# Comprehensive Maintenance Guide for Changjian Loader Summer Cooling Systems

Comprehensive Maintenance Guide for Changjian Loader Summer Cooling System I. High-Temperature Warning Indicator Monitoring System 1. Core Temperature Threshold Monitoring - Water temperature gauge warning range: 85-95°C (red zone). - Hydraulic oil temperature critical value: ≤85°C (efficiency drops by 15% when exceeded). - Turbocharger housing temperature: ≤120°C (detected via infrared thermometer). 2. Smart Warning System Setup - Install additional temperature sensors (three-channel monitoring for engine/hydraulic/transmission). - Cab audible and visual alarm linkage (automatic alert when temperature exceeds limits). - Remote mobile monitoring (4G module for real-time data transmission). II. Deep Maintenance Procedures for Cooling System 1. Water Cooling System Maintenance (every 250h) - Radiator dust removal: reverse blow cleaning with 0.3MPa compressed air. - Coolant replacement: ethylene glycol type (freezing point -35°C / boiling point 129°C). - Pipeline pressure test: hold at 1.5 times working pressure for 5 minutes. 2. Hydraulic Oil Cooler Maintenance - Clear fin gaps (using dedicated comb tools). - Check air guide hood sealing (air leakage rate <5%). - Install insect screen (20-mesh stainless steel mesh). 3. Air Conditioning System Specialized Maintenance - Condenser cleaning (neutral cleaning agent pH 6-8). - Refrigerant pressure check (high side 1.5-1.8MPa / low side 0.2-0.25MPa). - Compressor belt tension adjustment (deflection 10-15mm). III. Adaptive Modifications for High-Temperature Conditions 1. Active Cooling Solutions - Install electric fan (power ≥300W). - Upgrade oil cooler (heat exchange area increased by 30%). - Thermal insulation wrapping (ceramic fiber material for turbo section). 2. Passive Protection Measures - Reflective film application (on engine hood surface). - Sunshade extension (60cm extension over cab roof). - Ventilated seat modification (with 4 cooling fans). IV. Emergency Handling of Typical Faults Fault Symptom | Temporary Solution | Root Cause Remedy Excessive water temperature | Turn on heater to assist heat dissipation | Clean radiator / check thermostat Poor AC cooling | Flush condenser fins | Recharge R134a refrigerant Hydraulic system overheating | Stop operation and run at idle | Replace with 32# anti-wear hydraulic oil Tire overheating | Reduce driving speed | Adjust tire pressure to 80% of standard value V. Operating Procedure Optimization 1. Time Management - Avoid continuous operation from 11:00-15:00 (implement "work early, rest midday" schedule). - Shorten single operation sessions to 2 hours during high-temperature warning weather (35°C+). 2. Load Control - Reduce rated load by 10-15%. - Adjust lifting speed to 80% of standard gear setting. 3. Shutdown Management - Run at idle for 3 minutes before engine cutoff (turbo cooling). - Park with front facing the wind direction. - Cover exhaust pipe (to prevent rainwater backflow). VI. Maintenance Schedule and Record Table Item | Daily Check | Weekly Maintenance | Monthly Service Coolant level | √ | - | - Radiator cleaning | - | √ | - Belt condition | √ | - | √ AC refrigerant | - | - | √ Hydraulic oil temperature | √ | √ | - Appendix: Changjian Genuine Cooling System Parts Codes - Water pump assembly: CJ-WP2035. - Silicone oil fan: CJ-FAN4820. - Radiator assembly: CJ-RAD3050. VII. Economic Benefit Analysis 1. Preventive Maintenance Benefits - Failure rate reduced by 60%. - Cooling system service life extended by 2 years. - Fuel efficiency improved by 8-12%. 2. Cost Comparison - Routine maintenance cost: approximately 200 RMB/month. - Major overhaul cost: ≥15,000 RMB per occurrence. Case Data: After implementing this program at a quarry: - Engine overhaul interval extended from 4,000h to 6,000h. - Summer downtime rate reduced from 18% to 5%. - Annual repair cost savings of 23,000 RMB per unit. It is recommended to establish a "High-Temperature Season Special Protection File" to record daily key temperature data and maintenance measures, providing data support for equipment health management. When temperature warnings occur for 3 consecutive days, immediate deep system maintenance should be performed.