CG935G Wheel Loader. Manual - part 25

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Check AC generator belt and cooling fan belt conditions and tension. The belt sagging should 

be 14-20mm under an 110N force, otherwise adjustment is necessary. 

Cooling Fan Bearing 

Lubrication 

Open service door in engine to lubricate cooling fan bearing. 

Additional Maintenance Contents for the First 200 Hours after Usage of New 

Loader Are Given below 

Gearbox Oil 

Check oil cleanness, and replace oil if polluted. 

Refer to “Gearbox Oil” in Maintenance after 50-Hour Running-in of New Loaders. 

Front Axle and Rear Axle 

Check the cleanliness of the oil and replace it if it is dirty. 

See the steps in “‘Front axle and rear axle’ in the maintenance of 50 hours running-in of 

new loader”. 

Working device and hydraulic steering system 

Check the cleanliness of the oil and replace it if it is dirty. 

To see the steps in “‘Working device and hydraulic steering system’ in the maintenance of 

the running-in 50 hours of new loader”. 

9.7 Maintenance of Each 500 Working Hours or Every Season 

 Firstly carry on the aforementioned examination items 

Crankcase scavenging valve of engine 

Clean scavenging valve 

Carry on cleanup according to the service manual of diesel engine. 

Gearbox 

Replacing Filtering Element 

1. Open service door. 

2. Dismount filter casing. 

3. Dismount and discard old filtering element. 

4. Clean filter casing with clean nonflammable solvent. 

5. Clean casing base. 

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6. Install a new filtering element in the casing. 

7. Check filter casing seal and replace it if damaged. 

8. Start engine and apply brake. 

9. Slowly operate gearbox control lever to circulate gearbox oil. 

10. Place gearbox control lever on neutral position to check for leakage. 

11. Keep the oil at specified level, and add oil through filler pipe if necessary. 

12. Shut down engine and close service door. 

Hydraulic system 

Replace filter. 

1． Disassemble the oil filling cap, and release the pressure inside the gasoline tank. 

2． Loosen the fixed bolts of the filters. 

3． Disassemble the lid and filter element. 

4． Discard the filter element. 

5． Check the O-Ring and it shall be replaced if necessary. 

6． Install new filter element and lid, and tighten the fixed bolts of the lid. 

7． Maintain the hydraulic oil level in the middle of the oil gauge, and if necessary, refuel it 

through the oil filling port. 

8． Check the seal of the lid of oil filling port, replace the gasket if it is damaged, and install 

the lid of oil filling port. 

Fuel oil system 

Clean and replace the filter. 

Clean the coarse filter element. 

Carry on working according to the service manual of diesel engine and the following steps 

are for reference only. 

 Open the maintenance door by the side of the machine. 

 Loosen the holding bolt on the shell of the filter. 

 Discard the shell and filter. 

 Disassemble the filter element from the lag. 

 Clean the filter element and shell in clean, non-flammable solvent. 

 Dry the filter element by compressed air. 

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 Clean the shell base of the filter. 

 Check the seal ring and replace it if it is damaged. 

 Install clean filter element. 

 Encase the filtering element and lag. 

 Re-tighten the bolts. 

Before the installation of filter, do not refuel. Impure fuel oil will cause the 

accelerated wear of the fuel oil system. 

Carry on working according to the service manual of diesel engine and the following steps 

are for reference only. 

1． Disassemble the filter and discard it as useless. 

2． Clean the filter fixing base, and make sure that all the old seal rings have removed. 

3． Smear clean diesel on the new filter seal ring. 

4． Install new filter by hand and twist another three-quarters circle when the seal touch the 

base. 

5． Start the diesel engine system (see below). 

Start the fuel system. 

If the engine fails to start or run smoothly after refueling the filter and oil pump body, the 

injection pump and pressure duct shall be started with refueling. 

Each injection pump has an overflow one-way valve, which can not be opened by manual 

pump pressure. Refuel the injection pump and pipeline according to the following steps. 

 If loosen or tighten fuel line nut by only a wrench, the fuel injector may be 

irremediable defect by distortion. So clamp the injector by a wrench and loosen the 

nut by another wrench. 

1． Loosen spray bar at the engine junk head. 

2． Set the acceleration control leer to low speed idle position. 

3． Start the engine and stop it till the diesel flow out from all pipelines and no air bubbles. 

4． Tighten the nut of fuel oil pipe with a torsional moment of 40±7N.m, and chuck the injector 

with another wrench to prevent damage. 

5． Start the diesel and check its leakage. 

6． Close the maintenance door. 

Start pump 

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Filter and pump body 

1． Open air release valve for fuel system on pump body. 

2． Loosen the priming pump plunger and press it up and down. 

3． Close the pump and lock plunger when there is no bubble as the fuel oil flows out. 

4． Close the vent valve. 

5． Start the diesel and check its leakage. 

Fuel tank lock and fuel strainer 

Oil filling cap of the fuel tank locates in the back of the machine. 

1． Disassemble the lid. 

2． Replace the lid if the gasket is broken. 

3． Take out primary strainer from the oil filling port. 

4． Clean the primary strainer with clean, non-flammable solvent. 

5． Fit on the primary strainer. 

6． Fit on the oil filling cap of the fuel tank 

Additional Maintenance Contents for the First 600 Hours after the Usage of 

New Loader Are Given Below 

Differential gear and final transmission 

Replace oil. 

See oil replacement in “Front axle and rear axle’ in the maintenance of 50 hours running-in 

of new loader”. 

Working device and hydraulic steering system 

Replace oil. 

See the steps in “‘Working device and hydraulic steering system’ in the maintenance of the 

running-in 50 hours of new loader”. 

9.8 Maintenance of Each 1000 Working Hours or Every Half An Year 

 Firstly carry on the aforementioned examination items 

Gearbox oil 

Replace the gearbox oil. 

Start the engine to hear the oil and the machine shall be set at a level position. Set down