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CONTENTS

Chapter 1 Introduction of Sany full hydraulic motor grader

Chapter 2 Fundamental structure and principle of Sany full hydraulic motor grader

Chapter 3 Main parts and components of Sany full hydraulic motor grader

Chapter 4 Technology sharp point and advantage condition

Chapter 4 Configuration and technical parameter of Sany full hydraulic motor grader

Chapter 5 Comparison of different brand name graders

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Chapter 1

Introduction of Sany full hydraulic


motor grader

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1.1 Definition of motor grader

The motor grader is a kind of construction machine which


is used to cut, scrape and plane the soil with shovel blade
and other assistant operation equipments.

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1.2 Application of the motor grader

1. Roadbed and road forming


2. Gravel and grit road repairing
3. Ditching, peeling off the sward and topsoil
4. Scrape border and slope
5. Moving, mixing, backfilling and pave the materials
6. Using back scarifier to furrow the dry and hard, or solid
soil
7. Using snow shovel to clean the snow on the highroad or at
the airport

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1.3 Category of the motor grader

1、According to the travel methods: trailer-mounted and


self-propelled
2、According to the driving methods: Mechanical,
Hydraulic-Mechanical and full hydraulic method
3、According to the frame form: whole frame and
articulated frame
4、 According to the number of driving wheels: 4 wheels
driving, 6 wheels driving
5、According to the power: light, medium, heavy.

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1.4 Motor grader model number and the naming rule

Refers to DEUTZ engine

Refers to COMMINS
engine

Power of engine (Horse power)

Sany first-generation full hydraulic Grader

Sany second-generation full hydraulic


Serial
Grader
Number

Sany Mechanical Grader

Sany brand

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Chapter 2

Fundamental structure and principle


of Sany full hydraulic motor grader

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2.1 Fundamental structure of full-hydraulic motor grader

Power system
Hydraulic system
Transmission system

Full-hydraulic motor grader Mechanical system Operation device

Driving operation
system
Electrical system
Fundamental structure
& accessories

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1-moldboard (optional); 2-frame;
3-nameplate; 4-operation device hydraulic
system;
5-swing frame;6-control console;
7-cab; 8-operation control device;
9-engine speed control device; 10-chair
11-air-conditioning system; 12-diesel engine
and accessories;
13-engine cover; 14-electrical system;
15-scarifier (optional); 16-wheel;
17-braking system; 18-reduction tandem
assembly;
19-rear axle frame; 20-diesel tank assembly;
21-traveling hydraulic system; 22-Hydraulic
power control system;
23-hydraulic angular device; 24-shovel blade;
25-worm-gear box; 26-working device;
27-steering hydraulic system;28-front axle
assembly;

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2.2 Working principle of full hydraulic motor grader
The motor grader is traveling and drive the working device to work
Driving principle
Engine→traveling pump→ traveling motor→ tandem (Gear box)→Driving
wheel (Rear wheel)
Steering principle
Hydraulic servo-aid, front wheel turning
Braking principle
Service braking: rear wheel hub braking, wheel hug brake
Parking braking: Tandem’s input axle braking, friction plate wet brake
Adjust working device to work
Shovel blade (6 DOF motion), front moldboard (lift and lower), back scarifier
(lift and lower)

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Chapter 3
Main parts and components of Sany full
hydraulic motor grader

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3.1 Power system

Engine body

Fuel system

Intake system
Power system
Exhaust system

Cooling system

Bearing system

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3.2 Driving device

The transmission route of Sany motor grader

1-engine; 2-hydraulic
pump;3、6-hydraulic
motor;4、7- reduction
tandem;5、8、9、10-
wheel;11-coupling

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3.2.1 Rear axle frame
Support function, connect rear frame and reduction tandem

1-axle frame; 2-copper washer; 3-wearable sleeve;


4-screw; 5-bottom plate; 6-oil cup

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3.2.2 Reduction tandem assembly
Transmission, speed reduction, bearing and the balancing of the front
and back wheels of the rear axle.

1-locknut; 2-brake drum; 3-brake; 4-connecting disc; 5-secondary driven gear; 6-


secondary driving gear; 7-shaft; 8-parking brake; 9-primary driving gear shaft; 10-copper
gasket; 11-lubrication free wearable sleeve; 12-hydraulic motor; 13-ring flange; 14-rear axle
frame; 15-primary driven gear; 16-tertiary driving gear shaft; 17- tertiary driven gear; 18-
wheel axle; 19-tandem body

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3.3 Braking device-Service brake, parking brake
3.3.1 Service brake
Inner expanding drum brake, installed in the 4 rear driving wheel hub.

1-brake plate; 2-piston push rod; 3-bleeder cap;


1-brake cylinder; 4-adjustable bolt;5-cam; 6-brake shoe; 7-friction plate;
2,3-brake shoe; 8-bearing pin; 9-oil cylinder; 10-resilience spring
4-resilience spring

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3.3.2 Parking brake
It is installed at the outside of the input axle of the 2 tandems. It retrains
the movement of the whole grader by restraining the rotation of the axle.
The normal-closed wet multi-disc brake is used, when the hydraulic oil is
functioning, the brake is released; when the press of the hydraulic oil is
discharged, the brake is active through the action of the disc-like spring.

1-Friction plate 8-Locknut


2-Disk-like spring 9-Oil cylinder body
3-adjusting washer 10-O-shape ring
Oil intake chamber 4-piston 11-outside hub of brake
5-piston rod 12-tandem body
6-protective cover 13-Gear shaft
7-splint pin

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3.4 Working device-shovel blade

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Category of the shovel blade’s working device

Pallet mode
According to the connection mode
of the circle and traction frame
Meshing mode

Shovel blade
Hydraulic motor-worm
gear reducer driving
According to the driving mode
of the circle rotation
Dual oil cylinder
driving

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Pallet-mode working device: Meshing mode working device:
simple structure, low cost High working accuracy, don’t
need frequent maintenance.

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Hydraulic motor-worm gear reducer Driving oil cylinder

Hydraulic motor-worm gear reducer driving,


The self-lock is active by the worm wheel and Dual oil cylinder driving working device
worm mechanical self-lock The self-lock is active by the hydraulic lock

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Structure and working principle of the shovel
blade working device

Swing frame Depth of shovel


into the soil
Traction frame Planing
Angle of the
shoveling
Circle adjust carry out
components Horizontal
declination Ditching
Worm gear box
Side tilt angle Scrape the border
blade bearing
and slope
Shovel blade Side stretch value

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Adjustment mechanism of the shovel blade
working device 1-swing frame;
2-left-lifting oil cylinder of the
shovel;
3-right-lifting oil cylinder of the
shovel;
4-swing oil cylinder of the
shovel;
5-oil cylinder for shoveling
angle’s change;
6-oil cylinder of stretching the
shovel;
7-angular device;
8-shovel blade;
9-circle;
10-worm gear box;
11-traction frame;

②③action to perform shovel’s lifting; ④action to perform shovel’s side-swing; ⑤action to


adjust the angle of shoveling; ⑥action to perform shovel’s side stretching; ⑩action to
perform shovel’s rotation; ①②③④⑥⑩combined action to perform shovel’s side tilting

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3.4.1 Swing frame
It is used to install the shovel’s left & right lifting oil cylinder and swing
oil cylinder; it can be rotate around swing frame support center of the
front frame, to increase side-swing distance of the traction frame and
shovel blade and it can be drive the shovel to side-tilt to 90°.

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3.4.2 Traction frame

It is connected the shovel and circle to the frame, and transmit the
power needed for shovel working from frame to circle, then to the shovel.

1-big ball-head pin; 2-arm; 3,4,6-small ball-head pin; 5-bottom plate; 7-


Worm gear box mounting seat

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3.4.3 Circle

The blade is installed on the circle by angular device;

1-gear ring; 2, 4-cylindrical pin; 3-lug plate

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3.4.4 Worm gear box

It is used to drive the circle to rotate. It has the reduce-speed,


increase-torque and self-lock functions.
Friction plate

Common worm gear box Overloading protective worm gear box

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3.4.5 Blade bearing
Support the blade body and adjuct the angle between blade body and
vertical plane.

Oil cylinder for shoveling angle’s Oil cylinder for shoveling angle’s
change change

Dual oil cylinder Single oil cylinder

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3.4.5 Blade body

The intrados of the shovel body is the working face during


scraping the soil.

1-side blade; 2-main blade; 3-blade body; 4-bolt; 5-nut

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3.5 Working device-Moldboard
It is used to push a few of gravel or soil and assist shovel to plane
and pave the materials and so on. Normally it is installed at the
head of the frame.

1-moldboard;
2-working oil cylinder;
3-blade;
4-bearer

The moldboard is optional, and ordinarily


it is not chosen with the front
counterweight simultaneously.

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3.6 Working device-Scarifier

The purpose of using scarifier

is to enhance the construction

ability for harder road. It can be

installed at the tail of the grader.

Use the scarifier first to scarify

the road, then use the shovel to

scrape or use moldboard to

push the soil.

1-oil cylinder of scarifier; 2-tooth frame; 3-big tooth; 4-


small tooth

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3.7 Driving control system

Operation control device-Operator use 10 handles to control the action


during operation.

1-handle ball;2-handle 1; 3-handle 2; 4-


compound bearing; 5-fixed axle; 6-
conntecting rod; 7-protective sleeve; 8-
protective cover; 9-lever-rocker mechanism;
10-valve block mounting plate; 11-multi-way
valve

Control: Lift and lower, swing, rotation,


stretch of the shovel, shovel’s angle
adjustment, tilt of the front wheel,
articulated steering, lift and lower of
the moldboard and scarifer.

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Control console-install the operation control
device, steering wheel etc.

1-control head; 2-front rocker arm;


3-back rocker arm; 4-rack; 5-support;
6-spring; 7-bolt rod; 8-pedal

Control console body can be adjusted


to lean forward and backward, the
adjustment range is 65-90°; The
control head can be tilted at 15°too.

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Cab and accessories-the full floating structured is used for the cab

1-front control panel; 2-steering


wheel; 3-operation control handle;
4-brake panel; 5-accelerator pedal;
6-right control box; 8-gear device;
9-parking brake

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3.8 Front axle
Front axle is the steering axle, which controls the traveling
direction of the grader.

Turning angle of the front


wheel:±45°

Swing angle of the front


wheel:±15°

Tilt angle of the front


wheel:±17°

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3.9 Frame

1-front frame; 2-axis pin; 3-back frame; 4-axis pin

The front frame can be swung


15° around the articulated
Cylindrical pin of the front
and back frame and achieve
the turning at narrow space.

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Chapter 4

Technology sharp point and


advantage condition

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4.1. Higher reliability

 Full hydraulic driven technology


 Synchro-split-flow technology
 Load self-adaption

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Full hydraulic driven technology

 Automaticly gearshift
 Adjust speed without stage
 Operation comfortable
 Maintain convenience

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Synchro-split-flow technology

 Automatic control— pressure and speed collect by itself, the


procedure control input,secure.

 High synchronism— it hasn’t trackslip, drawforce is steady.


 Steady working— small pressure force shock, the radiation of
system is little.

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Load self-adaption technology

 Power self-adaption
 Obvious save energy efficiency
 Light labour intensity
Reduce speed
Large
Improve drawforce
Load
Add the speed

Small
Improve efficiency

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4.2. High reliability

 High configuration
 Optimization design
 Strict test

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Advanced configuration
Driven,pump,motor,multi-valve, diverter valve etc. key
point spare parts use the famous brand to ensure the quality.

Component Manufacture
Driven Deutz
Travel pump REXROTH
Travel motor REXROTH
Diverter valve REXROTH
Dual-hydraulic Parke
valve
Multi-way HSIK
steering valve

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Optimal design
 Power system-
Radiator inlet system fuel system

 Working device—
Rolling type, single shovel oil cylinder,
new scarifier

 Hydraulic —
Buckle and press air filter Fuel tank
Travel,brake,filter system

Rolling plate circle Single oil cylinder working device New scarifier

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Strict test

Automatic grade
Intensity test Destroy test
partial load work

Plum blossom pole test Draw performance test Dig channel

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4.3. High degree intelligentize

 Integration control technology


 Strong human-computer interface
 Intelligent fault diagnose system

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Integration control technology
SYMC

 SYMC,SYLD,SYMT controlled
via CAN bus line.

 Integration control box

SYLD

Integration control box


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Powerful human-computer interface

Lagrange choice

 Apply 5 kinds of language and change


freely

 Background light LED display, virtual


meter,alarm light.

 The data of product is displayed,


edited and also password protected.

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Breakdown intelligent diagnose system

 Data monitoring—real time monitor/ history


check /data statistics

 Self alarm—window popup/ indicator/ indicate


 Intelligent mention—fault treatment maintain
mention

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4.4. High safety performance

 Hydraulic assistance brake


 Accumulator still can offer 6
effective brake when brake circuit is
lose efficacy.

 Cab satisfy the international


security demand of ROPS,FOPS

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Chapter 5

Configuration and technical parameter of


Sany full hydraulic motor grader

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5.1 Main configuration of Sany full hydraulic motor grader

Item PQ190C/CA PQ190Ⅲ/ⅢA PQ160C SHG200

DEUTZ DEUTZ
BF6M1013E/ DEUTZ
TCD2012L06/COM COMMINS
Engine BF6M1013EC-
COMMINS MINS QSB6.7- QSB6.7-C192
C200
6BTA5.9-C200 C192
Traveling REXROTH REXROTH REXROTH REXROTH
plunger A4VG125EP4D1 A4VG125EP4D1 A4VG125EP4D1 A4VG145EP4D1
pump /32R-NAF02F0 /32R-NAF02F0 /32R-NAF02F0 /32R-NAF02F0
REXROTH REXROTH REXROTH REXROTH
A6VE160EP2/63W A6VM200EP2/63 A6VE160EP2/63W A6VE160EP2/63W
Plunger
- W- - -
motor
VAL027FTDB+HD VAB027FTB+HDD VAL027FTDB+HD VAL027FTDB+HD
D1 2L32/10 D1 D1

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Item PQ190C/CA PQ190Ⅲ/ⅢA PQ160C SHG200

central
SANY SYMC SANY SYMC SANY SYMC SANY SYMC
module
Working
Pallet mode Meshing moe Pallet mode Pallet mode
device
Shovel 3660mm(standard) 3660mm(standard)
3660mm
3965mm(standard)
blade 3965mm(optional) 3965mm(optional) 3660mm(optional)

Air
conditioner
optional optional optional optional

Moldboard
optional optional optional optional
/scarifier
12PR wave 12PR wave 12PR wave 12PR wave pattern
tyre
pattern tyre pattern tyre pattern tyre tyre
Front
counterwe optional optional optional standard
ight

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5.2 Main technical parameter of Sany full hydraulic
motor grader

Main technical
PQ190C/CA PQ160C SHG200
parameter
Overall weight
(basic model/Largest 15200/16830 12800/14870 15300/16800
model)kg

overall
Overall 8833×2648×32 8515×2498×32 9035×2648×32
dimensions(length*w
perfor idth*height) mm 15 40 45
mance
Axle base of front &
param rear axlemm
6208 5915 6208
eter
Max.
speed(forward)km/h
31.6 30 31.6

Working gears 5FWD/5RVE 5FWD/5RVE 5FWD/5RVE

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Main technical parameter PQ190C PQ160C SHG200

3660(396 3965(3660
Shovel size (optional size) mm 3660
5) )
operati Max. right side shift distance of
2500 2422 2500
on the shovel mm
perfor Max. left side shift distance of
mance the shovel mm
1970 1892 1970
param Max. lifting height of the shovel
eter mm
420 440 420
Max. depth of the shovel into
the soil mm
500 500 500

Custo Overall passable ability (Min.


7.9 6.8 7.9
mer turning radius) m
concer Oil consumption per house L/h 25.8 20 25.8
ned
perfor Noise near the ear of the driver
dB
84 84 81
mance
param Noise radiated outside the
eter machine dB
92 92 90

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Chapter 6

Comparison of different brand name


graders

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6.1 CAT mechanical motor grader
Main products:
120H, 135H, 12H,140H, 160H ,163H,
14H, 16H, 24H, 120M, 140M, 160M, 14M,
16M, the complete product series from
120 horsepower to 500 horsepower model.
Technical feature:
Gearbox direct transmission: 8 forward gears, 6 reverse gears, 1-4 gears for low-speed,
high-torque operation, 5-7 gears for high-efficiency snow-fighting. It possesses on-the-go,
full-power shifting function;
Electronic over speed protection: prevent engine and gearbox’s damage from downshift
before time or over speed on the downgrade;
Carry out inching function through inching pedal, complete the gradient finishing working
and working at narrow space;
Using ECU technology to increase working efficiency and decrease the oil consumption and
abrasion of the tyre;
SYMC, Engine, Gearbox perfect match to achieve power change control and front wheel
“crawling” driving.
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Transmission principle of mechanical grader

Engine Gear box Rear-axle Wheel


assembly
Wheel

Gear box Tandem

trans engine Rear-axle


missi
on
shaft

Parking brake

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6.2 Hydraulic-mechanical grader—KOMATSU,XCMG,
TIANGONG
Transmission principle of Hydraulic-mechanical grader

Engine Torque Gear box Rear-axle Wheel


converter gear assembly
box wheel

dosing pump Torque


converte
r Rear-axle

Parking brake

Transmissi
on shaft

Tandem

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Torque convert: pump impeller,
Torque guide pulley, turbine
converter Lockup function: direct drive

Gear
Gear ratio speed
Gear box gears meshi
ng Axle directi
steering on
Bevel gear Deceleration, turning 90O

Transmiss differential The differential speed of driving


ion axle
wheels at both sides when steering
Planet gear reducer Secondary speed-reduction,
power transferring

sprocket To achieve synchronization of driving wheels at both


wheel box sides during straight line traveling

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6.2.1 KOMATSU Hydraulic-mechanical grader

Main products:
The product series have move than 20 types from 65HP to 500HP, the main products are
GD series, the updated series is Laterra.
Technical feature:
KOMATUS power shift gear box, on-the-go shifting,
6 forward gears, 6 reverse gears, inching ability,
automatic shifting for high speed gears;
Laterra series support drive mode switching:
Torque converter mode for heavy load operation,
which has strong traction power,
good low-speed performance;
Direct drive mode for high speed traveling;
Shovel blade rotary accelerated function to increase production rate;
Hydraulic system of working device uses load-sensitive variable closed system.

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6.2.2 XCMG Hydraulic-mechanical grader

Main products:
GR135、GR165、GR180、
GR200、GR215、GR300
Technology origin:
Imitate TIANGONG technology
Product configuration:
Engine: Dongfeng COMMINS,
Shanghai Diesel, Import COMMINS ;
Transmission system: Xuzhou Meichi axle,
Hangzhou Gear or Liuzhou ZF gear box
Hydraulic, brake system: Domestic pump, Italian or REXROTH valve;
Monitor & Control system: Gears selector (import), PLC main controller,
text displayer (REXROTH), import instruments.

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6.2.3 TIANGONG Hydraulic-mechanical grader
Main products:
PY80、PY100、 PY160、 PY180、PY200、 PY220、PY220G、PY250、
PY280
Technology origin:
Imitate USSR technology and product
the first grader product in 1962;
Imported Germany FUN technology in 1985;
Imported main components of Caterpillar
16G large grader, and manufacture large
grader in 1990.
Product configuration:
Engine: Shanghai Diesel D6114, Weichai WD615 or 6BTA, DEUTZ,
Dongfeng COMMINS, Steyr WD615;
Transmission system: self-made rear axle, Hangzhou Gear 6WG180,
Liuzhou ZF6WG200 gear box.

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6.3 Comparison of Sany full Hydraulic motor grader
and other brand grader
Oil consumption:
——The oil consumption is a little lower than CAT grader and much
lower than KOMATSU, XCMG, TIANGONG grader and so on.
Operability:
——Sany grader possess the features as stepless speed change and
automatic gears shifting so the difficulty and strength of driving is
much lower than other brand graders.
Price:
——The price of Sany grader is much cheaper than CAT, KOMATSU
and other overseas brands’, but it is more expensive than domestic
brands’.
Reliability and working efficiency:
——The reliability of Sany grader is a little lower than CAT, KOMATSU
and other overseas brands’, but it is higher than domestic brands’;
——The Max. speed of Sany grader is slower than CAT and
KOMATSU’s but the reverse speed is higher than other brands’.

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After-sales service:
——The after-sales service of Sany is better than other
brands’.
Hardware configuration:
——The engine, hydraulic pump and motor of Sany are all
world-class products. The configuration is not lower than CAT,
KOMATSU and other overseas brands’ and much higher than
XCMG, TIANGONG and other domestic brands’.
Disadvantage analysis of Sany grader:
——The full hydraulic system of Sany grader needs closer
maintenance.
——The Max. speed is lower as 35km/h
——Using DEUTZ high quality engine, so the requirement for
fuel is high. Using bad fuel will damage the engine.

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Quality Changes the World!

Thank you!

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