PREFACE

The service life of a motor grader under normal usage is significantly hinged on the factor if the grader is
properly used or maintained. The correct operation and appropriate maintenance will definitely improve the
performance, liability and extend the service life of the grader. Therefore, to ensure the functionality of this
grader in the construction project contracted by the user, please read this operator’s manual before the first
operation is carried out by this machine and strictly follow all the regulations provided herein during the
usage.

After the repair and component replacing, please ensure the completion of scrupulous adjustment on this
system and the on its performance, which are both particularly indispensable to the braking system and the
steering system.

During the course of using our products, you may contact the local branch office of our company should any
questions arise.

Due to the constant technological development, we reserves the right to keep modifying the contents in this
manual without any prior notice.

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1
 Contents

Summary ........................................................................................................................1
1. Usage and features of this product ........................................................................3
1.1 Usage .......................................................................................................................3
1.2 Features ...................................................................................................................3
2. Main Technological Parameters ..............................................................................4
3. Structural characteristics and working principles ..................................................5
3.1 Diesel .......................................................................................................................5
3.2 Braking System ........................................................................................................5
3.3 Hydraulic System .....................................................................................................6
3.4 Working Device ........................................................................................................7
3.5 Electric System ........................................................................................................8
3.6 Torque converter—Gear Box ...................................................................................9
3.7 Rear Axle .................................................................................................................9
4. Usage ........................................................................................................................10
4.1 Items needed to be known before starting ............................................................. 11
4.2 Inspection and Debug ..............................................................................................13
4.3 Motor Starting .........................................................................................................14
4.4 After the Start of Motor ...........................................................................................14
4.5 Shutdown .................................................................................................................14
4.6 Running-in of New Grader .......................................................................................14
4.7 Driving ..................................................................................................................15
4.8 Usage of Air-conditioner...........................................................................................17
4.9 Recommendation to the Usage of Grader ..............................................................17
5. Maintenance and Repair ..........................................................................................19
5.1 Security Rules ........................................................................................................19
5.2 Cleaning and Lubricating of Grader .........................................................................19
5.3 Check on Oil Level, Renewal of Oil and Filter ........................................................21
5.4 Adjustment on the Brake ..........................................................................................25
5.5 Adjustment on Working Device ................................................................................25
5.6 Maintenance System for Grader ............................................................................27
5.7 Storage of Grader ..................................................................................................29
6. Common Failures and Corresponding Debugging ...............................................31

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 SUMMARY
General Requirements
The user should check the motor grader on any missing documents or spare parts.
The operator who is going to drive this motor grader should read these documents
carefully and receive proper training.
Besides reading this manual, operator and maintenance staff should read the main spare
parts manual attached in this motor grader.
Careful examine on cooling liquid, lubricating oil, hydraulic oil, cream, fuel, storage battery,
fastening pieces and other parts are necessary before operation and only when the
forgoing items are confirmed to meet standards can the motor grader be operated.
Safe operation requirements
The disassembly and assembly of motor grader should be carried out only under guidance
of professional.
The driving of a motor grader should limit to those who are equipped with a driving license
for motor grader and well acquainted with its operation.
The star-up, trail operation, and operation of motor grader should be conducted strictly
according to the procedure stipulated in the manual.
The driver should keep the motor grader in a well operating situation.
The driver should check the brake device and steering system daily before any operation.
If the driver find any abnormal condition, he/she should report to maintenance staff and
inform the driver on next shift about the condition. Where the operation of motor grader is
unsafe under this abnormal condition, the motor grader should be shut off immediately.
The driving handles of motor grader can only be operated in driver’s room.
Motor grader should be kept in a stable condition during its operation.
Driver should put into gear when motor grader is on the downgrade.
Safe distance should be kept during the operation or working in a busy street.
Driver must make sure that nobody is nearby before operation or start-up and whistle
before driving.
If the shovel blade is out of driver’s eyesight in the driving cab, necessary alarm signal
should be adopted by using flag signals limited to those drivers who are familiar with flags
signals or by other necessary means.
No one is allowed to enter into the working region during the operation of motor grader.
During breaks and idle state of Grader, the operating devices shall be landed or fastened.
● The driver is not allowed to leave the driver’s room before the operating
devices is landed or fastened, then replaced.
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 ● Before leaving the driver’s room, the driver shall release hand brake and
lock all the assisting safety devices.
● When the operation is suspended or completed, the motor be shut down,
ignition key pulled off and the master switch is cut off to prevent any
accident.
● Entry and exit from the driver’s room can only be allowed in the case
where the grader is in complete stop condition and approval from driver
has to be obtained.
● Unauthorized entry into the driver’s room is prohibited.
● The following steps must be taken when the repair of grader is being
conducted:
a) Shut down the motor, land or fasten all the operating devices;
b) Should the operation has to take place under an elevated operating device
the device should be fixed.
c) Due to the existence of articulated steering mechanism in the grader,
therefore the front and rear frames have to be locked up;
d) No rotation on the joint is allowed when pressure is imposed on the
hydraulic system.
e) All the safety devices (including split pin) shall be replaced after repaired.
Warning! The strict observation of the above regulations means significantly
to the prevention of accidents.

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1. Usage and features of this product
1.1 Usage:
Grader of this type covers a wide range of use, including the land leveling, trenching,
scratching the slope, moving earth, loosing earth, snow removing and other
operations on considerably enormous floor areas such as highways, airports and
farmlands.
1.2 Features:
1.2.1 The cooperation between the articulated frame and the front wheel
steering promises a smaller turning radius.
1.2.2 The optimization matching on the parameters of main frame ensures a
higher efficiency.
1.2.3 The rear axle, on which imported antiskid differential is installed,
serves as the special triple-section drive axle for grader.
1.2.4 The power-driven gear box with six forward gears plus 3 backward
gears assures the flexible control.
1.2.5 The imported HUSCO multi-way valve outputs liable performance.
1.2.6 The movement of agitator is controlled by all-hydraulic driving.
1.2.7 The adjustable control panel and driving seat are married up with the
various operating handles and instruments located in accordance with the principles
of ergonomics to improve the driving comfort and usage convenience.
1.2.8 The driver’s cap specially designed for grader features in its aesthetic
appearance, overhead air-conditioner, together with its broad vision and brilliant
tightness.
1.2.9 The adoption of hydraulic braking system and the caliper disc brake
produces more stable braking performance.
1.2.10 The bulldozer, shovel tooth, Rear ripper, rotation geared ring of
rubber disc and the automatic leveling device are all available to users’ options.
2. Applicable environment：
2.1 Environmental temperature：
without cold starting device: -10——45
with cold starting device: -30——45
2.2 Altitude：≤3000m

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2. Main Technical Parameters
Main Technical Parameter Table of the PP12G-VI
Specs
Engine Cummins
Type (kw/hp) 6BTAA5.9-C180
Normal Rated Power(hp)
Rated Speed(rpm) 180
2200
Shovel
Length*Chordal Height 3810×610
(mm)
Rotating Angle(°) 360
Inclination Angle(°) 90
Ground Depth (mm) 500
Driven Type Motor + Worm Gear Case
Gear Box
Pattern Electro-hydraulic Shift
Gear number F6/R3
4.9, 7.6, 12.3,
Forward speed(Km/h)
18.5, 26.8, 37.1
Backward speed(Km/h) 4.9,12.3, 26.8
Driven Type Rear drive
Maximum Traction(KN) 80
Tire Size 17.5－25
Front Axle
Inclination Angle(°) ±17
Steering Angle(°) ±45
Swinging Angle(°) ±15
Ground Clearance(mm)
430
Chassis Steering Angle(°) Left 25
Right 25
Braking
Service Braking Pattern Hydraulic caliper disc brake
Parking Brake Pattern Hand drum brake
Emergency Brake Pattern Hand drum brake
Overall mass (Kg) 15000
External Dimensions of
10330×2750×3300
classic type (mm)(L×W×H)

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3. Structural characteristics and working principles
3.1 Diesel
This series grader, Diesel Engine manufactured under Cummins.
3.2 Braking System
The braking system inside this grader consists of the service braking system (the pedal
brake) and the parking braking system (the hand brake). The emergency braking system
shall co-work with parking braking system. See attached graph 2 to understand the
working principles.

3.2.1 Service braking system

The service braking system falls into the category of single-loop hydraulic system and acts
on the four rear wheels of the grader. During the operation of the motor, the gear pump of
the hydraulic braking system absorbs oil from the oil tank, then the absorbed oil will flow to
the two accumulators via the pre fill valve to fill with liquid when the pressure of the said
accumulators drops below 120 bar, while to cut off the supply when the pressure amounts
to 150 bar. The oil filling for the accumulators only requires a short-time operation, after
which the overflow valve will lead the oil back to the oil tank. The oil filling for accumulators
enjoys the priority, which ensures the availability of the pressure oil needed by the braking
system upon the motor’s start. Once the braking valve is stepped down, the pressure oil in
the circuit of accumulators will flow to the braking sub-pump installed in the wheel brake to
enable the braking clip to tightly press against the braking disc, in this way the wheel brake
will be obtained. Simultaneously, the braking lamp will be turned on by the movement of
the braking lamp switch, which is installed on the braking valve. And the instrument plate’s
indicating light controlled by the low-pressure alarm switch, which is used to indicate the
disability of the service braking system to output the braking force needed, will be turned
on when the pressure in the brake valve descends below 100 bar. The pressure
measuring joint configured in the balance tank on the left side utilizes the special pressure
gauge to test the pressure of the braking system.

3.2.2 Parking braking system

Parking braking system consists of steering system and drum-brake, which is equipped at
the outlet of the gearbox. People can brake the rear wheel by manipulating the brake lug.

3.3 Hydraulic System

The machine hydraulic system mainly consists of two parts, working hydraulic system and
steering hydraulic system. A dual gear pump supply oil separately to the two circle, one of

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which is used by both working and steering. If the steering system is out of work, all the
hydraulic oil is supplied to working hydraulic system only.
3.3.1 Working Hydraulic System
This system is a dual pump, dual loop system, consists of oil tank, a dual gear pump, two
splited five linked multi-way valve, hydraulic tank for working equipment, motors, pipes and
joints. The oil flow of the two loops is at the same amount. When all the operating valve
stay at the median, then the left operating valve’s oil supply comes from one loop, and the
right operating valve’s oil supply from the other. The lifting tanks of the left and right are
supplied by two loops with same flow. Thus, the two lifting tanks can move at same speed
at the same time. In this way, it improves the performance of the grader. System pressure
is under the control of pressure valve of multi-way valve, which is set at 18 Mpa.
Working principle:
First circuit: During the idle state of steering system, the oil sourced from the twin pump
will enter into the multi-way valve through the priority valve of the hydraulic steering
system, then return to the oil tank through oil conduit.
Second circuit: The oil sourced from the twin pump enters into the multi-way valve and
then return to the oil tank through oil conduit.
Five-connection multi-way valve is the “5000 Type” directional valve with the slide valve
function of “O” type and is manufactured by American HUSCO Company. Its neutral
position is normally released, in this way the hydraulic oil can flow inside the internal
conduit of the valve and through the oil returning conduit then back to the oil tank. When
the operating lever is under operation, the hydraulic oil will burst out of the one-way valve,
whose function is to prevent the oil in the working device from counterflowing into the oil
tank to safeguard the normal operation of hydraulic system, and enter into the
corresponding hydraulic cylinder or hydraulic motor. The two-way hydraulic lock, which is
installed on the inclined positions of the bulldozer blade, front wheel, and on the two lifting
oil circuits of the two bulldozer blades, is able to free the components from relocation due
to their own weights. In this way the driving safety and the operation precision of bulldozer
blade are warranted. The two-way hydraulic lock fitted on the lifting oil cylinder of the
bulldozer blade also lays a one-way throttle valve, which is to ensure the stability of
descending of bulldozer blade, in the oil conduit of the rod end chamber.
The rotation of bulldozer blade is effected by the re-driving rotary gear ring of the driving
worm gear case in hydraulic motor. The BM30-100 cycloidal hydraulic motor applies the
valve plate distribution to enable the automatic compensation to the abrasion on the
distribution surface, so as to place the motor in a sustainable and efficient operation
condition, which saves the energy in a major scale.
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3.3.2 Steering Hydraulic System
The steering system of the front wheel applies the load-sensing all-hydraulic steering
device, which consists of gear pump, priority valve, load-sensing all-hydraulic steering gear.
The advantage of the load-sensing all-hydraulic steering system lies in its ability of
prioritizing the distribution of hydraulic power to steering oil circuit as required and assuring
the adequate oil supply to the steering system no matter what kind of change of the load
pressure and the wheel steering rate occur. Therefore, stable and reliable steering can be
procured. Apart from the oil flow needed by steering oil circuit to maintain its normal
operation, the other oil outlet from the oil pump may be completely supplied to the working
oil circuit. In this way the power waste caused by the exceeding supply to the steering
circuit may be eliminated and the efficiency of the system may be improved.
3.4 Working Device
The working device of this grader is composed of traction frame, rotary ring, bulldozer
blade and angle position device, etc.
In the front of towing frame is one big ball hinge, hinged with frontal frame, thus towing
frame can rotate or swing randomly around the ball hinge. Turning circle is suspended at
the towing frame, driven by turning drive device, it can rotate below the towing frame as to
drive the shovel blade turn around. At the back of the shovel blade are two upper and
lower sliding rails supported at the sliding track of angular position device, and it can slide
being pushed by the cylinder of the shovel blade. Angular position device is hinged with
lower end of ear plate of angular position device, upper cylinder can adjust the swing of
angular position device as to drive shovel blade to change shoveling angle.
3.5 Electric System
The principle diagram of electric system refers to attached figure 3.
The electric system of this machine consists of meter panel, control case, wire cluster,
detection sensor, various illumination and travel indicator, etc. This system can control not
only engine running, leveler traveling, various illumination and travel indicator, wiper blade,
horn, engine, torque converter, hydraulic system, brake system and storage battery
charging/ discharging.
(1) Power supply is made up of two 12V storage batteries in series, terminal voltage
24V, and negative ground. Storage battery shall be charged by electric generator of
the engine, and negative pole of storage battery is connected with machine frame
through ground. Fuse protection is available for each powered device, application
and maintenance:
Storage battery of this machine use dry battery of Optima, which is different from
liquid battery of regular car. It must be used and maintained per charging methods
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and rules of dry battery. Battery clips must be connected firmly. Regularly inspection
on the discharging situation of the storage battery, especially in winter. And
discharging degree cannot exceed 50%. Constant working in a state of charging,
and problems must be solved once storage battery fails to charge. If the machine
does not work for more than six months, the storage battery shall be stored in a state
of fully charged. During storage, engine should be started to charge battery at least
once a month.
(2) Start-up circuit of engine consists of storage battery, starting dynamo, and
starting switch. Operation instruction, mechanism, work principle, etc. of starting
dynamo and electric generator refers to operation instruction.
(3) Meter system consists of hour meter, water thermometer, fuel gauge,
engine oil pressure gauge, torque converter thermometer, oil pressure meter of
gearbox, ampere meter, and brake pressure indicator. It can monitor
charging/discharging of storage battery, torque converter oil temperature, gearbox oil
pressure, engine oil pressure, cooling water temperature, and fuel level.
(4) Leveler’s traveling shall be controlled by threshold selector. There are 6
thresholds for moving forward and 3 thresholds for moving backward.
(5) Illumination is made up of head lamp, rear lamp, work lamp, meter lamp,
and overhead lamp, to be controlled by relevant switches on the meter panel.
(6) Traveling indicators are made up of traveling lamps, left and right turning
lamp, stoplight and backup lamp, to be controlled by relevant switches on the meter
panel.
(7) Auxiliary appliances consist of horn, wiper blade, air conditioner, and
heater unit. Heater unit shall be assembled according to user’s demands.
3.5.4 Meter Indicator Table

No. Name Indicated Item Status or symbol of regular situation

1 Water Engine cooling 81～95
thermometer temperature
2 Fuel meter Diesel tank level
3 Hour meter Engine working hours Accumulation by hour
4 Oil pressure Engine oil pressure 69kPa for idle speed; 207kPa for
gauge rated speed
5 Voltage Charging/discharging of
meter storage battery
6 Thermometer Torque converter 80～110; instant 120
temperature
7 Oil pressure Gearbox operating 1.4～1.7MPa
gauge pressure

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3.6 Hydraulic Torque Converter -- Gearbox
6WG180 and YD13 gearbox assembly consists of torque converter and fixed-shaft
6-threshold gearbox. If can realize speed of 6-forward-gear and 3-backward-gear. Torque
converter is three-element structure, its elastic disc of pump wheel is connected with
engine flywheel, regular temperature of gearbox ranges from 80 through 110 , instant
temperature can reach 120 , and going beyond 120 the machine must be shut off.
Gear shift of gearbox can be realized through electric-hydraulic control, and control oil
pressure ranges from 1.4MPa through 1.7MPa. To the right of the driver there is one gear
selector, which can be operated manually. Through each electromagnetic valve linked with
the selector slide valve can be further controlled to realize gear shift. This control should
be operated one after another, and cannot be skipped.
When the main machine is towed, towing speed cannot exceed 10km/h, and towing
distance cannot goes beyond 10km so as to protect the gearbox. When welding work is
conducted in the main machine, cable of gear selector must be disconnected to protect
internal circuit.
3.7 Rear Axle
As the main constituent part of chassis transmission system, major function of rear drive
axle is to increase gearbox-output torque, transmit the power to left and right drive wheels,
and let the wheels at both sides have differential function; in addition, drive axle also has
to withstand various applied force from pavement and frame.
Rear axle is the special drive axle of triple-stage leveler, equipped with imported “no-spin”
differential gear. Rear axle mainly consists of main reduction gear assembly, planetary
reduction gear assembly, brake assembly, left and right equilibrium box assembly. The
main reduction gear is made up of main transmission countershaft, differential shaft, and
inputted flange, etc. Planetary reduction gear adopts straight spur gear planetary
transmission, central gear serves as driving part, planetary carrier is fixed, gear ring
outputs, and semi axle is in splined connection. Equilibrium box is tilting reduction
mechanism, tilting angle ±14°, reduction ratio 1.389, and driven by roller chain.

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4. Usage
Warning: please read the instruction book in detail.
Things need to be known beforehand.
Overall operating instrument and control mechanism see attached graph 4 to attached
graph 5.
Switches of general power and lights.
Switch on the knife switch and turn on the general power.
Lighting switch: Turn clockwise to class I and press the switch to turn on the lighting
switch.
Switches of instrument lights/top lights、turning lights, driving lights: Press button to switch
on the lights.
Switches of working lights: Press button to switch on the nearby lights.
Water thermometer: Its measurement scope is 50～115,indicating the water temperature
of engine cooling. Normally, the water temperature should stay under 95。
Hour meter: Its cumulative scope is 0～9999.9h, accumulating the working hours of motor.

Fuel gauge: Its measurement scope is 0～100%, indicating the oil level in the tank. It will
cause the problem of blocking the oil circuit or bringing in air if the motor is started and
runs out of oil.
Oil pressure indicator: Its measurement scope is 0～1Mpa, indicating the system pressure
of the motor’s lubricating system. The oil pressure should stay higher than 207Kmp at
rated speed, and 70Kmp at idle speed.
Thermometer: its measurement scope is 50～140, indicating the working temperature of
torque converter. Normally, the working temperature of the thermometer should stay in the
scope of 80～110, and it is all right that the instantaneous temperature reach 120.
Voltmeter: Its measurement scope is 20～30V. The normal value of the voltmeter should
stay in the scope of 24-28V. It means that there are some problems with the generator if
the figure is lower than 24V please repair the generator regulator when the figure is higher
than 28V.
Oil pressure indicator: Gearbox Operating Pressure Indicator: The measurement scope of
gearbox operating pressure indicator is 0-3.2Mpa. The pressure changing scope of the
gearbox is 1.3～1.7Mpa when its oil temperature is 80-90 . The pointer should always
stay in scope discussed above. Please turn off the motor and check it if the pointer go
beyond the scope.
4.1.4 Indicator light

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 The indicator light of the hydraulic oil filter is red when it’s on. During the
operation of motor, the illumination of the said light indicates that the oil filter in the
hydraulic oil tank is jammed cleaning and replacement is needed.
The braking pressure indicator light is red when it is on. During the
operation of motor, the illumination of the said light indicates that the hydraulic
braking system is on the blink and the shutdown shall be conducted to effect repair.
The air filter indicator light is red when it is on. During the operation of motor,
the illumination of the said light indicates that the air filter is jammed, cleaning and
replacement is needed.
Left turning indicator, yellow, shall be on while switching to “left turning”.
Brake indicator, red, shall be on while braking during traveling.
Right turning indicator, yellow, shall be on while switching to “right turning”.
4.1.5 Wiper Switch
Press down gear I of this switch, wiper blade move slowly; press down gear II,
it move fast.
4.1.6 Steering wheel
Turn steering wheel to control the direction of frontal wheels.
4.1.7 Accelerator pedal
This pedal controls the rotating speed of the engine.
4.1.8 Brake Pedal
This pedal acts on wheel brake of four rear wheels through hydraulic system.
Brake pressure is based on the pressure applied on the brake pedal.
4.1.9 Manual Brake Lever
Pull up manual brake lever to make the brake work; while releasing the lever,
firstly pull it up slightly, then press down the button, after that completely pull it down
to release braking.
4.1.10 Gear Shift Device
Gear shift lever can control the machine to move forward or backward,
including 6 forward gears, 3 backward gears, and one neutral gear. Customers must
be clear that this operation should be made in sequence without any skips. This
gearbox can only be operated reversely in gear I. In addition, select proper gear to
slide while sliding on a downward slope and rotation speed of the engine cannot be
less than 1200r/min so as to meet the lubricating demands of each part of the
gearbox.
4.1.11 Control of Work Device
In the cab, according to indicated board, all movements of work devices can
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 be under control through respective operation of the levers of work devices, and its
control methods all are hydraulic drive (except rake teeth). Each control lever
arrangement refers to attached figure 4.
4.1.12 Shovel Blade Adjustment
Control corresponding cylinder to make shovel blade work in various position, which shall
meet the demands of work situation. Shovel blade can extend or draw back at left and
right side. It can also stay in any angle and rotate 360 degree.

Attention: Forbid rotating shovel blade with load on.

Warning! Must not damage frame ladder, wheel and trapezoidal lever while moving the
blade.

4.1.13 Adjustment on Shoveling Angle

Hydraulic angle position device is equipped for this leveler, and simply through lever
control in the cab, shoveling angle can be adjusted to meet the demands of work situation.
4.1.14 Rocker Swing
Notes: usually rocker is locked horizontally, and it can be seen from the seated driver.
Rocker can be fastened at position 1 or 2 and 4 or 6 following steps below.

①Completely draw back rocker cylinder for position 1 or 2.

②Completely extend rocker cylinder for position 4 or 6.
After foregoing operation, use hoist cylinder to move the blade to ground
(hydraulic system is free of load).
Completely pull fastening pins out of swing frame.
Operate hoist cylinder and swing cylinder of the blade to adjust swing frame

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 to the desired position.
Lock swing frame with locking pins.
4.1.15 Front Wheel Tilting
Operate tilting control lever to make front wheel tilt to left or right, thus front
wheel can achieve smaller turning radius. Anti-lateral-sliding capability of the wheels
can be improved while leveling. Even working on a slope, there is still strong
adhesion between wheel and ground.
4.1.16 Rake (optional)
Through 180°turning of the blade, rake teeth can reach proper work position.
Namely 1 through 6 teeth can be selected to loosen earth.
4.1.17 Rear Rake (optional)
Rear rake has five teeth, usually only three of them are used to work on
relatively solid ground, and each tooth should be used symmetrically.
Rake includes two positions, one is for work, and the other is for running; take
out elastic pin, pull out pin axis, retract work teeth and also completely lift rake, then
rake shall stay in running position; take out elastic pin, extend work teeth, and rake
shall be in work position.
Operate rake control lever to place teeth onto ground, then drive the machine
forwards, meanwhile lower rake and let it move into ground.

Warning! Lift the rake prior to the turning and backwards movement of the leveler.

4.1.18 Front Dozer Board (optional)

Operate board control lever to control the lift of dozer board.

Warning! Dozer board must be lifted if it is not in service.

4.2 Inspection and Debug prior to the Use of New Leveler

Prior to engine start-up, please check following items, and eliminate abnormal
conditions.
* Whether there is sufficient engine fuel, engine oil, and cooling fluid.
* Hydraulic oil should reach the central line of the oil indicator
* Worm gear box of shovel blade circle should have proper oil level
* Whether the connection of each part is loose or not
* Whether tire pressure satisfies the provision or not
* Whether illumination and horn works properly or not
* Whether gearbox lever stays in the neutral or not

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 * Whether air conditioner stays in non-working status or not
4.3 Engine Start-up
Switch on the main power
Turn the start key to connect power for meters and step on accelerator
pedal.
Continue turning the key to connect start motor and the engine is started.
Immediately release the key once engine is started.

Attention: start duration should not exceed 10-15 seconds, if the second start
is necessary, interval time should not be less than 1 minute. Gear of the
gearbox must be placed in the neutral.

4.4 After Start-up of Engine

After starting engine, it should warm up for five minutes at 600~850r/min to let the
pressure of hydraulic system reach 10Mpa, at the same time brake indicator shall be
off, and then inspect the following items:
*Whether the brake system is safe and reliable or not.
*Whether the turning is flexible and reliable or not.
*Whether the circuit can work properly or not.
*Whether the illumination and meters are in good condition, and can indicate
properly or not.
4.5 Shut Off
Do not shut off engine immediately after work, and engine cannot be shut off until it
runs for 5 minutes at idle speed and already cooled down completely. Depress
shut-off switch to stop engine, switch off start-up key, and control main switch to
disconnect circuit.
4.6 Running in of New Machine
* Many parts (engine, case, axle, pump, motor, valve, etc.) of this machine all
need some time to run in, through it new machine then can reach the longest service
life and the best efficiency. The leveler must not work in a state of full load within
running in period.
* The leveler cannot work in full power within the first 50 work hours.
* The leveler may work in full power within the first 50-100 hours, but not for a
long time.

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 4.7 Driving of the Machine
4.7.1 Preparation for Work
Start diesel engine.
Inspect and see if each meter can indicate normally.
Inspect brake indicator, horn and release manual brake.
On the basis of road condition, begin from gear I, and choose suitable gear.
Step on accelerator pedal, then the leveler to move.
4.7.2 Gear Shift
Gear shift should be conducted in sequence.
Applicable scope of gear shift:
Gear I and II: Operation, climbing, uneven road.
Gear III: Operation in a state of light load, climbing light slope.
Gear IV, V, and VI: Flat road, high-speed traveling.

Notice: during traveling, if alarm indicator is on or gearbox pressure gauge

reads abnormally, immediately stop and shut off engine, and inspect failure.

4.7.3 Operation
(1) Leveling Operation
Leveling operation is used for road construction, roadway trimming, site leveling,
trench backfilling or pavement distribution, etc.

While working, according to engineering requirements and soil quality, properly

adjust the angle of shovel blade, move forward at gear I or II, lower the blade into
soil, at any moment adjust soil cut depth, plane angle and traveling direction per to
load and landform, let shoveled soil move towards side along the blade to be
discharged at one side of the leveler or between two wheels. We should make sure
that the earth pile not in the course of rear wheel ,otherwise , it will influence the traction force
of the leveler and cause uneven problem of the cut section.

When filling trench, shovel blade should extend laterally to the trench side, discharge
soil into trench, and at the same time ensure the safety of traveling. While reversing,
turn the blade 180 degree prior to reversing so as to improve efficiency. While
leveling or paving sand or stone materials, at the last stage of shoveling, adjust
shovel blade perpendicular to its longitudinal axis, move forwards in gear I, adjust
properly the height of the blade, slightly cut soil, bulldoze most of the shoveled soil
15
forwards, and leave small amount of the soil at either side. Lower the blade to
ground, residual soil can be totally distributed by leveler in a high speed. While
working on a curve, operator should travel towards a precise direction or use
full-wheel steering mode, and work flexibly.
(2) Trench Digging
Trench digging is applied for the digging of side ditch of a road and
discharging channel of a yard. While digging, generally incline shovel blade, and use
one side of the blade to work. Digging includes three stages, namely marking,
deepening, and trimming. Clear off obstruction prior to digging, and roughly level the
site. If necessary, loosen the soil to mark the central line of the trench.
(3) Slope trimming
This operation is mainly used to trim slope of 25°~70°and 3-4m height. Prior
to the operation, the shovel blade should be adjusted to one side of the leveler
through inclination methods, then let blade top stay forwards, travel in gear I, and
lower the blade to conduct shoveling. During work, adjust the height of slope
trimming through running circle or shovel blade, and adjust the gradient of slope
trimming through lifting shovel blade. In order to improve the stability of the operation,
incline frontal wheels towards the lateral slope.
Warning!
* High speed must not be used while traveling on uneven road.
* Urgent acceleration or deceleration is banned in any case.

4.7.4 Temporal Stop

(1) Release throttle.
(2) Move gear lever to neutral position, step on foot brake, until leveler can
stop stably.
(3) Pull manual brake tightly
(4) Shut off engine
Notes: Don’t shut off engine immediately once after full-load work, it should
run for 2-3 minutes at idle speed before stalling, and work device should be moved
onto ground prior to shutdown.
4.7.5 Parking
(1) Pull manual brake tightly
(2) Lower work device onto ground
(3) Take out ignition key, switch off main power, and lock the door to cab.

16
Warning! Wheels should be wedged when parking on a slope.

4.7.6 Towing
Gear lever should be put in neutral position while towed. Run the engine if
possible, then auxiliary devices of steering and brake can still work. If leveler is
towed by steel cable, between towing vehicle and leveler should be clear of people.
4.8 Air Conditioner Use
4.8.1 Refrigeration
a. Start engine;
b. Control wind switch of air conditioner to start blower, increasingly improve
rotation speed of evaporator blower from left to right, and wind rate is adjustable.
c. Turn on air conditioner, and adjust to the coolest, then indicator shall be on,
after that adjust to turn off the indicator;
d. Adjust switch and wind switch according to the demands of driver.
4.8.2 Heating (optional parts)
Start engine and last for ten minutes, after water temperature goes up, and
adjust wind knob, then warm wind can come out.
4.9 Following advice is given for the use of leveler:
a. Hinged steering can considerably reduce turning radius, and let leveler
conduct foregoing operation more flexibly, this leveler can travel like a crab, and this
can allow the blade extend beyond rear wheels, thus rear wheels can avoid to travel
on leveled ground, and hinged steering also let leveler have self recovery capability
in case of difficulty.
b. One dominant factor for leveler to have the best efficiency is to choose right
turning angle and shoveling angle, and we advise to adopt relatively big turning
angle so as to improve shoveling force of each centimeter of working length. During
shoveling, small shoveling angle can reduce cut resistance, and big one can
enhance leveling precision.
c. Front wheels should incline towards the direction of material discharging,
while working on a slope, front wheels should stay vertical so as to get a better
adhesive force through inclining front wheels.
d. Since exhaust gas of engine is not treated specially, it is not a good choice
for a leveler to work underground or in an environment without good ventilation.
e. In order to avoid insufficient engine lubrication, work slope of the leveler
can not go beyond following value, since engine can be in danger due to bad
lubrication.

17
 transverse slope longitudinal slope
Allowable angle 20 degree for left and 25 degree for forward and
right respectively backward respectively

18
5. Maintenance
5.1 Safety Rules
A. Place leveler on a solid ground horizontally.
B. Move work device (shovel blade) onto ground.
C. Pull manual brake tightly.
D. Insert safety lever to fasten hinged steering mechanism of leveler.
E. Do remember to shut off engine (except maintenance and inspection
cannot be done if engine does not run).
F. Support firmly work device that must be hung in the air.
G. Fasten suspended overhead objects of leveler
H. Connectors must not be loosened if pressure is still available in hydraulic
system
I. Restore all fastening parts (split pins, elastic ring, etc.) after maintenance
5.2 Cleaning and Lubrication
Regularly keep air filter clean, and lubricate key parts. Detailed requirements
and processes are showed below.
5.2.1 Lubrication Instruction
A. Conduct maintenance carefully. After maintenance, machine should be
washed. Engine oil can only be changed under stated temperature. Various oils all
should be changed within stated period of the manual, at least once a year.
B. Clean all oil cups prior to grease adding. Sufficient grease should be added
until new grease comes out of opening.
C. Clean all filling and drain plugs prior to oil change. Fine filter screen should
be used while filling. Filled oil must meet the requirements of cleaniness.
D. Wash sealing face.
E. Within the first 200 hours, regularly check engine oil amount, and at least
twice each day (10 hours)
F. While adding grease to drive axle, pressure should be low, and strong
adding force or too much grease should be avoided. Grease should be added until
new grease comes out of opening.
G. In dusty environment, water tank and blades of oil coolers should be
washed regularly, and washing duration should not be less than stated time.
5.2.2 For the first time of grease adding, changing and maintenance of the
filter should be conducted as per to following provision.

19
 Work hour Demanded work
1 change engine oil
2 change oil filter element of engine
3 screw up tightening bolts at oil tank of engine
After 50 hours 4 tightly screw up fixing clip of oil suction and drain tube of
cylinder cap
5 tightly screw up loose parts of engine device
6 check valve clearance, and adjust it if necessary
1 change oil of torque converter and gearbox
2 change oil of rear axle
3 change oil of equilibrium box
The first check 4 change oil of worm wheel box of shovel blade turning
at 100 hours 5 wash oil filter screen of gearbox
6 change hydraulic scavenge filter element

Change oil of hydraulic oil box (new added oil must satisfy the
500 hours requirements of mark and contamination, not less than grade
18/15)

5.2.3 Lubricant and grease

Classification Lubricant Substituted lubricant

Oil cup and oiling 2# extreme pressure MOBIL UXEP2
place lithium lubricating oil
Grade 15W/40-CF-4diesel Grade SAE 15W/40 diesel
Engine
engine oil engine oil
Torque converter and 15W/40-CF-4 diesel SAE 15W/40 diesel engine
gearbox engine oil oil
Equilibrium box of SAE 85W/90 gear oil
GL-5 85W/90 gear oil
rear axle
Worm wheel box GL-5 85W/90 gear oil
YB-N46 abrasion MOBIL DTE25 abrasion
Hydraulic oil box
resistance lubricating oil resistance lubricating oil

5.2.4 Lubricating Figure (referring to attached figure 7)

5.2.5 Cooling Agent
Anti-freezing fluid with 50% consistency must be used as cooling agent for
engine. Consistency shall be improved to 60% when air temperature is lower than
-37 and necessary adjustment should be made per to maintenance manual.
5.2.6 Volume Table
Notes: given volumes are only approximation, and actual volume should be
on the basis of oil scale or oil blockage of glass control opening.
Parts Approximate Lubricant or fuel
volume (L)
GB252-77 diesel, -10 to -35 in
Fuel tank 240
winter, and 0 or 10 in summer

20
 For hydraulic N46 abrasion resistance hydraulic oil
system 110 With N32 abrasion resistance
The first filling 100 hydraulic oil under 0 .
The first changing
Oil changing and 24 15W/40-CF-4 diesel engine oil
filtering of engine 10W/30-CF-4 diesel engine oil under
-10 .
Gearbox, torque 38 15W/40-CF-4 diesel engine oil
converter 10W/30-CF-4 diesel engine oil under
-10
Worm wheel box 2.5 GL-5 85W/90 gear oil
Rear axle 28 GL-5 85W/90 gear oil
Equilibrium box 46 GL-5 85W/90 gear oil
Water tank 50 Anti-freezing fluid
5.3 Oil level inspection, oil change, and filter change
Lubricating figure (attached figure) and maintenance time illustration can be
referred to.
5.3.1 Engine
5.3.1.1 Engine Oil Level Inspection
Notes: Usually consumption of engine oil is relatively huge, thus during running
in period (around 200 hours), check oil level twice each day at least, after running in
period, check once each day. Leveler should stay at a flat place when engine oil
level is inspected. Take out oil indicator, clean it with soft cloth, and then insert it to
the limited position, after that take out oil indicator, at this time, oil face should stay
between upper and lower scale of the indicator.
5.3.1.2 Engine Oil Change
Notes: Engine oil should be changed while engine is in a hot state, old oil shall
be discharged into a suitable container, and oil burn should be prevented.
Refill new engine oil to the upper scale of oil indicator.
Change schedule of oil change:
Oil mark Change schedule (work hour)
15W/40-CF-4 diesel engine Referring to engine
oil maintenance manual
Notes: Avoid mixing with other types of oils.
5.3.2 Worm Wheel Box of Blade Turning
Notes: change oil and inspect oil level per to lubricating figure.
5.3.2.1 Oil Change
a. In order to speed up oil discharging, towing frame should be tilted towards
drain plug side, and shovel blade should be supported on ground.
b. Remove drain plug to let out oil to container. In order to speed up oil
21
discharging, filling plug can also be removed.
c. Wash drain plug, use new gasket ring, and mount drain plug and screw it up.
d. Towing frame shall be operated until worm wheel box stays in a level state.
e. Refill oil through filling aperture, and let oil reach central position of sight hole.
f. Wash filing plug and use new gasket ring, and then fit on the plug and screw it
up.
Volume: oil is around 2.5 liter when it reaches the central position of sight hole.
5.3.2.2 Oil Level Inspection
a. worm wheel box of blade steering should stay at a flat position.
b. oil level (the highest oil level) must stay at the central position of sight hole.
c. add oil through filling aperture if necessary.
5.3.3 Work Hydraulic System

Notes: Hydraulic tank is assembled at the left side of cab back, inspect oil
level, change oil, and change filter per to provision.

5.3.3.1 Hydraulic Oil Change

Notes: Change oil when service time reaches stated work hour, and there are
other two special situations in which oil should be changed, namely
maintenance or severe polluted environment. Drip one drop of oil onto filter
paper or blotting paper, if obvious black spot is left around the drop after
several hours, then oil should be changed otherwise hydraulic system would
be damaged.

Lower shovel blade onto ground.

Shut off engine.
Release air from fuel tank.
Loosen nut at the bottom of fuel tank, and let out oil into a container.
Fasten nut after completely drain oil.
Open fuel preliminary filter aperture. Add filtered hydraulic oil until oil level
reaches the central position of sight hole.
Fit on preliminary filter cap.
Start engine, operate all control levers of work devices, and let control levers
move in maximum range repeatedly, this shall completely add oil to hydraulic system
and also discharge air, in addition, fully fill hydraulic system.
Place all work devices onto ground, shut off engine, and release air from fuel
tank.
22
 If necessary, add oil through preliminary filter aperture until oil level reaches
the central position.
Notes: Pay special attention to the tightness of filter aperture, change gasket
ring if necessary. Fit on the cap carefully to prevent fine thread of filter cap from
damage.
5.3.3.2 Oil Level Inspection
Shut off engine, lower work devices onto ground and oil level must stay at the
central position of sight glass.
If necessary, add stated hydraulic oil.
Notes: Inspect leakage cause and tightness if oil amount is reducing.
5.3.3.3 Scavenge Oil Filter Element Change
Loosen fastening clip, and remove cover.
Release air from fuel tank.
Loosen filter cap.
Take out whole filter element and cap.
Pull out split pin, unscrew channel nut, and take out spring seat, pressure
spring, and filter element.
Wash it.
Change with new filter element, and fit it on in opposite processes.
Notes: Change split pins in assembly. Inspect gasket ring at filter bearer, change
it if necessary. While fixing new filter element, ensure its closeness against bearer.
Carefully restore whole filter to fuel tank to avoid any damage of gasket ring of
bearer, and screw up filter cap tightly.
5.3.4 Gearbox
Notes: Check oil level, change oil per to lubricating figure; change filter, wash
cooler, and avoid burning while releasing oil.
5.3.4.1 Oil Change
Remove oil drain plug and completely let out oil into container.
Wash oil drain plug and oil cup, and then tighten them.
Add oil through filling aperture at the left side of machine frame, observe oil
indicator, and oil level should be higher than upper scale.
Adjust change gear to the neutral position. Start engine and it shall run slowly,
add oil after two minutes, observe oil indicator, and oil level should stay between two
scales.
Fasten filling cap, and let gearbox heating up to 80 degree.
Oil level must stay between upper and lower scale; if necessary add oil
23
sufficiently.
5.3.4.2 Oil Level Inspection:
Check oil level every day, and gearbox should heat up to 80-90 degree and
engine and gearbox should stay at the neutral position while checking.
Add oil sufficiently if necessary.
5.3.4.3 Oil Suction Filter Screen Washing
Loosen off filter screen of oil suction.
Completely wash filter in gasoline or diesel.
Change gasket piece, fit on filter screen, and check if tightness is in good
condition. Tightening torque of screen ranges from 14Nm through 21Nm.
5.3.4.4 Filter Element Change
Remove filter shell, and take out the element and throw it away.
Wash shell and spring.
Fit on new element and spring into filter shell, fasten filter at gearbox, and
tightening torque ranges from 28Nm through 34Nm.
5.3.5 Rear Axle (referring to rear axle instruction)
5.3.5.1 Oil Change
Loosen off plug screw, completely let out oil into container, and then screw up
the screw.
Wash plug screw, and restore plug screw tightly after change one new gasket
ring.
Add new oil to axle body through filling aperture until it reaches the central
position of level indicator.
Fit on plug screw to filling aperture and screw it up tightly.
5.3.5.2 Oil Level Inspection
Oil level must stay in the center of oil indicator.
5.3.6 Equilibrium Box (referring to rear axle instruction)
5.3.6.1 Oil Change
Loosen off plug screws (each equilibrium box has two), and let out oil
completely into container, then screw it up.
Wash plug screws, change new gasket ring, and then screw up plug screws
tightly.
Unscrew ventilation cap, and add new oil to the center of level indicator, the
highest oil level.
Fit on ventilation cap and screw it up.
Volume: each equilibrium box is around 23 liters, and oil should reach the center
24
of level indicator.
5.3.6.2 Oil Level Inspection
Oil level must stay in the center of oil level indicator, the highest oil level.
Remove ventilation cap, and add more oil if necessary.
5.3.7 Fuel System
5.3.7.1 Fuel adding: while adding fuel to fuel tank, engine must be shut off, fuel
must be clear of naked fire, and don’t smoke or let fuel overflowing. Fully add fuel
each time. Immediately fit on cap to prevent fuel from pollution after adding.
5.3.7.2 Fuel Tank Washing
a. Carefully wash fuel tank cap and filter screen in kerosene.
b. Shut off leveler engine for some time so as to deposit impurities in fuel tank,
unscrew nut at the bottom of fuel tank, discharge waste oil into container, after that,
screw up nut tightly, and tightness should be in good condition.
5.4 Brake Adjustment
This brake is spot-type disc brake, adjustment and detailed mechanism refers to
leveler rear axle operation instruction.
5.5 Work Device Adjustment
Notes: If shovel blade clearance of leveler is too big, then guide board and bush
should be changed in pairs. Roughness on guide tracks can be eliminated in time by
file, and then abrasion situation can be eased.
5.5.1 Bush Change (figure 1)
a. Place shovel blade onto two blocks of
wood.
b. Remove baffle plate (figure 1/2)
c. Remove blade by sliding, and then remove
bush.
d. Fit on new bush, and fasten guide board.

Figure 1

5.5.2 Guide Board Change (figure 2)

a. Put the blade onto two blocks of wood.
b. Loosen fastening bolts (figure 2/1).

25
 c. Remove guide board (figure 2/2).
d. Fit on new guide board, and screw it up
tightly.

Figure 2

5.2.3 Fixed Blade Draws Out Cylinder Piston

Shaft (figure 3)
In our factory, after channeled nut is locked by
piston shaft (figure 2/3), the washers (figure 3/3)
can be turned around manually.

Notes: While repairing or changing this cylinder,

same methods can be used to fasten piston shaft
(figure 1/3).

Figure 3

5.5.4 Circle Gear of Shovel Blade Adjustment

Notes: If radial jumpiness goes beyond 3mm, axial clearance exceeds 1.5mm, and then
circle guide board must be adjusted.
A. Axial adjustment of guide board
1. Use clearance gauge to measure gear
ring (figure 4/1).
2. Axial clearance between guide boards
(figure 4/2)
3. Ensure clearance in 0.6-0.8mm (figure
4/3)
4. Loosen off nut (figure 4/4), take out four
adjusting pads (3), let clearance meet the
requirements, and fit on guide board
again.
B. Radial adjustment of turning circle : Loosen
nut (figure 4/4) and nut (figure 4/5), loosen adjusting
guide board of nut (figure 4/6) Screw up all nuts, tightening torque of nuts (figure 4/4) is
590Nm. Have a test, and turning circle must be able to rotate 360 degree freely.
26
 5.6 Maintenance system of the grader
The maintenance of grader shall be conducted regularly as required. The
specific time requirement and contents of maintenance. Please refer to the form
bellow:

Labor Hour Contents of Maintenance

Motor:
1. Examine the lubrication oil surface of the oil pan, speed
regulator and the injection pump, should the oil level shows sign of
increase, identify the course, should the oil is inadequate,
supplement it until it meets the requirement.
2. Check the quantity of cooling water
3. Inspect the fixedness of the bolts of the diesel and its auxiliary
attachments.
4. When the surrounding temperature drops below 5 , the
Daily cooling water (except for the anti-freezing liquid) shall be
Maintenance completely discharged after parking.
(Every 10 labor 5. Keep the tidiness of the diesel, perform necessary cleaning.
hours) 6. Eliminate all the failures and abnormalities detected.
Hydraulic System: Check the tightness (by vision)
Electrical System: Check the conditions of the circuit and the joint
(by vision)
Wheel and tyre:
1. Check the pressure on the tyres to ensure that it meets the
technological requirements.
2. Check the damage condition of the tyre and remove the
adhesive objects.
Braking system: Check the performance of the pedal break
Steering system: Check the performance of the steering system.
Whole machine:
1. Clean the exposed surface, spread the grease on the processing
Weekly surface.
Maintenance 2.Check the tightness of the nuts and the bolts, inspect the
(Every 50 labor wear-out parts as well.
hours ) Electrical system: Check the battery.
Wheel and tyre: Check the pressure on the tyres, check the nuts of
wheels, screw them up if necessary （torque of screwing: 450Nm）

27
At first 100 labor Motor
hours 1. Discharge the engine oil in the engine oil filterer and the diesel
(First repair ) oil in the diesel oil filterer, clean the inner candles of the both
filterers.
2. Maintain the air filterer, clean up the dusts in the inner candle
and the dust collector.
3. Check the tension of the belt of fan .
4. Clean the external part of the motor, the engine oil radiator fan
and the radiator fan of the water tank.
5. Check the conditions of the induction and exhaustion systems,
make sure that the connection of joint is tight, clean the induction
and exhaustion systems if necessary.
6. Check the idling speed of the motor and adjust it, ensure
correctly replace the dismantled parts maintained, then start the
motor and check its operation, eliminate any existing failures and
abnormalities as well (The following maintenance of all levels shall
perform the above-listed procedure).
Braking system: check the hand brake, adjust it if necessary.
Operating and steering hydraulic system
1. Check the tightness of the oil tank, oil pump, cylinder, circuit,
hose and the joint. (by vision)
2. Check the operating tension
Steering system
1. Check the connection among the fasteners of the steering
system, should any looseness exists, screw them up.
2. Check the operating pressure.
Operating device: Check the guiding clearance of the bulldozer
blade.
Wheel and tyre: Screw up the wheel nuts （torque of screwing:
450Nm）
Equilibrium box: Check the tension of the roller chain, tense it up if
necessary.
Motor: Except for the items required by the maintenance of every
Every 250 labor 100 labor hours, the following works shall also be performed:
hours 1. Replace the engine oil of the motor;
2. Employ technician to adjust the valve lash if necessary.
3. Check the injection pressure and the injection condition of the
injector, cleaning and adjustment is required if necessary.
4. Check the director angle for the oil supplying, adjust it if
necessary.
5. Check the inner candle of the fuel filterer.
6. Clean the filter screen and the circuit of the oil pump in the fuel
tank.
7. Blow away the dust on the surface of the motor with compressed
air, and check to make sure the proper function of each part,
meanwhile take appropriate measures to deal with the abnormal
parts.
Operating and steering hydraulic system
Check the tightness of the oil tank, oil pump, cylinder, circuit, hose
and the joint. (by vision)
Steering system: Check the connection among the fasteners in the
steering system and screw them up if necessary.
Braking system: Check the hand brake , adjust it if necessary,
replace the damaged brake pad.
Operating device: Check the director clearance of the bulldozer
blade, check the director clearance of the rotary ring and adjust it if
necessary.
Every 500 labor Motor: Perform the items required by maintenance of all of the
hours foregoing levels.
28
 Braking system: Check the pad of the wheel-side brake.
Torque converter-gear box: Replace the inner candle of the filterer
in the gear box.
Equilibrium Box: Check the tension of the roller chain, tense it up if
necessary.
Transmission shaft: Check the clearance between the gear and the
transmission shaft in the rear axle to ensure that it doesn’t exceed
the standard, fasten it if necessary.
Every 1000 Motor: Perform the items required by maintenance of all of the
labor hours foregoing levels.

In the case where the temperature is below 5 , special protection

shall be given to the usage of the motor.
1. It’s a must to use the engine oil and fuel special for usage in
winter, check to ensure the appropriate percentage of water in the
fuel to avoid the oil circuit jamming.
2. Fill the cooling system with the anti-freezing liquid.
In cold weather or in the cold areas, it’d better not to park the
grader in the open air, if it has to, please warm up the grader with
anti-freezing liquid before the start, meanwhile preheat the engine
oil with the air heater. Then the start of the motor can be effected
after the completion of the above-listed work.
Every 2000 Motor: Perform the items required by maintenance of all of the
labor hours foregoing levels.
Front axle: Replace the lubrication grease in the wheel hubs, adjust
the clearance between the bearings of the front wheels.
Rear axle: Check the axial clearance between the master
transmission gears, readjust it should it exceeds 0.05.
Every 3000 Motor: Except for the items required by the maintenance of all of
labor hours the foregoing levels, the following works shall also be performed:
1. Clean the cooling system;
2. Clean the engine oil cooler;
3. Check the internal water seal in the water pump, fill it with new
engine oil.
4. Dismantle the motor and the starter, clean and repair it and fill it
will new engine oil.
5. Decide whether to dismantle the cylinder lid and repair the
valve according to the specific situation.
6. Decide whether to adjust the injection pump according to the
specific situation.
7. Decide whether to check the oil supply quantity of the engine
oil pump according to the specific situation.
8. Decide whether to replace the inner candle of the air filterer.
9. Rear axle: Check the axial clearance between the master
transmission gears, readjust it should it exceeds 0.05.

5.7 Motor grader‘s storage

5.7.1 Motor grader’s placing
A. For a long period storage, motor grader should be given an overall cleaning and
lubrication first and its fine finishing has to wear grease lubricant while piston rods should
be brushed with Vaseline and wrapped by paper if applicable.
B. Motor grader is preferable to be stored in warehouse to protect its tires from any
sunlight-exposure and humidity, meanwhile, regular pressure check should be conducted

29
on motor grader’s tires.
C. In case that motor grader is placed in open air or on uneven ground,
wood sleeper should be placed beneath motor grader to lighten tire load-bearing and
tire pressure have to reduce 50%, then all tires should be shielded to avoid any
exposure of direct sunshine.
D. Full oil should be filled in fuel tank, combined with sanitizer in a quantity of
10% of the oil volume (if applicable) to avoid any corrosion.
E. Regular operation should be carried out on an interval of two weeks to warm
up motor grader and, if applicable, it should be driven for a short-distance. For the
warm-up of motor grader standing on wood sleeper, gear drive can be motivated to
activate operation of the system.
F. If motor grader has an idle time for more than 4 weeks, its battery should be
removed and kept in a dry place where the temperature is higher than 0 and a
monthly charge is required.
5.7.2 Restart-up for operation
In the case where the motor grader is restart-up for operation after a year, its gear box,
rear axle drive box, balancing tank, shovel rotary worm gear case should be lubricated with
new oil and hydraulic oil and engine oil should be replaced as well.
Piston rods should go through an overall cleaning and every oil lubricator must be refilled
with grease oil.

Necessary check must be conducted as follows:

a）Check on oil volume in engine, hydraulic transmission box, rear axle balancing box,
shovel rotary worm gear case, and hydraulic oil tank.
b）Check on electrolyte volume in the battery and tire pressure.

30
6. Analysis on Common Failures and Corresponding Debugging
During the usage on the grader, by virtue to the defects in the performance and
production precision of this machine, which are combined by the hostile
environmental factors, it’s common to stumble on some failures, whose prompt
elimination is the only way to improve the efficiency and utilization ratio of the grader,
to elevate its economic efficiency as well. The subsequent forms tell us about the
diagnosis and corresponding debugging of the grader’s common failures

Table 1 of Diagnosis of Common Failures of Grader and

Corresponding solutions
Failure Cause Debugging
1. Air exists in the fuel 1. Deflate and tighten the joint in
system the oil conduit.
2. Jamming in the fuel 2. Clean and dredge.
Motor’s failure conduit or the fuel filterer. 3. Recharge
to start 3. Insufficient charge of 4. Repair the circuit.
the battery
4. Joint looseness in the
electrical system
1. Inadequate engine 1. Fuel it up.
Motor

oil. 2. Repair or replace

Abnormal
2. Abrasion or damage 3. Clean and dredge.
pressure of
in the engine oil pump.
engine oil
3. Engine oil filterer
jamming
Excessively 1. Inadequate cooling
high water. 1. Top it up with water.
temperature 2. Failures in the water 2. Repair the water pump or the
of the cooling pump or the circuit for circuit.
water cooling water
1. Oil leakage in the 1. Fuel and eliminate the cause
braking system of oil leakage.
Defective or 2. Existence of air in the 2. Deflating
malfunction braking oil circuit. 3. Clean and dredge
brake 3. Oil circuit jamming 4. Repair
Braking system

4. Low pressure in the

braking system
1. Oil circuit jamming, 1. Clean and dredge
difficulty in oil returning. 2. Replace
Brake’s failure
2. Aging seal ring of the
to be
piston.
released.
1. Dirt on the surface of 1. Clean up the dirt
Malfunction of
the parking brake 2. Adjust
the parking
2. Exceedingly large
brake
idle stroke of the parking
brake

31
 1. Failure in the rotary
motor. 1. Refer to the part concerning
2. Failure in the worm hydraulic pressure
Bulldozer
gear case 2. Repair or replace the worm
blade’s failure
3. Exceedingly large gear case
in rotating
guiding clearance in the 3. Adjust the clearance or
rotary ring. replace
4. Premature setting of 4. Adjust the link lever.
control lever
1. Failures in the
retraction cylinder and
Bulldozer 1. Refer to the part concerning
the maneuvering valve.
blade’s failure hydraulic pressure
2. The retraction sliding
in retracting 2. Clean and lubricate
track sticking
Operating
device Bulldozer 1. Damage or internal 1. Replace the seal ring
blade’s failure leakage of the seal ring in 2. Repair
in stabilizing the piston of cylinder.
in the proper 2. Malfunction of the
position locking valve
1. Jamming in the guiding 1. Adjust and eliminate the
Violation mechanism of the sticking and jamming
occurring in scraper. 2. Repair
operation of 2. Oil leakage in the 3. Deflate
bulldozer central rotary joint
blade. 3. Existence of air in the
hydraulic system

Failure Cause Debugging

1. Low oil level
2. Oil leakage or jamming in
1. Fuel
1. Abnormal the pump or the cooling system
2. Repair and clean
pressure in the 3. Filterer jamming
3. Repair and clean
outlet of torque 4. Sticking or damage in the
4. Repair and clean
converter pressure valve of the outlet
5. Replace
5. Damage in the pressure
Torque
sensor
converter
2. Torque
1. Damage in the gear 1. Replace
converter’s failure to
2. Sticking of bearing 2. Replace
start
3. Exceedingly high
1. Oil leakage in the oil seal 1. Replace components
temperature in the
2. Damage of the oil and fuel
oil of torque
temperature sensor 2. Replace
converter
1.Low oil level 1. Fuel
1. Low levering
2. Failure in the control pump 2. Repair or replace
pressure in each
3. Failure in the control 3. Readjust the pressure
shift
Gearbox pressure valve or repair
2. Exceedingly low 1. Serious abrasion in the seal
control pressure of component of clutch, piston 1. Replace
certain shift ring or the friction disc.

32
 1. Low oil level 1.Adding fuel
2. Dirtiness of the radiator fan 2.Clean the oil radiator
3. Exceedingly high for oil cooling fan
oil temperature 3. Overuse of certain shift 3.Drive in different gear
4. Failure in the valve of torque 4. Clean or replace
converter
1. Malfunction of the 1. Check, adjust or
4. Failure in the
electro-hydraulic shift replace
shifts
2. Clutch sticking 2. Adjust or replace
1. Abrasion or damage in the
oil pump 1. Repair or replace
2.Filterer jamming 2. Clean or replace
1. Low flow or 3.Low oil level 3. Fuel
abnormal pressure 4. Improper adjustment on the 4. Adjust according to
vales, such as the flow valve. requirements
5.Oil circuit jamming in the 5. Clean
hydraulic system
1. Looseness of joint 1. Tighten the joint
2. Oil leakage
2. Damage in seal ring 2. Repair or replace
1. Existence of air, exceedingly 1. Fuel or deflate
low oil level 2. Heat
3. Abnormal noise or 2. Exceedingly low temperature 3. Repair or replace
vibration of pump or high stickiness of oil,
exceeding exhaustion of pump
3. Failure of pump
Hydraulic 4. Difficulty in 1. Low oil pressure of the
system controlling the steering system, inadequate 1. See the above
steering wheel flow
1. Inadequate tightness of the
1. Replace the sealing
5. Failure of levering joint sealing
element and fasten it
valve 2. sticking of pressure-limiting
2. Clean or replace
valve
1. Different strokes of the two
1. Adjust the control
6. Malfunction ends in the control lever
linkage
related to control of 2. Internal leakage in the
2. Replace the sealing
cylinder sealing element of the
element
cylinder’s piston
1. Jamming of oil returning 1. Dismantle and clean
circuit 2. Repair relevant
7. Overheat of 2. Exceedingly large internal elements
system leakage 3. Shut down
3. Exceedingly high
environmental temperature
1. Check and adjust the
1. Improper circuit connection
1. Failure of circuit
2. Failure of electrical
electrical apparatus 2. Repair or replace the
apparatus
electrical apparatus
Electrical 1. Check and adjust the
system circuit
1. Improper circuit connection
2. Abnormal display 2. Repair or replace the
2. Failure of instrument
of instrument instrument
3. Malfunction of sensor
3. Repair or replace the
sensor

33
 1. Rectify the feeding
amount of refrigerating
1.Improper feeding amount of
medium
1. Failure to refrigerating medium
2. Repair or replace
Air-condi refrigerate 2. Malfunction of compressor
3. Tighten and then
tioning 3. Leakage of circuit
supplement the
system
refrigerating medium
1. Adjust the fastening
2. Failure to produce 1. Failure of electric circuit
joint in the circuit
wind 2. Damage of electrical motor
2. Repair or replace

Table 2 of Diagnosis of Common Failures of Grader

and Corresponding solutions

Type of Sources of
Cause of failure and the debugging method
failure failure
1. Air pocket （method a）
A. Noise from
2. Existence of air in the oil (method b)
the hydraulic
3. Wrong positioning of joint (method c)
pump
Serious 4. Abrasion or damage of hydraulic pump (method d)
noise B. Noise from 1. Incomplete centralization of shaft coupling (method c)
the 2. Abrasion or damage of component (method g)
transmission
element
1. Air pocket （method a）
A. Heating of 2. Existence of air in the oil (method b)
3. Exceedingly high setting value of safety valve or unload
hydraulic
valve (method e)
pump
4. Overloading (method c)
5. Abrasion or damage of hydraulic pump (method d)
1. Exceedingly high setting value of safety valve or unload
B. Heating of
valve (method e)
hydraulic
2. Overloading (method c)
Overheating motor 3. Abrasion or damage of hydraulic pump (method d)
1. Exceedingly high pressure of system (method e)
2. Exceedingly high or low setting value of unload valve
(method e)
3. Abrasion or damage of valve (method g)
C. Heating of
4. Dirtiness of oil or insufficient oil supply (method a)
oil
5. Improper oil viscosity (method a)
6. Failure of cooling system (method g)
7. Abrasion of hydraulic pump, valve, hydraulic motor,
cylinder or other elements (method g )
1..No oil goes into the hydraulic pump. (Method a)
2. Hydraulic motor driven by hydraulic pump doesn’t work.
(Method d)
3. Dislocation between hydraulic pump and hydraulic motor
(Method d)
Improper A. No flow 4. Difference in transmission direction between the hydraulic
flow pump and the motor driven by itself (Method c)
5. Wrong position of the steering controller (Method f)
6. The entire liquid flow passes through the safety valve
(Method g)
7. Damage of the hydraulic pump (Method g)

34
 1. Exceedingly low setting value of the flow (Method e)
2. Exceedingly low setting value of safety valve or unloading
valve (Method e)
B. Low flow 3. Internal and external leakage of the system (Method b)
4. Abrasion of the hydraulic pump, valve, motor, tank or other
elements. (Method g)

C. 1. Exceedingly high setting value of the flow (Method e)

Exceedingly
huge flow
1. Exceedingly low setting value of the pressure reduction
valve(Method e)
A. Low
2. Severe internal leakage (Method b)
pressure
3.Abrasion or damage of the pressure reduction valve.
(Method g)
1. Existence of air in the oil (Method b)
Improper B. Pressure 2.Abrasion of the safety valve (Method g)
pressure incorrect, 3.Abrasion of the hydraulic pump , motor or hydraulic
unstable cylinder. (Method g)
4.Pollution of the oil. (Method a)
1.Maladjustment of the pressure reduction valve or the
C. Pressure unloading valve (Method g)
too high 2.Abrasion or damage of the pressure reduction valve or the
unloading valve. (Method g)
1.No liquid flow or pressure (Method a)
2.Mechanism block (Method c)
A. No move
3.Abrasion or damage of the hydraulic tank or motor.
(Method g)
1.low flow (Method a)
2.Exceedingly high viscosity of the oil. (Method a)
B. Slow
3 Insufficient control pressure of the valve. (Method e)
movement
4.Abrasion or damage of the hydraulic cylinder or motor
Failure in (Method g)
controlling 1.Abnormal pressure (Method e)
2. Existence of Air in the oil. (Method b)
C. Improper
3.Abration or damage of the hydraulic cylinder or the motor.
moves
(Method g)

D.
Exceedingly 1. Exceedingly high flow (Method e)
fast
movement

Debugging method
a. By one or all followings methods: replace the dirty filter; clean the blocked
filling oil pipe and tank breather pipe; refill the hydraulic system oil till the right oil
mark; adjust the oil hydraulic pump and drive hydraulic engine to a proper speed;
carry a overall maintenance on overloaded hydraulic pump or change it.
b. By one or all followings methods: fasten the leaking inlet joint for fuel suction
pipe; fill oil till the right oil mark (all oil return lines should be lower than the liquid
level in fuel tank, which is inapplicable for minority); discharge the air from the
hydraulic system; change the seal ring of the hydraulic pump element.
35
c. By one or all followings methods: adjust the components to the corrective position
and check the sealing members and the bearings; fix and adjust components; check
whether the working load goes beyond the design requirement. Fix or replace the
abraded oil hydraulic pump or the hydraulic motor; change and adjust the coupling
gear.
d. Install the pressure gauge, change it after adjusting pressure if necessary.
e. Check the manual control position; check the circuit of the electromagnetic
controlling valve.
f. Overall or replace

36
VII. Attached Figure
Attached figure 1
External Dimension Diagram

37
 11 12 13 14 15 16

1
18
3
2 19
1
10

21 20

1.Main Power Switch 2.Hand Brake

3.Front Blade up-down operation 4.Left Blade up-down operation
5. Blade oscillating operation 6. Blade rotating operation
7. Front Wheel inclining operation 8.Steering wheel
9.Dashboard 10.Gear selector
11. Frame articulated steering operation 12.Brake footboard
13. Blade lead-out rod 14.Accelerator
15. Blade angle change operation 16. Rear Ripper up-down
17. Right Blade up-down operation 18.Hand accelerating operation
19.Operation box 20.Combined switch

Diagram 2. Control Mechanism

38
1. Oil Level/Time Meter 2. Break Indictor Light
3. Voltage Meter 4. Left Indictor Light
5. Oil Pressure Gauge 6. Air Filter Indictor Light
7. Water Temp gauge 8. Right Indictor Light
9. T.C. Oil Temp Gauge 10.Brake Pressure Indictor Light
11. Gearbox operating Oil Pressure Gauge 12.Warning
13. Start-upSwitch 14.Hydraulic Filter Indictor Light
15. Front working lamp 16. Width indicating lamp
17. Rear working lamp 18. Extinguish

Diagram 3. Dashboard

39