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CG935G Wheel Loader. Manual - part 19

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III Daily Maintenance Guide

“Healthy examination” for the loader shall be conducted regularly or irregularly

(examination and repairing).

Causes of failure or lower performance of the loader shall be found out early and removed

in time. In this way, a higher production rate and long service life may be attained.

Grease or oil accumulated on the loader will cause a fire. Therefore when the loader works

for some time (about 1000 hours), the grease or oil on the loader shall be cleaned with

steam or high-pressure water.

Prior to maintenance, all joints, caps and blocks shall be wiped away.

In case the leakage is suspected or found out, the liquid level shall be examined regularly.

The hinging part of the frame is the central unit connecting with the front and rear frames.

Good lubrication of the hinging part can ensure the normal and safety operation of the

machine.

Regularly lubricate the pin of the rotating and hinging parts to extend the service life.

Regularly examine whether all parts have any deformation, crack or abnormal factor.

In hoisting, the lifting lug on the frame shall be used. Hoisting weak part and pin hole is not

allowed so as to prevent them from damage.

As the external power source is used to start the engine, please follow the explanation of

“Starting of Engine” in the chapter of “Operation”.

The machine has one 24kv starting system. Starting the engine with the external power

source only can use the voltage of 24kv. High-pressure voltage will damage the electrical

system.

Examine the dust and foreign substances on the coarse filtering net. If necessary, the dust

and foreign substances shall be eliminated. Prior to discarding the coarse filtering net, clean

it for six times. In cleaning the filter element, examine completely whether the filtered

material has any crack. The filter shall be replaced once per year, even if the time of

cleaning does not reach 6 times. As the coarse filter is repaired for three times, the thin

filter shall be replaced.

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IV Maintenance of Engine’s Cooling System

4.1 Coolant

Keeping normal working temperature of diesel engine will improve the efficiency of the

engine. Therefore it is necessary to maintain the cooling system properly. Overheat,

overcooling, pitting corrosion, gaseous cavitation, crack of cylinder end, piston sticking and

blockage of radiator are common failures of the cooling system.

It is suggested to add 30% anti-icing fluid into the cooling mixture. Under the working

temperature of the engine, all kinds of water have causticity, regardless of the high

concentration of the anti-icing fluid. 3%~ 6% coolant additives shall be added to protect the

cooling system.

Do not add coolant into the overheated engine, or not the engine will be damaged. Prior to

adding the coolant upon request, the engine shall be cooled firstly.

As the concentration of the additive exceeds 6%, and the sum of the additive’s

concentration and the one of the anti-icing fluid exceeds 65%, sedimentation will be

formed, and results in blockage of radiator’s pipe, engine’s overheat and inefficient sealing

of water pump.

If the machine is stored or transported to the area 0℃ below, the cooling system shall be

protected as per the possible minimal temperature.

Under lower temperature, the specific gravity of the coolant shall be examined frequently

so as to facilitate taking enough protective measures.

If the coolant is polluted, the engineer is involved in overheat or radiator has foam, the

cooling system shall be cleaned.

Per 1500 hours or one year, the coolant shall be discharged, and the system shall be cleaned.

And new coolant shall be added.

In case the speed of adding coolant exceeds 20L/min, air bubbles of cooling system will be

caused possibly.

After adding the new coolant, start the engine and uncover the radiator until the coolant is

up to the normal working temperature and the liquid level is stable. If necessary, more

coolant shall be added in the system until reaching the proper liquid level.

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4.2 Cooling Water

If hard water or water with many calcium or manganese

ions mixes with the silicon and phosphorus of the

additive in the cooling system, indissoluble compound

will be formed easily.

The tendency that silicon and phosphorus form

indissoluble compound will increase with the increase of

the water’s hardness. After a series of heating and

cooling circulation, the hard water or water with many

calcium or manganese ions will form indissoluble

compound easily.

We suggest using distilled water or plasma water to weaken the possibility and severity of

the formation of indissoluble compound.

ppm= number of particles per one million

Using the water that meets this requirement not always prevent the formation of the

indissoluble compound, but reducing the rate of deposition for eligible level.

4.3 Anti-icing Fluid

The coolant shall adopt the eligible water and shall contain about 30% anti-icing fluid so as

to maintain the operation temperature of water pump’s cavity for a higher efficiency of the

water pump.

To protect the possible minimal ambient temperature, antifreezing agent may be added in

the coolant in advance. The amount of the antifreezing agent depends on the antifreezing

agent purchased and possible minimal ambient temperature at the machine position.

Nevertheless, the concentration of the antifreezing agent in the coolant shall not exceed

60%. Over 60%, the antifreezing protection action on the engine will be weakened and the

possibility of precipitation formation in the cooling system will be increased.

Try best to buy anti-icing fluid with less silicate and proper coolant additive for heavy

diesel engine.

Add properly anti-icing fluid additive

Adding the anti-icing fluid as make-up liquid into the cooling system’s liquid is a kind of

unacceptable method. In this way, the concentration of the anti-icing fluid in the coolant will be

Usable Water Minimally

Ingredient of

Water

Ingredient of Water

Chlorine

(CL)

Chlorine (CL)

Sulfate (SO

) Sulfate

(SO

)

Total

hardness

Total hardness

Total

granularity

Total

granularity

PH value

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increased. The mixture of water and antifreezing agent shall be added into the cooling system.

Refer to the following table to determine the concentration of the anti-icing fluid (only as

reference, please see the user’s manual of anti-icing fluid for details)

Concentration of Anti-icing Fluid

Protection

Temperature

Concentration

-15℃ above

30% anti-icing fluid, 70%

water

-23℃above

40% anti-icing fluid, 60%

water

-37℃above

50% anti-icing fluid, 50%

water

-51℃above

60% anti-icing fluid, 40%

water

Ancillary coolant additive

The coolant additive is used to prevent rust, dust, pitting corrosion and corrosion of the

engine’s parts due to contact with the coolant. Most anti-icing fluid has no enough ancillary

coolant additive.

In the coolant, the additive or corresponding liquid of proper amount shall be added. The

coolant cannot be used separately, except the anti-icing fluid with the additive above. Under this

circumstance, the additive may not be added. Nevertheless, in the process of maintenance, the

additive shall be added.

As the coolant additive is used, the concentration in the cooling system may increase by

3%~6% to prevent corrosion.

In order to excessive antirust in the cooling system of the engine, the concentration of the

coolant additive shall not exceed the maximum 6% we recommend.

For a higher concentration of the additive, precipitation may be formed possibly at the

high-temperature surface of the cooling system, and an adiabatic layer may be formed to

weaken the heat exchange performance of the engine. The decrease of the heat exchange rate

will possibly cause the crack of the cylinder end and other high-temperature parts. The higher

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