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CG938H Wheel Loader. Manual - part 33

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Test the braking capacity of the parking brake.

There shall not have any people and obstacles around the machine.

Fixed link of the front and rear frames shall be packed up.

Carry on the test on dry cement road which slant angle is about 8 degree and the length

of the slope is about 20 meters.

The following tests are used to determine whether the service brake functions are normal

or not, not to measure the maximum braking force.

1． Start the engine, and raise the bucket to the transport position (40 centimeters above the

ground).

2． Drive the machine to the center of the slope, tramp the service braking pedal to stop the

machine (do not loosen the pedal at this time).

3． Set the gearshift to the stop short and close up the parking brake.

4． Loosen the service braking pedal (shall not turn off the engine), observe whether the

machine moves down or not. At this point in time, if the machine doesn’t move in five

minutes, the parking brake is normal.

Warning

If the machine moves, immediately tramp the service braking pedal to stop the

machine and quickly drive it off the slope.

Caution

If the machine still moves when testing the parking brake, please connect with

related service station and allow serviceman to check the machine. If necessary, the

parking brake shall be repaired or adjusted before re-use the machine.

Cooling system

Add coolant additive.

Caution

Do not add additive randomly before reading and understanding the content of the

chapter “Cooling System Specification”.

The maintenance door of the radiator cap is located on the top of the aft closure of the

machine.

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1． Open the maintenance gate.

2． Slowly unscrew the radiator cap and release pressure.

3． Add 0.25L coolant.

4． Fit on the radiator cap and close the maintenance gate.

Splines of propeller shaft

Lubricant splines

1． Disassemble the fixed link of the front and rear frames and start the engine.

2． Turn the machine right or left to the limit position.

3． Put the bucket on the ground, close up the parking brake, and shutdown the engine.

4． Lubricate the hinged splines of propeller shaft.

Air-conditioning

Service test - adjusting belt

1． Start the engine and allow it run at high speed idle.

2． Set the temperature knob of the air-conditioning at the largest refrigeration position

(anticlockwise at full) and the switch of air volume at high position.

3． Wait two minutes for the stability of the air-conditioning system.

4． Check the refrigerants of the system by the following methods: touch the low-voltage

tube and high-voltage tube by hand. If there has any refrigerant in the system, the

high-voltage tube shall be hotter than the low-voltage tube. If there has no refrigerant or

few, the air-conditioning system will stop working.

5． Shut down the engine and check the compressor belt.

6． Check the work and adjust the compressor belt. The belt shall lop to 14~20mm under a

power of 110 Newton.

7． Screw the adjustable nut till it gets the correct belt tension and tighten the nut to

150±20N.m.

8． Re-examine the regulation of the belt.

9． Repeat the 1~3 steps.

10． If the refrigeration is poor, shut down the air-conditioning and the engine. Connect

with the service station for the maintenance of the air-conditioning if necessary.

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Additional Maintenance Contents for the First 200 Hours after Usage of

New Loader Are Given below

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

z Firstly carry on the aforementioned examination items

z Firstly carry on the aforementioned items.

Before carrying out any operation or maintenance, the warnings and annotations in this

manual’s safety chapter shall be read and understood.

Crankcase scavenging valve of engine

Clean scavenging valve

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

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

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the lid of oil filling port.

Fuel oil system

Clean and replace the filter.

Caution

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

accelerated wear of the fuel oil system.

Clean the coarse filter element.

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

steps are for reference only.

1． Open the maintenance door by the side of the machine.

2． Loosen the holding bolt on the shell of the filter.

3． Discard the shell and filter.

4． Disassemble the filter element from the lag.

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

6． Dry the filter element by compressed air.

7． Clean the shell base of the filter.

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

9． Install clean filter element.

10． Encase the filtering element and lag.

11． Re-tighten the bolts.

Replace the thin fuel oil filter

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.

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