CG938H Wheel Loader. Manual - part 34

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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. 

z  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 

Filter and pump body 

1． Open the engine fuel system vent valve. 

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 

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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 

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

manual’s safety chapter shall be read and understood. 

z  Firstly carry on the aforementioned examination items 

z  Firstly, carry on the aforementioned 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 

the bucket and exert downward pressure on it slightly. 

Close the parking brake and shutdown the engine. 

4.  Disassemble the oil drain plug at the bottom shell of the gearbox to discharge the 

oil, clean and fit on the oil plug. 

5.  Disassemble the oil drain plug which locates below the torque-converter’s oil 

radiator at the backmost of the machine and discharge the oil. Clean and fit on 

the oil plug. 

6.  Replace filter. 

7.  Fill up oil with special volume into the torque-converter and fill to the high 

position of the oil gauge when the machine is offstate. 

8.  Start engine and pedal the service brake. 

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9.  Under the idle speed, slowly manipulate the joystick of the gearbox, and recycle 

the oil so that oil torque-converter and pipeline may be full of oil. Check the oil 

level of the torque-converter which shall between the low and high level of the 

oil gauge. 

10. Set the joystick of gearbox at stop short, shutdown the engine and park it well. 

Specific see “Instructions of 4WG200 Power Shift Gearbox”. 

Gimbal of driving shaft 

1． Fill lithium-based lubricant into the grease fitting of the gimbal of middle shaft.   

2． Fill lithium-based lubricant into the grease fitting of the gimbal of forward shaft. 

3． Fill lithium-based lubricant into the grease fitting of the gimbal of fork of rear driving 

shaft. 

4． Fill lithium-based lubricant into the grease fitting of the gimbal of rear driving shaft. 

Additional Maintenance Contents for the First 1500 Hours after 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”. 

9.9 Maintenance of Each 2000 Working Hours or Every Year 

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

manual’s safety chapter shall be read and understood. 

z  Firstly carry on the aforementioned examination items 

z  Firstly, carry on the aforementioned items. 

Oil in hydraulic tank 

Replace oil. 

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Let the machine work for longer hours to heat the oil. 

The machine shall be on level ground, set all working devices in the ground and exert 

downward pressure on them. Close the parking brake and shutdown the engine. 

1．Disassemble the oil filling cap of the hydraulic tank. 

2. Open the vent valve at the bottom of the hydraulic tank and discharge the oil. 

3. Close the vent valve. 

4. Replace the filter of hydraulic system. See “Hydraulic System” in “Maintenance of Each 

500 Working Hours or Every Season”. 

5. Disassemble the fuel strainer, clean it and install it. 

6. Refuel to the hydraulic tank. See “Viscosity and Full Capacity of Oil”. 

7. Check the gasket of the oil filling cap and replace the damaged gasket. 

8. Fit on the oil filling cap. 

9. Start the engine and run it for a few minutes. 

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

through the oil filling port. 

11. Shut down the engine. 

Differential gear and final transmission 

Replace oil. 

1. Disassemble the oil drain plug of front axle and rear axle, and discharge the oil. 

2. Clean the oil drain plug and reinstall it. 

3. Disassemble the oil drain plug of front axle and rear axle, refuel the axle through the oil 

filling port till bleeding. See figures and tables in “Viscosity and Full Capacity of Oil”. 

4. Install the oil drain plug. Start the engine and let it work for a few minutes. Re-check the oil 

level and refuel to the specified position if necessary. 

5. Install the oil drain plug. 

Service brake system 

Check the preliminary filling pressure of nitrogen gas of the accumulator. 

Please connect with the appointed maintenance service of the SICHUAN CHENGDU 

CHENGGONG CONSTRUCTION MACHINERY CO.，LTD. to check the preliminary 

filling pressure of nitrogen gas of the accumulator for you. 

Caution