LG959/969

LG959/LG969 assembly guideline manual

SHANDONG LINGONG CONSTRUCTION MACHINERY CO.LTD.

LG959/969
Exports Appliance of LG959/969
2008 12
2008-12

S H A N D O N G

L I N G O N G

Assembly Manual

Version1

C O N S T R U C T I O N

M A C H I N E R Y

C O . , L T D

AddLingong Industry Park,Linyi Economic Development Zone,Shandong,china

86-0539-8785597

Tel 86-0539-8785597

86-0539-8785618

Fax 86-0539-8785618

86-0539-8785800

Webwww.sdlg.cn

LG959/969

LG959/969
4WG180 ZF ZF

-1-

list
chapter 1

foreword3

chapter 2

disassembly fuel tank and relay6

chapter 3

disassembly front &rear axle9

chapter4

assembly fuel tank and relay15

chapter 5

assembly exhaust pipe17

chapter 6

assembly tire 18

chapter 7

assembly cabin 20

chapter 8

assembly left/right bench and ladder of tool box23

chapter 9

assembly front lamp28

chapter 10

assembly bucket30

chapter 11

assembly left/right fender32

chapter 12

connect brake pipe and lubricate brake oil33

chapter 13

start and inspect35

-2-


1.1

-3-

10
11

12

13

14

15

16

17

-4-

12 oil
there are some kinds oil
brake oil

APIGL-5abroad brake oil

SDLG brake oil

MOBIL

1310

1310

SAE10W

lubrication

SDLG lubrication

MOBIL

CALTEX

CASTROL

ESSO

BP

SHELL

23

GB7324

XHP222

Marfak
multi
Purpose

MP

LM
grease

Beacon EP
2

Energrease

Retinax A

Alvania

13 Condition before assembly

-5-

Chaper2 disassembly the fuel tank and relay

1Caution case
assemble

rear

axle

before

disassemble the fuel tank and relay, or

else we cant assemble the rear axle

fuel tank

there are 3 relays on the left side

of rear frame, 2 start relays, 1 power
relayDK2312A.

DK2312A power relay

Fix the start relay with screw and washer

-6-

start relay

Fix the start relay with screw and washer

start relay

Disassemble pre-heater implement in the

right side of machine.

different engine install different relay. For SHANGCHAI engine install

two same relay JN3A-24V For DONGFENG commins engine, one relay is
JN3D-24V ( stop machine), anther isJN3A-24V(start machine),.

-7-

 JN3A-24V
JN3D-24V
JN3A-24V

2
2.
disassemble the fuel tank

Disassemble inlet fuel pipe from fuel tank to

engine.

Protect the pipe end of fuel pipe

from the dust inlet the pipe.

Disconnect outlet pipe from the engine

to fuel tank.

Protect the pipe end of fuel pipe from the dust inlet the pipe.

Disassemble the window pillar. Or else we

cant disassemble the fuel tank bolt.

-8-

Load the fuel tank with hydraulic vehicle.

Making sure the fuel tank is ok when disassemble the fuel tank bolts.

there are 3 fix bolt. First, disassemble

left front bolt

left front bolt.

Second, disassemble the right front

bolt

right front bolt

rear bolt
-9-

Fix the nut with spanner when disassemble the last nut.

Fuel tank

Chapter 2 assembly the front/ rear axle
1.
1. Disassemble the bracket bolts

2 2

Disassemble the bracket bolts, front 2 bolts, rear

2 bolts.

- 10 -


disassemble

the connect bolt between bracket and frame

2 lifting the machine

750mm
1000mm
Prepare two bracket, one is on front frame
bottom ,one is on bottom of counter weight. The
front bracket is over 750mm, rear bracket is
over 1000mm. enough strong.

Protect the frame away from the damage

paint.

Choose the right lift machine and tools according to the loader weight.

It is very danger that the loader weight over the rate weight of
tool. other caution cases

Lock the machine with lock rod.
Keeping all gear rod on the neutral position
Stop engine, lock all
locks,take away the key.
- 11 -

Dont hang the

machine with one steel wire rope.
( 8m)Hang up the machine with
4 (>8m) steel wire rope.
Keeping the machine blance.
Keeping all hood,cab,hydraulic
pipe is ok.
Dont let every one
under the

Down the machine slowly.

Caution:the counter weight is not a flat surface, making sure

the safty.
- 12 -

3
3 Assemble the front axle

Making sure the main drive and axle in

the same direction

Assemble the connect bolt of front axle.

Fix the bolt

73070N.m
Tightening torque: 73070N.m

Prepare 4 connect bolts

4
1/2"-20UNF-2B*50-8.8

Connect the front drive shaft and front axle

with 4 bolts.
9015N.m
Tightening torque: 9015N.m

- 13 -

4
4 Assemble the rear axle

Fix the bolts follow the right

order
73070N.m
Tightening torque: 73070N.m

Prepare 4 bolts connect rear axle and rear

drive shaft.

- 14 -

1/2"-20UNF-2B*50-8.8

Connect the rear drive shaft and rear axle

with 4 bolts.
9015N.m
Tightening torque: 9015N.m

Condition of assembly

Chapte3 assembly fuel tank and relay
1 assemble fuel tank

Fuel tank

- 15 -

Pushing the fuel tank on the bottom of

machine. Prepare for assemble.

Making sure the fuel tank no slide.

GB5785-M24*2*130EpZn-8.8

left bolt

Fix the tighten bolts.fix the left front

bolt( GB5785-M24*2*130EpZn-8.8)
40080N.m
Tightening torque: 40080N.m

GB5785-M24*2*130EpZn-8.8
Fix the tighten bolts.fix the right front
bolt( GB5785-M24*2*130EpZn-8.8)

40080N.m

right bolt

Tightening torque: 40080N.m

- 16 -


GB5785-M24*2*80EpZn-8.8

Fix third bolt(GB5785-M24*2*80EpZn-8.8)

40080N.m
Tightening torque: 40080N.m
rear bolt

Connect the inlet pipe between fuel tank

and engine.
345 N.m
Tightening torque: 345 N.m

Connect the outlet pipe between fuel tank

and engine.
345N.m
Tightening torque: 345 N.m

connect the sensor plug of fuel level.

- 17 -


GB5783-M10*20EpZn-8.8
Assemble the window pillar.
Bolt GB5783-M10*20EpZn-8.8
5213N.m
Tightening torque: 5213N.m

Chapter4 assembly mufflerexhaust pipe

Exhaust pipe

Connect the clamp which is between muffler and

exhaust pipe.

Caution: the end of exhaust pipe on the rear

Dont touch the side door of engine. Safty hat is must.

- 18 -


Chapter5 assembly tire

Disassemble the rim nut.

1 assembly rear tire

L/RR/R

Making sure all tire on their position.

Makeing sure 2 bolt is works before

assemble other tire.

Tighten all rim nut.

end face

Caution: end face inside.

- 19 -

 36

Fix all the nuts with sleeve.

0800N.m
30
fix all nuts.
53050 N.m
Tightening torque: 53050 N.m.

2
L/FR/F

According to assembly the rear tire, the same way.

Chapter6 assembly cabin
assemble
cabin.
1.
M161006

16 6
M12100
4
12 4

Disassemble bench boltsM216*100(QTY6)

- 20 -

Washer(QTY16),boltM12*100(QTY4)

washer(QTY12)

Disassemble operate box cover bolt(QTY4)

Take away operate box cover.

Clean the bench of cabin and assemble

floor cushion

Hand up the cabin

M16 22552N.m
M12 9025N.m
Fix the cabin with bolts.
Tightening torque: M16 22552N.m
M12 9025N.m

Dont jump on/down the machine.

M616 123N.m
Fix the operate box cover.
M6 tightening torque: 123N.m

- 21 -

2 connect the harness

Connect the under cabin harness plug

assembly FOPS & ROPS cabin

1. assemble cabin
M20806
20 6
M16802
M12802
12
2

Disassemble bench boltsM20*80(QTY6)

washer(QTY20) boltsM16*80(QTY2)
boltsM12*80(QTY2)washer(QTY2).

Disassemble operate box cover bolt(QTY4)

Take away operate box cover

Disassemble the bolts

Take away the operate box.

- 22 -

Clean the cabin bench, assemble the

floor cushion.

Hand up the FOPS & ROPS cabin

Fix the cabin on the bench.

M20 44062N.m
M16 22552N.m
M12 9025N.m
Tightening torque: M20 44062N.m
M16 22552N.m
M12

9025N.m

Assemble the operate box cover.

M6 123N.m
M12 9025N.m
Tightening torque: M6 123N.m
M12 9025N.m

dont jump on/down the machine.

2

Connect the cabin harness plug.

- 23 -

Chapter8 assembly left/right bench and handrall of tool box

1.assemble the right bench.

1.1 assembly right ladder

M1225

.
Assemble the right ladder with 4 bolts(M12*25).
9025N.m.
Tightening torque: 9025N.m.

1.2 assembly
right fender.
M1235 12
M12

fix the right bench on the right

ladder with M12*35washer12nutM12.

9025N.m.
Tightening torque: 9025N.m.

- 24 -


caution: big washer on the top.

M1225

Fix

right

fender

bracket

on

the

hydraulic tank.
as the picture
9025N.m.
Tightening torque: 9025N.m.

Condition after assembly

1.3
M1225

Fix the right handrall on the right

ladder and bench with 2 bolts(M12*25)
as right picture.
9025N.m.
Tightening torque: 9025N.m.
M12

Fix the right grate on the right

- 25 -

bench with 2 bolts(red line M12)

M1235 12 12

Fix right grate on the right bench

and right bracket with M12*35washer12
nut12.QTY are 2.
as right picture
9025N.m
Tightening torque: 9025N.m

2. assembly left
bench.
21 assemble left ladder

M1225
Disassemble 4 bolts(M12*25).

Assemble the left ladder on the

left of frame.
9025N.m.
Tightening torque: 9025N.m.

M12
25

- 26 -

Fix the boost on the left ladder with 4 bolts(M12*25).

9025N.m.
Tightening torque: 9025N.m.
22

assemble the left

fende.
M1235 12
M12
Fix the left bench on the left fender with 4
bolts M12*35washer12nutM12.
9025N.m.
Tightening torque: 9025N.m.

Caution: big washer on the top

M1225

Fix left fender on the hydraulic tank with 4 bolts(M12*25)

23 assembly left handrallleft grate
M1225

Fix left handrall on the left bench and

left ladder with 2 bolts(M12*25)
as the picture
9025N.m.
Tightening torque: 9025N.m.

M1225
Fix left grate on the left bench with 2 bolts(M12*25).

- 27 -

 M1235 12 M12

Fix the left grateleft bench on the bracket

with M12*25washer12nut12. QTY:2.
as the picture
9025N.m.
Tightening torque: 9025N.m.

Condition the assembly.

3 assembly tool boxhandrall.

4 M1225

Fix the left\right soft ladder on

the tool box with 4 bolts(M12*25)
9025N.m.
Tightening torque: 9025N.m.

- 28 -


Caution: fix top bolt in inner, down
bolt in outer.

As the right picture.

Chapter9 assembly front lamp
1 assemble the lamp bracket

Disassembly the bracket bolts(red

line in the picture).

- 29 -

 M1230

Pushing the front frame harness through left/right bracket. Fix the
left/right bracket with 6 bolts(M12*30)
, as the picture
9025N.m.
Tightening torque: 9025N.m.

2. assemble the front lamp

CN13B
3 M1025

Connect lamp plug with front frame

harness CN13-B.fix the left lamp/right
lamp

on

the

bracket

with

bolts(M10*25).
As the picture
5213 N.m..
Tightening torque: 5213 N.m

Caution:

making

sure

the

left/right lamp and bracket on

theirseve position.

- 30 -

Chapter10 assembly bucket

1. assemble
bucket and lift arm.
O
Take away the bolt,pin, o-rint,washer.

0.3

Start the machine, lifting the arm (front

arm is over ground 0.3m),lubricate
grease.

Caution: making sure the lock rod on

the rear frame. Inspect the machine and
read carefully operator and mainternance before start it.

Hand up the bucket, adjusting the bucket

- 31 -

in the right position.

0.51.5mm O

connect bucket and lift arm with pin,

washer,making sure the leak is 0.5
1.5mm with washer,assemble the o-ring.

Fix the pin with 2 bolt.

22552 N.m
2

O O

M16
Connect bucket and rod with pin, fix the
pin with M16 bolt.
22552 N m
Tightening torque: 22552 N m

3 2 3

- 32 -

Lubricate the pin until the grease leak from the pin and wash.

Chapter11

assembly left/right fender

1 assemble right front fender

M12
25 (),

Assemble the right front fender with 3

bolts( red line in the right picture)
9025N.m.
tightening torque: 9025N.m.

Fender on the machine

2 assemble the left front

fender

Assemble the left front fender in the same way.

Caution: protect the paint of fender

Chapter12 assemble the brake pipe/lubricate brake oil

- 33 -

1. connect the brake pipe

Connect the brake pipe and 3 way block.

30~35 N.m
Tightening torque: 30~35 N.m

Connect the brake pipe and 3 way block

30~35 N.m
Tightening torque: 30~35 N.m

2. lubricate brake oil

Open the brake cup. Release the air

bleeder,lubricate 2/3 brake oil.

Air bleeder

3.
connect the lubrication grease
pipe
- 34 -

Assemble the lubrication grease pipe on the

top of rear axle
305 N.m
Tightening torque: 305 N.m

Assemble the lubrication grease pipe

Fix the lubrication grease pipe on the left

side of rear frame .

Chapter13 start and inspect

- 35 -

According to the
assembly require.
Check the all oil level.
Check engine
oil, transmission oil, brake oil.
Lubricate the machine.

0.3330.353MPa
0.2750.294MPa

Check the tire air pressure(front

tire0.390.41MPa,rear tire air pressure0.3330.353MPa)

.

- 36 -

 510s 2min
3

400mm

3

55
45

5
20

- 37 -

- 38 -