Technical Training

LG936 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

3 Nominated load

6 Power train version

LG 936
 LG 936
Specifications – Performance

• Rated Power: 92kW / 124HP (2200 r/min)

• Travel Speed:
- Forward Æ 1st: 0~13 km/h
Æ 2st: 0~38 km/h
- Reverse Æ 1st: 0~17 km/h
• Total Time of the cycle: ≤ 9,2 s
- Lifting Time (full load): ≤ 5,3 s
- Lowering Time (empty bucket): ≤ 2,9 s
- Dumping Time (empty bucket): ≤ 1,0 s
 LG 936
Specifications – Performance

• Operation Weight: 10700 kg

• Rated Load: 3000 kg
• Rated Bucket Capacity: 1,8 m³
• Max Breakout Force: ≥ 96 kN
• Max Traction Force (engine): ≥ 105 kN
• Max Tipping Load: ≥ 66 kN
• Tire Charge Pressure:
- Front: 3,43 ± 0,1 bar = 50 psi
- Rear: 2,85 ± 0,1 bar) = 40 psi
 LG 936
Specifications – Performance
• Length: 7100 mm
• Width: 2510 mm
• Height: 3170 mm
• Max Dumping Height: 2950 mm
• Max Climbing Angle: 30º
• Dumping Angle: ≥ 45º
• Dumping Space: 1050 mm
• Wheel Track: 1865 mm
• Wheel Base: 2850 mm
• Min Ground Clearence: 370 mm
• Min Turning Radius: 5381 mm
• Level Passing Radius: 5912 mm
• Max Turning Angle: 38º
 LG 936
Specifications

Engine Weichai
Lingong Axle
Deutz TD226B

Transmission Planetary power

shift (Forward II / Reverse I)
 Engine

SDLG Loaders
 Engine TD226B
Model TD226B-6IG15
• Water cooling;
Type • In-line
• Direct injection
Rated power (kW) 92
Rated speed (rpm) 2200
Displacement (L) 6.234
Cylinder 6
Bore/stroke (mm) 105/120
Min. Fuel consumption ratio (g/kW·h) ≤215
Max torque (N·m) 500
Emission
Engine TD226B
Specifications

• Explosion order: 1-5-3-6-2-4

• Cylinder number 1 is in the distribution side
• Compression ratio: 18:1
• Rated oil consumption: ≤
• Noise limit: ≤
• Air intake method: turbocharged
• Lubricating system: forced lubrication
• Oil capacity (sump): 14 L
• Oil temperature: ≤ 110 ºC
• Working oil pressure: 3~6 bar
• Starting method: electric starting
 Engine TD226B
Over view right side

• Intake
Manifold • Turbocharger

• Alternator • Exhaust
• Oil filler Manifold

• ID Plate • Inline Injector

Pump

• Fuel Filter
(optional)
 Engine TD226B
Over view left side

• Restriction • Air Compressor

Indicator • High and Low
• Air Filter Pressure point (AC)
house • AC Compressor

• Fuel Filter
(Water
Separator)
 Engine TD226B
Name explanation
TD 2 26 B-6 G
Application code (G stands for construction machinery)

Number of cylinders (“6” reffers to 6-cylinders)

Wet liner

Serial number for diesel engine family

Water-cooled

Aspiration method code:

• D Æ natural aspiration
• TD Æ turbocharged
• TBD Æ turbocharged and intercooled
 Engine TD226B
Construction

1. Front cover
2. Cylinder block
3. Cylinder line
4. Flywheel housing
5. Rear oil seal cover
6. Main bearing cover
7. Oil sump
8. Oil seal
9. Seal plate

Coat sealant on “D” Coat sealant on “D”

joint face and “E” joint faces
 Engine TD226B
Construction

• Seven crankshaft bearings

• Wet cylinder liners

• Two seal rings in downside
• Two seal rings in upside
Engine TD226B
Construction

• Composed of piston, piston ring, piston pin

and retainer
• 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 TD226B
Construction

• Connecting rod bolts can

be 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
Engine TD226B
PTO
 Engine TD226B
Valve adjustment

• Remove valve cover plate

• Remove the plate that
give access to flywheel
• Set the engine in TDC
• Put cylinder 1 in overlap
 Engine TD226B
Valve adjustment
Cylinder 1 in overlap:
• Adjust valves 1-2-3-6-7 and 10
• Turn the engine 360º and put the
cylinder 6 in overlap
Cylinder 6 in overlap:
• Adjust valves 4-5-8-9-11 and 12

Clearance:
• Admission valve: 0,20 mm
• Exhaust valve: 0,30 mm
 Engine TD226B
Valve adjustment

Reminder:
Cylinder 1 is near to
distribution side of the
engine.
A Admission
E Exhaust
A E
 Engine TD226B
Lubricant flow
• Working pressure 3,0~6,0 Bar Main gallery

Pressure limiting valve (10 bar)

Oil Cooler
Housing

Oil Pump
Oil Filter Relief Valve
(7,5 bar)
Oil Suction
Pipe
Engine TD226B
Lubricant flow

• Oil from oil cooler goes through

the main gallery and lubricates all
moving parts: camshaft, crankshaft,
piston, connecting rods, etc.
Engine TD226B
Lubricant flow

• Oil also lubricates the air

compressor and the
turbocharger
Engine TD226B
Cooling system
 Engine TD226B
Cooling system

Cooling system
• Cooling system includes water pump, fan, water tank, expansion tank,
radiator and thermostat
• Cooling system working pressure is 0.5 bar, for avoiding boiling.

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 75 ºC.
 Engine TD226B
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 75 ºC
- Fully open at 90ºC
 Engine TD226B
Fuel supply

• Tank
• Filters
• Supply Pump
• Injection Pump
• Drain
Engine TD226B
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 TD226B
Fuel supply

Working pressure: 250 bar

Transmission

SDLG Loaders
 Transmission system
Specifications
Model LG A300 Series
Type Planetary power shift
Gears 2 forward, 1 reverse
Variable-speed pump model CBGj2063/2040
Gearshift pressure (MPa) 1.1~1.5

• Single phase/ 4 elements/

Type Hydraulic
Modulus of converter 4.56
Oil cooling method Cycle water cooling
Inlet oil pressure (MPa) 0.45~0.55
Outlet oil pressure (MPa) 0.15~0.25
Transmission system
Specifications
Transmission system
Specifications
• Planetary power shift

• Two forward shifts, one reverse

gear

• Working pressure 11~15 bars

• Low pressure warning light in

dashboard: ≤ 8,8 bar

• Torque converter (Shantui)

• Input pressure to toque converter:

4.5~5.5 bar

• Output pressure from torque

converter: 2~3 bar
 Transmission system
Specifications – A300 Series
 Transmission system
Specifications – A300 Series
Transmission system
Oil supply flow

1. Radiator
2. Diesel engine
3. Torque converter
4. Axis gear
5. Speed shifting pump
6. Work pump
7. Oil filter
8. Transmission
9. Shift operating valve
 Transmission system
Specifications – A300 Series
1. PTO
2. Primary input gear
3. Secondary input gear
4. Overrunning clutch
5. Reverse gear piston
6. Reverse gear
7. Reverse internal gear
8. Isolate plate
9. Internal gear
10. 1º gear
11. 1º gear piston
12. 1º gear cilinder
13. Midlle cap
14. Direct gear
15. End cap
16. Gear output shaft
17. Output shaft
 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
Oil check and drain
Transmission system
Transmission oil filter
Transmission system
Advanced material
Axle System

SDLG Loaders
Axle system
Main view
Axle system
Construction
Axle system
Main view
 Axle system
Advanced material
Hydraulic System

SDLG Loaders
 Hydraulic System
Pressure and connections

Description BAR Where

Pressão principal hidraulico
Pressão de direção
Pressão servo
Pressão sobrecarga/ lado base
Pressão de sobrecarga/ lado haste
Pressão de transmissão
Pressão sistema de AR FREIO
Pressão hidraulico de FREIO
160 Ponto de conexão na entrada do MCV
120 Ponto de conexão na entrada da valvula de prioridade
32 Instalar "T" na saida da bomba servo
180 Ponto de conexão do tubo de entrada (lift cil)
120 Instalar "T" na linha cilindro - MCV
14 Intalar ponto de conexão no lugar do sensor de pressão
7 to 8 Ponto de conexão no reservatorio de ar
140 Ponto de conexão no lado hidraulico do booster
Hydraulic System
Specifications

• Hydraulic pilot control

• Gear main hydraulic pump

• Open center system

• Relief pressure: 160~165 bars

(relief valve in MCV)

• Gear servo pump

• Servo pressure: 23 bars

• Hydraulic tank capacity: 128 L

 Hydraulic System
Main components - Tank
 Hydraulic System
Main components - Pumps

• Main Hydraulic
• Steering Pump
Pump

• Servo Pump
• Transmission
Pump
 Hydraulic System
Main components – Servo pump
 Hydraulic System
Main components – Pumps

• Transmission Pump • Steering Pump

 Hydraulic System
Main components – Main pump
• PUMP
• OUTPUT

Model = CBGj3100/1010-XF
Flow = 100ml / rpm
PN = 4120001058

• INPUT
 Hydraulic System
Main components – Oil cooler

•Foto do radiador de oleo

 Hydraulic System
Pumps flow

• Working Pump = 100 ml / R

• Servo Pump = 10 ml / R
• Steering Pump = 63 ml / R
• Transmission Pump = 40 ml / R

• Working / Servo = 4120001058

• Steering / Trans. = 4120000866
 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

160 bar
Base – 180 bar
Rod – 120 bar
 Hydraulic System
Main components – MCV
 Hydraulic System
Diagram

1-Pumps – Working and servo 5-Steering pump 11-MCV 15-Hyd. lock

2-Tank 6-Filter 12-Lift cylinder 16-Solenoid valve
3-Presure select valve 7-Priority valve 13-Tilt cylinder
4-Oil cooler 8-Directinonal valve – orbitrol 14-Quick change
9-Steering cylinder 15-Lock
10-Joystick
Hydraulic System
Diagram
Hydraulic System
Diagram
Steering System

SDLG Loaders
 Steering System
Specifications

Load sensing all hydraulic articulation

Type
steering
Priority valve VLE-150

Steering pump CBGj2063/2040

Redirector BZZ5－500

Steering angle ( º) 38º

Steering pressure (MPa) 12

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 120 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
• Belt 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

• Two brake calipers for front and

rear axle
Brakes System
Parking brake

• Two different forms:

- 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

• Gear Shift • Directional lights

- Forward: F1 and F2 • Working lights
- Neutral
- Reverse: R1
• Emergency Light
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
LG936 Number of hours
Part number Description QTY 100 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000
4110000054305 Filter Oil (Engine) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7200002384 Filter Air (Engine) 1 1 1 1 1 1
7200002385 Filter Fuel (Engine) 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
4110000189006 Filter Fuel (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
2030900065 Filter Oil (Transmission) 1 1 1 1 1 1
29100004061 Filter Oil (Returning Hydraulic) 1 1 1 1 1 1
4120000452 Filter Oil (Hydraulic Tank) 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 26 liters 1 1 1 1 1
ISO46* Hydraulic Oil 128 Liters 1 1
Glicol** Anti Freezing 1 1 1 1

GREASE Base Lithium - Extreme Pressure NLGI 2

Indent Numbers
E3613115A36
E3613115A39
E3613115AK6
* Temperature from -30º to 40º HVI - ISO46
** Usage percentage according O&M
 Maintenance
System Pressure
LG936
MPA BAR
Working Hydraulic Pressure (relief valve) 16 160
Working Hydraulic Pressure (safety valve) 16 160
Safety Valve (tilt - ) 18 180
Safety Valve (tilt + ) 12 120
Pilot pressure (joystick) 1,8 to 3,2 18 to 32
Steering System working pressure 12 120
Brake (air system) 0,784 7,84
Brake (hydraulic system) 14 140
Transmission oil pressure 1,1 to 1,5 11 to 15
Torque converter oil pressure (inlet) 0,45 to 0,55 4,5 to 5,5
Torque converter oil pressure (outlet) 0,15 to 0,25 1,5 to 2,5
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