jet
lights switches

• 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 • Engine cut off

• Rotate the key clockwise to • Pull up to cut off the engine
turn on the electrical system • Connected to the injection
and then the engine pump
 CAB System
Panel and instruments

• A/C

• Hydraulic
functions

• Engine cut off • Parking brake

 CAB System
Panel and controls

• Front
• Gear Shift
• Neutral
-F/R1–2–3-4
• 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
LG918 Number of hours
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
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 1
29100006611 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 1
80W90 - 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
 Maintenance
System Pressure
LG958
MPA BAR
Working Hydraulic Pressure (relief valve) 17,5 175
Working Hydraulic Pressure (safety valve) 17,5 175
Safety Valve (tilt - ) 20,5 200
Safety Valve (tilt + ) 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) 14 140
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
2009 X 2010 Main changes

SDLG Loaders
 Improvements
Transmission pressure gauge

filtration joint is
Direct feeling type Inductance type 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 fly-

wheel 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!
guilherme.godoy@volvo.com