Larsen & Toubro 9020 Operation & Maintenance Manual

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OPERATION & MAINTENANCE

MANUAL

WHEEL LOADER

LARSEN & TOUBRO

Table of Contents

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Summary of Contents for Larsen & Toubro 9020

Page 1 OPERATION & MAINTENANCE MANUAL WHEEL LOADER LARSEN & TOUBRO...
Page 2 LARSEN & TOUBRO...
Page 3 & & – N 601 – WARNING Improper & unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with the machine.
Page 4: Foreword
If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your L&T dealer before operating the machine. ***** L & T-9020...
Page 5: Warranty
  Easy to operate the hydraulic joystick. Both the Congratulation! You are now a proud owner of L&T 9020 Wheel Loader. lift arm & bucket operations are done by a joystick. All the components of this unit have been thoroughly ...
Page 6: Information On Safety
---------------------------------------------------------------- --------------------------------------------------------------  The signal word NOTICE is used to indicate the interlocking functions, operator tips, precautions that must be taken to avoid actions which could shorten the life of the machine. NOTICE: ---------------------------------------------------- ----------------------------------------------------------------- ----------------------------------------------------------------- ***** L & T-9020...
Page 7: Identifying Your Machine
Table to enter Machine & Engine serial numbers (to be filled by the owner for reference): MACHINE MODEL NO MACHINE SERIAL/PIN NO ENGINE MODEL NO ENGINE SERIAL NO DEALER DETAILS NAME ADDRESS PHONE NUMBER SERVICE PERSONNEL ***** L & T-9020...
Page 8: Table Of Contents
2.11 Hot & Cold Weather Operations ...... 49 2. OPERATION ........28 2.11.1 Hot weather operation ........49 2.11.2 Cold Weather Operations ......49 2.1 General View ........... 29 2.12 Parking & Locking the Machine ....... 50 2.2 Controls and Gauges ........30 L & T-9020...
Page 9 3.5.22 Starter motor ..........71 3.5.23 Brake System ..........71 3.5.24 Recharging the accumulator with Nitrogen ...71 3.5.25 Checking Axle Oil Levels (Front & Rear) ..71 3.5.26 Changing Axle Oils (Front & Rear) ....72 3.5.27 Axles & Wheels ..........72 L & T-9020...
Page 10 This Page is Intentionally Left Blank L & T-9020...
Page 11: Safety
SAFETY SAFETY L & T-9020...
Page 12: General Safety
If your country demands licence to drive your travelling downhill. loader, should licence before operating your loader. 3. Battery disconnect switch L & T-9020 O-10...
Page 13  Accumulators – It is a pressure storage device which is parking brake indicator lamp is used. used for braking purpose. Even if the engine is in shut off condition, the accumulator pressure lasts for a minimum of 20 operations of braking. 6. Steering Lock bar L & T-9020 O-11...
Page 14: Clothing
Do not wear loose clothing. It can get caught in attachments may fall and will lead to severe the controls or moving parts of the machine injury or even death. Keep away from the raised which leads to personnel injury or even death. attachments. L & T-9020 O-12...
Page 15: Communications In Worksite
Exhaust gases from the machine can harm and possibly kill you.  If you begin to feel drowsy, immediately stop the machine and get into the fresh air.  Fuel is FLAMMABLE and can be HAZARDOUS. L & T-9020 O-13...
Page 16: Visibility
Safety for Transporting the ramps again. 1.2.1 General Safety NOTICE: When transporting machine, observe all related laws and regulations, and be careful to assure safety. L & T-9020 O-14...
Page 17: Shipping
 Before starting the machine, thoroughly check the area for  Check and remove the steering & lift arm locks. any unusual conditions that could be dangerous. Examine the shape of the ground and quality of the soil at the jobsite. L & T-9020 O-15...
Page 18: Safety When Travelling
CAUTION Do not apply the brakes suddenly to stop the machine, except in case of emergencies. Your machine is equipped with Hydraulic Power brakes, which may stop your machine with sudden jerks harming you. L & T-9020 O-16...
Page 19: Travel In Reverse
NOTICE: Do not let the lift arm to raise or lower even death. rapidly to reach its maximum height or hit the ground. It will reduce the life of the equipment. L & T-9020 O-17...
Page 20: Safety In Parking
 Never work under the machine if the machine is not supported or poorly supported on all the tyres. If the tyres Blocks are removed for maintenance purpose, use solid blocks to support the machine at the axles. If necessary, change L & T-9020 O-18...
Page 21: Precautions During Maintenance
If such lighting equipment is not used, there is a CAUTION danger of explosion. When working with tools such as spanners, levers etc., beware of surrounding metallic parts L & T-9020 O-19...
Page 22: High Pressure Hoses
Do not use any cracked tube, piping, or hoses. They may burst during use. Inflate the tyres to the specified pressure (refer  chapter 3.6). Abnormal heat is generated particularly when the tyre inflation pressure is too low.  Avoid overloading. L & T-9020 O-20...
Page 23: Precautions With Load And Carry Method
Do not open the radiator cap immediately after operations are stopped. Always wait for the temperature to go down and proceed further. Failure to do so may lead to splashing of hot coolant on your body causing injury. L & T-9020 O-21...
Page 24: Cleanliness Of Machine
 Towing in a wrong way may lead to serious injury or 1.4.8 Cleanliness of Machine death.  Never tow a machine on a slope.  When using another machine to tow your machine, use a wire rope which is sufficiently strong. ***** L & T-9020 O-22...
Page 25: Location Of Safety Labels
 Maintain all the labels free from environmental dust particles. Fix the labels or change it if labels are damaged or lost.  Carefully read the instructions given in the labels and be aware of hazards. L & T-9020 O-23...
Page 26 SAFETY Location of Safety Labels L & T-9020 O-24...
Page 27 4. Always use steering lock bar during maintenance. 10 m WL10 950 C 3181 WL10 950 C 3185 5. Do not touch rotating parts. 6. Instruction for operator WL10 950 C 3174 WL10 950 C 3183 7. Precaution for accumulators 8. Caution foot L & T-9020 O-25...
Page 28 SAFETY Location of Safety Labels GAS FILLER WL10 950 C 3184 WL10 950 C 3470 L & T-9020 O-26...
Page 29 SAFETY Location of Safety Labels This Page is Intentionally Left Blank L & T-9020 O-27...
Page 30: Operation
OPERATION OPERATION L & T-9020 O-28...
Page 31: General View
Dashboard ( Type A / Type B ) Rear combination lamp Cabin Front head light Rear work light Operator seat Front fender Steering lock bar Muffler Emergency window Exhaust pipe Front work lamp Lifting hook Air Filter Steering wheel L & T-9020 O-29...
Page 32: Controls And Gauges
OPERATION Controls and Gauges Controls and Gauges Type A Type B L & T-9020 O-30...
Page 33  This gauge shows the rpm of engine.  When the float switch is switched on the lift arm follows the ground irregularities by using its self-weight only, without using its hydraulic circuit. This system is useful in L & T-9020 O-31...
Page 34  This lamp glows when the filter in the hydraulic tank is  This switch has several functions and that are explained clogged. below: N. Engine oil pressure gauge  This gauge indicates engine lubrication oil pressure. L & T-9020 O-32...
Page 35: Operator's Seat
Depressing this pedal applies the brakes. Wiper ON *****  WIPER CONTROL – By rotating this switch in forward direction, wipers switch OFF; rotating it in reverse direction switches the wipers ON. L & T-9020 O-33...
Page 36: Transportation
 Then fix the ramps in line with the centres of the trailer and the machine. Be sure that the two sides are at the same level as one another. L & T-9020 O-34...
Page 37: General Checks Before Starting
No fouling of hoses in the AC circuit. Always take care when handling rope or chain  No leakage of oil, fuel, lubricant, and Coolant. will lead injury.  No loose wiring connections. *****  No wear and damage of the tyres. L & T-9020 O-35...
Page 38: Checking Engine Oil Level
Lubricants only (refer chapter 3.3.5). NOTICE: Never operate the Engine with the oil level below the lower mark or above the upper mark. Insufficient oil will cause Wear and tear of Engine components. Excessive causes foaming and other problems. L & T-9020 O-36...
Page 39: Checking Hydraulic Oil Level
2.4.7 Checking Air Filter Dust cause Vacuum, Wear and tear of Hydraulic elements. Excessive oil causes foaming and NOTICE: Do not operate the engine with more other problems. dust in the Air Filter which will cause the engine stall. L & T-9020 O-37...
Page 40: Checking Tyres
 Sit in the operator seat and adjust the rear view mirror so that you can see the rear view properly. CAUTION Do not operate the machine if you cannot see the path clearly. Accidents can be caused by working L & T-9020 O-38...
Page 41: Starting Engine
 Turn the key of starting switch to the “START” position to start the engine.  Check the cut-off sensors of the work equipment to work properly. To know the operation of work equipment refer chapter 2.7. L & T-9020 O-39...
Page 42: Travelling
2.7.  When moving the machine on slopes, set transmission cut-off switch to the OFF position, depress brake pedal when depressing accelerator pedal, then gradually release brake pedal to allow the machine to start moving. L & T-9020 O-40...
Page 43: Turning The Machine
1st speed position, stop the machine, place the lever in neutral, and run the engine at medium speed until the gauge indicates the green range. ***** L & T-9020 O-41...
Page 44: Operating The Loader
Float Dump Hold Roll back Automatic Roll back Raise Roll back Lower Dump Automatic Raise  In this position bucket raises automatically, without holding joystick. After reaching the raise position, joystick returns back to hold position. L & T-9020 O-42...
Page 45: Return To Dig Operation
 Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket at HOLD, stop the engine and adjust as follows,  Loosen the screws. L & T-9020 O-43...
Page 46: Possible Work Using Loader
 This operation should be carried out in 1st gear.  Always try to load the bucket in its centre. If the load is on one side of the bucket, the load will be unbalanced. L & T-9020 O-44...
Page 47: Filling The Bucket
This prevents spillage of the load during hauling. L & T-9020 O-45...
Page 48: Carrying The Material
 In this method loader bucket is penetrated horizontally into the material with intermittent and successively higher levels, or steps, until the bucket is filled.  Approach the material slowly, with bucket horizontal at ground level with engine running at full throttle, penetrate L & T-9020 O-46...
Page 49: Levelling Operation
 Scoop soil into the bucket. Move the machine backward while spreading soil from the bucket little by little.  Go over the spread soil with the bucket edge touching the ground and level the ground by back dragging. L & T-9020 O-47...
Page 50: Pushing Operation
 Place the drive control switch in neutral.  Operate the joystick to lower the bucket to the ground (refer chapter 2.7).  Make sure that the joystick is in neutral position, before leaving from the cabin. L & T-9020 O-48...
Page 51: Hot & Cold Weather Operations
 Use antifreeze coolant during cold weather operation. 1.23 1.24 1.25 1.26 1.27  Keep antifreeze fluid away from an open flame. Never shake when using antifreeze.  Never use methanol, ethanol, or propane based antifreeze. L & T-9020 O-49...
Page 52: Parking & Locking The Machine
Button NOTICE: To avoid battery electrolyte from freezing, cover the battery and keep it in a warm Parking Brake Lever place.  Pull the parking brake lever to apply the parking brake as shown above figure. L & T-9020 O-50...
Page 53: Locking
Engine hood doors (left, right & rear)  Ensure that the key is kept at proper location. ***** 2.13 Towing Toe bar NOTICE: Do not tow unless it is absolutely necessary. Towing may create further damage to the machined. L & T-9020 O-51...
Page 54: Maintenance
MAINTENANCE MAINTENANCE L & T-9020 O-52...
Page 55: Maintenance Instructions
L&T service personal immediately.  When O-rings or gaskets are removed, clean the faces and replace the O-rings and gaskets with new ones. Be sure to fit O-rings and gaskets when assembling. L & T-9020 O-53...
Page 56: Maintenance Chart
3.3 for detailed specifications of consumables.  Read the hour meter to determine the maintenance intervals. NOTICE: If the machine is operated under dirty environment, clean all lubricating points and lubricate more often. 16 17 L & T-9020 O-54...
Page 57 BUCKET - ARM PIN REAR AXLE TRUNNION PINS UPPER AND LOWER CHASSIS PIVOTS TRANSMISSION TRANSMISSION OIL * ENGINE ENGINE CRANK CASE OIL *** CHECK LEVEL / LUBRICATION OIL ENGINE RADIATOR COOLANT COOLANT HYDRAULIC OIL HYDRAULIC OIL L & T-9020 O-55...
Page 58 HYDRAULIC OIL FILTER (ELEMENT) CHANGE BRAKE ACCUMULATOR NITROGEN GAS 40 BAR CHECK / REFILL FUEL STRAINER CHANGE CHECK LEVEL / BATTERY ELECTROLYTE AFTER EVERY 1000 HOURS TRANSMISSION TRANSMISSION OIL (TOTAL SYSTEM) * 38 L DRAIN & REFILL L & T-9020 O-56...
Page 59 TRANSMISSION & RADIATOR  Check the battery electrolyte level at every 4 weeks.  For detailed information on Engine maintenance, refer Engine Operators Manual.  For detailed information on Transmission maintenance, refer Transmission Operators Manual. ***** L & T-9020 O-57...
Page 60: Consumables
 Grease is used to reduce noise and wear & tear of the overheating. parts at joints. L & T-9020 O-58...
Page 61: Engine Lubrication Oil
HIDUSTAN PETROLEUM (HPCL) 3.3.8 Transmission Oil S.No SPECIFICATION BRAND NAME MANUFACTURER HINDUSTAN PETROLEUM POWER GLIDE C-430 CORPORATION TYPE : C4 SERVO TRANSMISSION FLUID INDIAN OIL CORPORATION SAE GRADE : SAE 30 BHARAT HYDRAULIC TRANSMISSION BHARAT PETROLEUM CORPORATION FLUID L & T-9020 O-59...
Page 62: Axle Oil
 When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, pleas e contact your L&T service personnel.  Do not open packs of spare filters until just before they are to be used. L & T-9020 O-60...
Page 63 OUTER ELEMENT ASSEMBLY WELD ON TOOTH TOOTH WHEN REQUIRED BUCKET TOOTH TOOTH WHEN REQUIRED BOLT ON CUTTING EDGE BOLT ON CUTTING EDGE WHEN REQUIRED WEAR PAD WEAR PAD WHEN REQUIRED PARKING BRAKE SYSTEM EXPANDING SHOE WHEN REQUIRED ***** L & T-9020 O-61...
Page 64: Location Of Maintenance Elements
Filling & Level check Point Central Housing Oil Drain Point Pre Cleaner Air Filter Engine oil Filter Transmission Oil Filter Engine Fuel Filter Hydraulic oil Filter Radiator Hydraulic Tank Hydraulic Oil Strainer Engine oil Dipstick Transmission suction strainer ***** L & T-9020 O-62...
Page 65: Maintenance Procedure
3.5.3 Engine Oil Level Checking  During run-in period of the new machine (i.e. within first Wing nut 200 hours of operation), check engine oil twice a day. Procedure  Place machine in horizontal position. Dust Collectors Filter cover L & T-9020 O-63...
Page 66: Engine Oil Changing
 Bleeding of the fuel system is required when air has  Fill the oil filter bowl with new engine oil and refit using entered during the time of removing and refitting the fuel filter, fuel lines etc. dome nut. L & T-9020 O-64...
Page 67: Cooling Devices
Open radiator cap slowly when the engine is at still hot. If you do so, scalding water can come out operating temperature. Failing to do so will cause resulting in personnel injury. the boiling water splashes and will cause personnel injury. L & T-9020 O-65...
Page 68: Checking Fan Belt Tension
NOTICE: If the strainer is damaged, replace the strainer with new one. NOTICE: Never operate the Transmission with the oil level below the Minimum or above the  Clean the suction strainer at every 1000 hours of Maximum. operation. L & T-9020 O-66...
Page 69: Changing Transmission Oil Filter
 Check the transmission oil level and top up if required. filling the oil. Ensure that the presence of foreign material into the oil should be avoided.  Clean around the filler cap always before topping up the oil in the hydraulic tank. L & T-9020 O-67...
Page 70: Checking Hydraulic Oil Level
 Remove the spring and bypass valve, then remove the tighten the bolts properly. filter element.  Refill the hydraulic oil in the hydraulic tank only through the oil filler port (not through breather) to the required level (refer figure in 3.5.13). Hydraulic oil level L & T-9020 O-68...
Page 71: Hydraulic Oil Pressure Setting
Change the filters Hydraulic tank breather after the specified interval. And check that there is no foreign matter inside the tank. 3.5.17 Hydraulic oil pressure setting  This has to be done only by your L&T service Engineer. L & T-9020 O-69...
Page 72: Battery
If the control inserts are missing, proceed as follows:  Insert a clean wooden stick into the cell opening as far as to the upper edge of the lead plate. L & T-9020 O-70...
Page 73: Starter Motor
 Circulation of lubricants between planetary end and the nitrogen bottle (7). centre bowl of central housing is partially restricted by gears, bearings, washers and other components.  Turn charging unit to a position where the gauge can be easily read. L & T-9020 O-71...
Page 74: Changing Axle Oils (Front & Rear)
While welding bucket planetary ends. enforcement, pin joints should not be distorted.  Fill each of the 4 wheel ends as follows, ***** Move the wheel until the fill/drain plug is at the  horizontal position. L & T-9020 O-72...
Page 75: Handling The Tyres
Thoroughly close up air filter intake and exhaust openings. Front wheel assembly 4.13 Remove battery from the machine and check its  Rear wheel assembly 3.45 condition for every 4 weeks.  During the time of storage do the following, L & T-9020 O-73...
Page 76: Re-Commissioning
Usage of proper tools can avoid damaging your machine and injury on you.  Following tools are provided along with the machine.  If any of the tool broken or missed, please order them to your L&T dealer. L & T-9020 O-74...
Page 77: Trouble Shooting
Clog and clean the element Exhaust gases Defected turbocharger Clean and replace the turbocharger occasionally turns to Engine compression pressure is wrong Check and adjust engine compression black Defected nozzle inside engine Replace or repair nozzle L & T-9020 O-75...
Page 78 Use specified fuel Air filter getting clogged Replace or clean the filter element Engine fuel Engine overloaded Shift to lower gear and reduce load consumption Fuel connection leaks Tighten the loose connections Incorrect valve clearance Adjust valve clearance L & T-9020 O-76...
Page 79 Check the connections for leakage Abnormal noise Improper oil Use specified oil Damaged gears Replace the gears Damaged gears Replace the gears Machine moves slowly when in full Add oil to specified quantity Insufficient oil throttle L & T-9020 O-77...
Page 80 Replace the gears Air leak in suction line Repair the system Incorrect main relief valve setting Adjust the pressure setting Sluggish operation or Excessive clearance between spool and spool no movement Replace or repair the spool valve bore L & T-9020 O-78...
Page 81 Use specified engine lubricant oil for cranks slowly Incorrect viscosity engine lubricant oil different conditions Infrequent driving Charge periodically Low specific gravity Loose fan belt tension Adjust the tension in cells Current leaks Clean battery top terminals L & T-9020 O-79...
Page 82 Reverse position - Pin A and B Forward 2nd position - Pin A and C Ensure declutch switch is OFF and check Declutch Relay - R4 the supply across pin 1 and 3 of R4 relay. L & T-9020 O-80...
Page 83 Check 24 V supply at connector L05-1 Stop light bulb L06-1 Fuse Check Fuse F16 and F17 Detents coil not Check 24 V supply at following terminals working at various operation in automatic mode : Proximity switch Height operation - C28-2 L & T-9020 O-81...
Page 84 Trouble shooting Float operation - C29-2 Roll back operation - C30-2 Fuse Check Fuse F-15 Safety solenoid not Rocker switch Check 24 V supply at terminal T08 working Safety solenoid Check 24 V supply at C27-P2 ***** L & T-9020 O-82...
Page 85 MAINTENANCE Trouble shooting This Page is Intentionally Left Blank L & T-9020 O-83...
Page 86: Specifications
SPECIFICATION SPECIFICATIONS L & T-9020 O-84...
Page 87 Hydraulic cycle time (Rated load in bucket) KMPH Raise 5.1 sec Forward – 1 Low Turbine Dump 1.9 sec High Turbine Lower 2.8 sec Forward – 2 Low Turbine 16.1 High Turbine Reverse Low Turbine High Turbine 11.8 L & T-9020 O-85...
Page 88: Operating Specifications
(With Weld on Tooth) 886 kg Note:  Operating Specifications are as per SAE J818, SAE J732 & SAE J742.  Materials & Specifications are subjected to change without notice.  Loader flow includes steering pump flow also. ***** L & T-9020 O-86...
Page 89: Static & Operating Dimensions
Overall Width 2325 mm Machine Clearance Radius (Over 5021 mm the tyres) Loader Clearance circle 5795 mm Articulation Angle 40 deg Load Over Height 3495 mm Note:  Measured with Weld on Teeth & Standard tyre. L & T-9020 O-87...
Page 90 MISCELLANEOUS This Page is Intentionally Left Blank L & T-9020 O-88...
Page 91: Miscellaneous
MISCELLANEOUS MISCELLANEOUS L & T-9020 O-89...
Page 92: Manual Revision Request Form
Photocopies or sketch, use Sheet if needed. Typing Preferable) SI.NO Group No. Page No. Correction Details Comments / Suggestions to Improve Publication review done by: Sl.No. Action Details Remarks __________________ ________________ Publication in charge Service Manager ***** L & T-9020 O-90...
Page 93: Quick Reference Information
MISCELLANEOUS Quick Reference Information Quick Reference Information ITEM NO ITEM DESCRIPTION REMARKS ***** L & T-9020 O-91...
Page 94: Periodic Maintenance
Periodic Maintenance DATE SERVICE METER READING REMARKS DELIVERY PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC PERIODIC ***** L & T-9020 O-92...
Page 95 MISCELLANEOUS Quick Reference Information L & T-9020 O-93...