Sany PQ190IIIA FULL HYDRAULIC MOTOR GRADER USER’S GUIDE Manual - PDF DOWNLOAD

PQ190ⅢA 全液压平地机 使用说明书

PQ190ⅢA FULL HYDRAULIC MOTOR GRADER USER’S GUIDE

QUALITY CHANGES THE WORLD

SANY

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Preface Thank you for choosing “SANY” Full Hydraulic Motor Grader. We will offer you high-quality products and after-sales service in the star grade.

Our company, absorbing the domestic and international advanced technology of motor graders currently, and on the basis of long-term experience in designing and manufacturing construction machinery, has developed an innovative technical product-- Full Hydraulic Motor Grader. It is a kind of engineering machinery with multiple purposes and high efficiency. It can be widely used in the construction of projects such as high-grade highway, airport, dam, port, railway, and mine.

In this User’s Guide, we will introduce to you such contents as performance parameters, technical characteristics, working principle, structure components, safety operation, and maintenance and repairing of “SANY” Full Hydraulic Motor Grader.

In order to properly use the machine, please read this User’s Guide carefully before operation. This will help you: ——To get to know the machine.

——To avoid troubles due to improper operation.

——To increase the reliability of the machine.

——To prolong the service life of the machine.

——To reduce the maintenance cost and stoppage time.

In order to handy read this guide, it should be within easy reach. Only when you completely understand the User’s Guide can you operate the machine expertly and safely.

Respectable friends, thank you for your trust in “SANY”, we wish you great success in your career.

SANY Heavy Industry Co., Ltd.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Special Instruction:

Users should carefully maintain and properly use the motor grader. If you operate the machine against the rules, SANY has no obligation to undertake the responsibility. ¾ Before operating the motor grader, please read this User’s Guide carefully, and operate it in accordance with the detailed requirements. ¾ The motor grader should work within the range shown in the User’s Guide. It should not be used for other purposes. ¾ The operator should be well-trained and skillful. And keep in calm, quick-witted and in steady mood when operating. ¾ It is not allowed that the unskilled technician repairs or dismantles the machine. ¾ The machine must be maintained according to the requirements as specified in this guide. ¾ The maintenance of the engine shall be conducted strictly in accordance with the requirements in the Maintenance User’s Guide provided by the engine manufacturer. is the safety warning symbol. If you see such a symbol on the motor grader or in the user’s guide, please pay special attention and avoid possible body injury.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Ladies/gentlemen: It is our ceaseless pursuit to provide our clients with reliable and high quality products. Your suggestion is welcomed for further improving our products’ quality, so we greatly appreciate that if you can send your suggestions and opinions by mails to following address.

Postcode: 410100 Address: Surface Machinery Co., Ltd. in SANY Industry Town, Changsha Economic and Technological Development Zone, Changsha, Hunan, China Your Suggestions & Opinions:

Company Name: Address: Tel: Fax: Thanks you for your support to SANY Products!

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Contents Part I Operation Guide ............................................................................................................................5 Chapter I Safety Regulations.............................................................................................................6 Chapter II Utilization of New Machine .............................................................................................25 Chapter III Overall Parameters ........................................................................................................29 Chapter IV Transmission System ....................................................................................................34 Chapter V Hydraulic System ...........................................................................................................38 Chapter VI Electrical System ...........................................................................................................44 Chapter VII Driving and Operation ..................................................................................................63 Chapter VIII Operation of Working Device.......................................................................................78 Chapter IX Use and Operation for the Accessories .........................................................................84 Part II Maintenance ...............................................................................................................................91 Chapter I Periodic Technical Maintenance ......................................................................................92 Chapter II Check of Fastening Pieces .............................................................................................96 Chapter III Maintenance of Hydraulic System .................................................................................98 Chapter IV Maintenance of Engine................................................................................................100 Chapter V Maintenance of Electrical System ................................................................................106 Chapter VI Maintenance of Worm Gear Case ...............................................................................108 Chapter VII Maintenance of Reduction Tandem ............................................................................ 110 Chapter VIII Utilization and Maintenance of Copper Sleeve of Rear Axle Frame .......................... 117 Chapter IX Adjustment and Maintenance of Working Device ........................................................121 Chapter X Maintenance of Front Axle............................................................................................126 Chapter XI Maintenance of Air Conditioner ...................................................................................128 Chapter XII Wheel Maintenance....................................................................................................133 Chapter XIII Lubrication.................................................................................................................135 Part III Analysis on Malfunctions .......................................................................................................141 Chapter I Analysis on Malfunctions for the Mechanical Part ..........................................................142 Chapter II Malfunctions Analysis on Diesel Engine System...........................................................155 Chapter III Malfunctions for the Hydraulic and Air-conditioning Parts ............................................166

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

PQ190IIIA Full Hydraulic Motor Grader User’s Guide Part I Operation Guide

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter I Safety Regulations

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Chapter 1 Qualification of Operators and Maintainers & Special Instruction 1.

Qualification Requirement for Operators and Maintainers

(1) Only the person with approved qualification certificate, professionally trained and tested to bear operating capacity is permitted to operate the motor grader.

(2) Only the professional technical staff and after-sales service staff are permitted to service the motor grader.

2.

Safety Cautions during Commissioning and Operation

(1) Carefully read and comply with all safety symbols on the machine, and learn how to correctly and safely operate the machine and controller; (2) Only allow to initiate the engine on the operating mat (on the ground is forbidden), and make sure that all control levers are at neutral position before initiating the engine; (3) Before back swing of the shovel or transfer and operation of the machine, make sure the position of personnel around, and especially be careful to not collide with them; (4) Keep the alarm for backward running and the horn in working state all the time, and whistle to warn the personnel around when the machine starts to move; (5) If the running and slewing or the operation of machine is conducted in narrow area, it is suggested to employ the signaler and harmonize the meaning of gesture signals. Only one signaler is allowed, and it is forbidden to employ two signalers or above at the same time to give guidance; (6) If the engine shall be initiated by cross-cover method, it shall be conducted by two persons, and it is forbidden to use frozen storage battery. The breach of proper cross-over initiation procedure will result in battery explosion or machine out of control; (7) The passenger may block off the sight line of operators, and hence result in operation of machine under the unsafe condition. Therefore, only the operator is allowed to appear in the cabin, other passengers are forbidden; (8) The cabin bears the capacity for FOPS and ROPS, but the assessment shall be conducted in advance to ensure the safety of operators and machine, if the operation is conducted at the place to be fallen with stone block or macadam; (9) Prevent other personnel from access to working area, warn the person around by pressing horn or sending out other signals when the machine is moving forward, seek help from the signaler if your sight line is blocked during backward running, and the signaler shall send out the gesture signals in accordance with local regulations. It is allowed to move the machine only when the signaler and the operator clearly understand the signals. During backward running, turning or operation, prevent the people from access to the machine as much as possible, from collision with the machine, and from severe casualty accident; 7

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

(10) Keep the window in good condition and the rearview mirror and light clear; (11) Dust, heavy rain and mist will reduce visibility. Slow the speed and properly turn on the illuminating light if the visibility is reduced; (12) Prevent the machine from working on the slope with the gradient over 14°; (13) If clearing snow on a frozen ground, the vehicle shall be equipped with antiskid chain and prevented from overturning due to too rapid speed.

3.

Special Instruction In addition to provisions in the user’s guide, relevant regulations or rules for safety and accident prevention as specified in the law are still valid.

The users shall carefully maintain and properly use the motor grader, and our company has no obligation to take responsibility for the results due to breach of one of the following regulations;

(1) Use the motor grader in accordance with the user’s guide, and forbid using it for other purpose at random; (2) Operators shall be trained to expertly operate the machine, and shall keep stable emotion, clear mind and quick response during operation; (3) Carefully read the users’ guide for motor grader and diesel engine before operation, and forbid any operation violating relevant regulations; (4) Familiar with your working position and environment before operation, and take care possible safety accidents at your working position; (5) Conduct all technical maintenance in accordance with requirements in the user’s guide; (6) Do not dismantle the machine without permission, and do not employ unskilled technician to service or dismantle the motor grader; (7) Do not change the machine without authorization. The change of machine or installment of additional accessories will affect the stability and reliability of the machine, and increase danger to the operator as well; (8) We are unable to forecast all potential dangers, so the user’s guide can’t cover all warnings. If the operation procedures, tools, devices or working methods especially recommended by our company are not fulfilled, you shall make sure that the operation procedures adopted by yourself are safe to you and other people, and will not create any damage on the machine or generate any danger; (9) Our company is exempt from responsibility to the loss due to utilization of spare parts not supplied by our company.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

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Chapter 2 Safety Warning Symbol Figure 1-1 is the safety warning symbol. If you see such a symbol on the machine or in the user’s guide, please pay attention to potential danger to your safety.

The symbol words used in coordination with safety warning symbol include: DANGER, WARNING, and CAUTION, among which DANGER is the highest grade of danger.

On the machine, “DANGER” is written in red, “WARNING” in orange, and “CAUTION” in yellow.

“WARNING”

and

“CAUTION”

indicate

dangerous

and “CAUTION” is for normal prevention.

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states,

Figure 1-1

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Chapter 3 Safety for Equipment Running and Operation 1． Basic Operating Protection (1) Use the ladder and armrest in a proper way (Figure 1-2) “Please use footboard and armrest for getting on the motor grader, do not take the control lever as the armrest”! When you get on and get down from the motor grader, please face the machine, pay attention to the consistency of your body, keep contact with armrest and footboard, and do not take the control lever of machine as the armrest, so as to avoid trip and injury.

Take special prevention measures in the case of slurry, snow and dampness; keep the footboard clean and free of oil stain;

Fig. 1-2

do not jump from the motor grader, and do not up and down the running grader at random.

(2) Only allow to initiate the machine when siting on the control seat (Figure 1-3) The operator is allowed to initiate the machine only when he/she is sitting on the seat. When parking, all control levers and working devices shall be ensured at proper positions, so as to avoid unexpected action when initiation of the machine.

(3) Tie the seat belt during operation (Figure 1-4)

Fig.1-3

Please tie the seat belt during operation or travel of the machine.

Regularly check the seat belt, and make sure that the safety buckle isn’t broken or lost. Replace the seat belt if it is broken and can’t be used.

Replace the seat belt once per three years no matter whether it is broken or not, so as to guarantee the safety.

(4) Prevent unexpected action of the machine If the motor grader stops working, the person nearby is allowed to

Fig.1-4

access to the machine only when all working devices are set down, the gear shift is set at the neutral position, and the red button of parking brake is pressed.

Please comply with the above rules when you stand up or leave the seat or motor grader, so as to avoid accident.

(5) Aviod operation in dangerous environment 10

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Before operation, make sure that whether there are any public facilities as gas conduit, cable and water pipe in working area, so as to avoid damage on these public facilities.

During the running of motor grader, avoid contact with obstacles or cables at high altitude.

Set road obstacles or maintain working orders at worksite by staff; forbid the stander-by to access to working area, and make sure that motor vehicle and walkers make a detour.

If the motor grader runs on a solid ground, especially at the edge of deep hole or nearby earth dike, close attention shall be paid to prevent the machine from overturning due to earth collapse.

(6) Only the operator in the cabin During the travel or operation of motor grader, only the operator is allowed in the cabin, otherwise the sight line of the operator will be blocked, which will affect the operation and easily cause accident.

(7) Avoid extrusion on shovel (Figure 1-5) “Do not stay because of possible injury during operation”！During operation, the shovel will make rotary movement and up-down movement; keep away from shovel working area when the motor grader is running, so as to avoid injury on your feet.

(8) Avoid accident when backward running (Figure 1-6)

Fig. 1-5

When the motor grader is running backward, use rearview mirror for observation, so as to ensure no other body or vehicle is on the running lane. If the sight line is blocked, the staff shall assist the driver to backward run the motor grader.

Check the alarm to ensure the warning for backward running

Fig. 1-6

can be given out during the backward running.

Keep the windows of cabin and the rearview mirror clean.

(9) Extrusion Danger (Figure 1-7) “Do not stay because of possible injury during operation”！When the working device of motor grader is debugged or operates, do not stay at the area between working device and cabin, so as to avoid severe injury due to extrusion when the working device slews.

Fig.1-7

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

(10) Prevent the machine from overturning (Figure1-8) The operator shall tie seat belt during operation of motor grader.

Special attention shall be paid when the motor grader runs or works on slope, so as to ensure the best stability of motor grader and prevent the machine from overturning.

Special attention shall be paid when the machine runs on the wet, slippery, loose and frozen ground, for the machine will slip easily.

Fig. 1-8

The motor grader shall run on a solid ground, do not near to the river dike or deep hole, so as to avoid overturning.

If the motor grader overturns, do not jump from the motor grader, otherwise major injury will be created due to roller compaction.

(11) Avoid Being Crushed or Pressed (Figure 1-9) “No loitering, injuries may be caused in work”! To avoid serious injuries caused by crushing or pressing, the operator should make sure that no one is loitering around when the motor grader is under maintenance

Fig. 1-9

and repair or in operation.

(12) Avoid Being Burnt (Figure 1-10) To avoid being burnt, please don’t touch the exhaust pipe of the diesel engine by opening its protective cover when it is in operation or just stops working.

(13) Avoid One’s Hand Being Drawn into the Engine Belt Transmission

Fig. 1-10

Device (Figure 1-11) Please don’t open the protective cover of the diesel engine and get close to its belt when it is running, otherwise one’s arm might be drawn into the belt transmission device, thus causing serious injuries.

(14) Avoid One’s Hand Being Cut by the Engine Cover (Figure 1-12)

Fig.1-11

“Avoid being cut on one’s hand when the engine cover is closed ”! When closing the engine cover, pleased pay attention to the safety of one’s hands to avoid being cut by it.

Fig.1-12

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

(15) Emergency Exit (Figure-13) To ensure that the operator could leave the cabin and danger immediately once an accident happens, a second exit is equipped with the motor grader (emergency exit).

Once an accident happens, one can leave from the second exit if the first exit doesn’t work.

Please have a check of the motor grader before operation, ensuring

Fig.1-13

that the second exit can be opened.

(16) Adding Operation Accessories The reliability and stability of the motor grader might be influenced if accessories without permission are added.

If the motor grader needs adding operational accessories, please contact the seller to check its compatibility first and employ experienced workers for the installation.

Please read carefully the relevant pamphlet of accessories and follow its requirements and points for attention.

(17) Emergencies Please prepare for emergencies or fires, ensuring easy approach to such tools as fire extinguishers.

Once one is in danger, please call the hospital, emergency center and the fire department as well.

Attention: all the safety illustrations and danger warning marks on the motor grader should be kept intact, and in clear pictures and texts. Please contact our after-sales service engineers for a change if there is any damage. We will not be responsible for the accidents caused by the damage of the marks.

2.

Protection by Materials

(1) Wearing Labor Safety Articles The operator must wear proper labor safety articles, such as safety helmet, gauze mask, loose and comfortable work clothes and work shoes of high skid-preventing quality. Please wear gas masks while maintaining the air conditioners!

(2) Avoid Being Hurt by Chips Please wear eye-protecting glasses or protective eyeshades while operating or maintaining to avoid being hurt by splashing soil or mental chips.

(3) Noise Preventing (Figure 1-14) Noise will cause damages or failure to hearing. Equipments of our

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Fig.1-14

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

company have been strictly marked for the noise. Please wear proper hearing protecting articles, such as protective ear covers or earplugs to reduce the damages caused by the noise.

3.

Fire Prevention

(1) Using Fire Extinguisher The cabin is equipped with a powder type fire extinguisher. At least there should be one person at the construction site knowing how to use it. Please pay attention to fire prevention when refueling the motor grader or opening the fuel tank lid.

(2) Safe Treatment of the Fuel (Figure 1-15) Inflammable liquids should be kept from fires. Please don’t add fuels when you are smoking or near fires.

(3) Clearing the Motor grader at Regular Intervals Clearing the rubbish, chips and oil at regular internals. Rags with greasy dirt and other materials easy to cause fire should not be left in the motor grader.

(4) Maintaining Hose and Wires The hydraulic oil tube should be immediately replaced once it begins seeping, and the oil oozing out should be cleaned. The electrical lines and connecting device should be examined frequently to avoid dangers.

Fig.1-15 The capacity of the fuse should not be enlarged without permission!

4.

Working Environment

(1) Elevation The elevation at which the motor grader works is ≤2000 meters as usual. Special motor grader made by our company should be employed when the elevation is over 2000 meters.

(2) Surrounding Temperature The surrounding temperature in which motor grader works is -35℃~40℃, and the average temperature in 24h should be within 35℃. The lowest surrounding temperature should be no less than -40℃ (discharging oil and water) when it doesn’t work. The highest working temperature of the hydraulic oil in the oil tank should be less than 80℃, and the temperature of the water in the water tank should be less than 95℃.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Chapter 4 Safety Regulations for Service and Maintenance Please carefully read the user’s guide and the drawing volume of spare parts for servicing the equipment. If there are any problems about procedures or techniques, please contact with after-sales service department of our company. Do not make repair if not quite clear about it.

1. Parking Please park the motor grader before maintenance and service: (1) To ensure the unexpected moving of motor grader will not occur, park the motor grader on flat ground before service, the servicing area shall not be less than 120m2 (8×15), and the space height shall not be lower than 6m.

(2) Lower the working device to the ground; (3) Make sure that the gear shift is at neutral position, and locate it at “P” position by pressing parking brake button.

(4) Turn off the engine, and take away the key for initiation; (5) Hang a warning board “No Not Operate” at the operator’s seat.

2. Maintenance (1) Inspection Please inspect the machine before operation every day, so as to make sure that all protective device and shield are normal. Special attention shall be paid to hydraulic pipeline and electrical wire connection, and the broken accessories shall be repaired or replaced in time.

(2) Support Make sure safe, stable and reliable supports to the machine and the accessories when checking and servicing the motor grader and its attached devices under the motor grader; ¾ Do not use hydraulic power plant to support the motor grader; ¾ Do not overlap many hollow bricks or wooden strips to support the motor grader; ¾ Do not use device that may slip to support the motor grader; ¾ If the machine shall be lifted or supported by shovel, scarifier and blade for service and maintenance, many jacks and iron poles shall be used to support the machine or working devices.

(3) Gas Filling Regulation Following safety measures shall be taken when filling the gas; ¾ Turn off the engine; ¾ No smoking; ¾ No naked fire nearby; 15

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

¾ Do not fill gas in close area; ¾ Make sure to fill acceptable fuel gas to proper level in gas tank; ¾ Clean off residual gas before initiating the machine; ¾ Screw down the cover of gas tank, so as to avoid accident due to leakage of fuel gas.

(4) Service and Maintenance Regulation Forbid to use broken motor grader or that with potential traffic danger.

Qualified servicing personnel shall be professionally trained. However, the operator of motor grader shall maintain the motor grader in accordance with maintenance manual.

Keep the servicing area clean and dry; Before servicing, find out the places for fire extinguisher, first aid apparatus and telephone firstly; Set up the safety consciousness to avoid accident. If any accident occurs, do not be scared and perplexed, but rapidly take effective measures. The first and the most important is to guarantee the life safety, and then to avoid material loss.

In order to protect life safety, you shall always wear: ¾ safety helmet; ¾ Working boot with steel toe cover; ¾ Earmuffs; ¾ Glistening clothing； ¾ Working gloves; ¾ Protective glasses and gauze mask if necessary.

No smoking and any action that will create fire and heat during working!

(5) Repair of Diesel Engine Special attention shall be paid when the engine is initiated. If possible, turn off the engine before repair (if the engine shall be kept running, it shall be cooperated by tow persons). All parts dismantled shall be reinstalled after repair. Do not wear loose clothing when repairing the engine in operation. Pay attention to the potential danger indicated in the operation manual for the engine.

Cool the engine before repairing, and do not fill lubricating oil when the engine is running.

(6) Repair of Cooling System Turn off the engine before inspection, or cool it if possible. Be careful in opening the radiator’s cover if the engine is hot, and wear working gloves, working clothing and protective glasses. Stand away from the cover, and do not open the cover if the cooling system still has pressure. Be careful in filling coolant into hot water tank.

(7) Repair of Storage Battery The storage battery contains poisonous and corrosive sulfuric acid, so the operator shall wear 16

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

gloves to prevent the skin, clothing and machine from sulfuric acid. If the clothing is stained with sulfuric acid, take off all polluted clothing, rapidly rinse the skin with water for 15min at least, and finally conduct medical treatment and rescue at once. During the route for a medical treatment, go on wiping it by sponge.

The gas generating in the storage battery has explosibility, and it will explode if the naked fire or spark is too close to the storage battery.

When installing or replacing the storage battery, pay attention to avoid short circuit of binding post of storage battery. Firstly disconnect the cathode binding post when dismantling the storage battery.

Be caution of connecting the anode with the cathode of storage battery, or earthing the anode of power supply, so as to avoid electric discharge and human injury.

When using the charger to charge the storage battery, disconnect the power supply switch of charger before connecting cable from charger to storage battery.

(8) Repair of Tyre Repair the tyre at the repair or service place. Do not forget to fill the tyre with compressed air. Use particular tools and instruments to replace the tyre.

The charging pressure for tyre shall conform to the explanation on the motor grader and in servicing manual. The pressure of tyre will be increased due to solarization and friction. Do not open the vent valve of tyre to release gas by hand, but use air pin to lower the tyre pressure.

Check whether the tyre is broken or not, so as to ensure no accident, and periodically check the abrasion of tyres.

(9) Welding The high voltage generating due to welding may damage the electric components of electrical system, so following works shall be made before welding the motor grader: Turn off the engine; Turn off the power supply switch or disconnect the anode connection of battery; Disconnect the earthing wire of engine, storage battery, cable and other components.

(10) Prevent High Pressure Liquid Flow As the machine adopts high pressure hydraulic system, so attention shall be paid to prevent the skin from severe injury due to high pressure liquid flow. Before operation of motor grader, check whether the high pressure rubber hose and the adaptor are in good condition, so as to avoid human injury due to leakage or sudden breakage of aging rubber hose.

Do not directly check leakage by hand (Figure 1-16), but use baffle plate to determine the position with fuel leakage (Figure1-17).

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

Fig. 1-17 Fig. 1-16

Please immediately go to hospital if the liquid penetrates the skin, which shall be drained out of human body, otherwise the skin will be rotten (Figure 1-18).

Fig. 1-18

Caution: Release the pressure in accumulator before servicing braking hydraulic system.

(11) Do not use the compressed air to rinse oil tube, or fill the seawater or the water containing salt into washing chamber and water tank.

(12) The motor grader is equipped with air-conditioning system, so do not conduct welding around the air conditioner or at its inlet. Any servicing for air conditioner, including coolant replacing, shall be conducted in the workshop with particular apparatus.

Do not dismantle the cold air duct of air conditioning system at random due to pressure in it.

If the hot water duct shall be dismantled, it shall be cooled before dismantlement.

3. Maintenance of Cooling System The pressed cooling system will release liquid and hence result in severe burn.

Turn off the engine. The funnel cap can be moved only when it cools to can be touched by hand.

Before moving it, slowly loosen the funnel cap to release pressure.

Do not conduct welding or heating near high pressure liquid line, otherwise combustible spray will be generated after heating the high pressure liquid line and hence result in burn. Prevent the working area of high pressure liquid line from heat flow.

Move the paint. Do not inhale the dust and gas of paint. Employ the skilled welding technician to

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

service the machine. Keep a ventilated working environment, and wear protective eyepatch and other protective apparatus when welding.

4. Regulation for Maintenance of Motor Grader (1) Periodically inspect the motor grader based on the working condition, at least once every year. If it isn’t used for one year, as long as the operating time lasts for 1000h since last inspection, it shall be inspected again by professional personnel, and the inspection record shall be carefully made and kept. The motor grader, with the service life over 5 years, shall be re-inspected in accordance with additional requirements specified in user’s guide. The potential trouble harmful to safety shall be dealt with.

(2) If the motor grader to be placed for a long term (over 30 days), the whole body shall be maintained once at first, and it shall be carefully inspected and properly maintained when reusing it.

(3) During utilization of this machine, it shall be properly lubricated. It is suggested to adopt the recommended time interval for lubrication and type of lubricating agent. Under strict working condition, the time interval shall be adjusted.

(4) Check whether all fastening pieces (connecting bolts and pins) are loose.

(5) The service life of rubber hose shall not exceed 6 years (including storage time), so it shall be replaced with hydraulic rubber hose in specified time limit, even through no visible damage is found.

(6) The operating platform and the working surface are installed with particular skidproof materials that shall be inspected periodically for it is easy to be damaged and shall be replaced if necessary.

5. Prevent Erosion by Exhaust Gas, Dust and Wastes (1) Prevent exhaust gas The exhaust gas of diesel engine is harmful to people’s health (Fig. 1-20). If you have to operate the machine indoors, it is better to use exhaust system or open doors and windows, so as to ensure a well ventilated environment and the fresh air.

(2) Prevent battery explosion As the battery will explode, so keep the flame far away from the

Fig. 1-20

battery.

Forbid the short circuit when checking the battery. Use the voltage meter or liquid densimeter for measurement.

Do not charge the cold battery, otherwise it will explode. The temperature of battery shall reach 16℃ when charging.

(3) Properly deal with chemical substances 19

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

The lubricating agent, coolant, paint and binder used in motor graders belongs to hazardous substances. The exposed hazardous chemical substance is harmful to the environment, so it shall be properly dealt with. If it is not sure that whether the hazardous chemical substance is safely dealt with or used, please contact with the dealer.

(4) Move away paint before welding or heating The paint, once being heated, will generate poisonous gas.

Keep the paint at least 76mm away from heating supply, and wear gas mask when working at sands or spraying paint. If the solvent or paint deliquescent agent is used, please use the soapy water for rinse. Move the container of solvent or paint deliquescent agent away from working area, and ventilate the working area for 15min before welding or heating.

Work in the open air or well ventilated room, and properly deal with the exhaust gas.

(5) Properly deal with wastes Improper treatment of wastes is harmful to the environment, so if the fuel, gas, coolant, filter and battery used in the machine are not properly treated, the great harmfulness will be generated to the environment.

Do not pour the wastewater to the ground, drainage ditch or water source.

The refrigerant of air conditioner will pollute the air, and the government allows the appraisal service center to recycle the used refrigerant.

If it is not sure that whether the exhaust gas is safely treated, please contact with local environment protection bureau or recycle center for more information.

It is possible for explosion when dealing with fuel, hydraulic oil and other functional liquids (such as braking liquid, and electrolyte for storage battery).

Please recycle in accordance with the safety regulations for relevant products and the local laws and regulations.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

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Chapter 5 Packing, Transportation and Storage 1.

Packing

(1) Motor graders are allowed of no packing when dispatched from the factory, but antiseptic and rustproof treatment and should be applied to the exposed surface.

(2) The skill documents supplied with the motor grader should include: a) User’s manual; b) Product certificate of quality; c) Packing list.

2.

Transportation

(1) Before loading and unloading, the slope or loading platform and the trailer board should be completely cleaned, as the ones with greasy dirt, soil or ice has the danger of slipping; (2) The motor grader should be loaded and unloaded on solid horizontal ground, keeping a certain distance from the road side for safety; (3) Limit stop should be properly placed under the wheels when one uses the slope or loading platform; (4) The loading platform should be of enough width and strength to support the motor grader and with a slope of less than 15 degrees, see figure 5-3; (5) The mean axis of the motor grader should correspond with that of the trailer when it is being loaded.

And the motor grader should be slowly driven up to the slope lest that the shovel might destroy the tyres or other parts of the transportation vehicles; (6) When the motor grader is adjusted to a proper position, the articulating carriage should be straightened, the center of the front wheels adjusted to coincide with that of the motor grader, the tyres vertical with the ground, the shovel lowered to its proper position in transportation. Rubbers or cork should be put under the shovel to avoid the bending of the lifting oil cylinder because of the bump in transportation.

(7) The blade and scarifier should be lowered and padded with rubber or cork; (8) Tie the chain or rope to the frame of the motor grader and avoid striding across or pressing over the hydraulic pipelines or hoses. Fix the four corners of the motor grader and working device to the trailer with chains and ropes; (9) In transportation, the steering of the hinge should be fixed by the rob, the tyres with pegs. And other measures also should be adopted to fix the motor grader; (10) Drain off the water in the water tank of the diesel engine and save some fuel for transportation; (11) Cut off the circuit connecting the accumulator and the frame; (12) Elevate the working device while unloading and move the motor grader slowly. The motor grader 21

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should be carefully driven as the joint where the trailer board and the slope meet is rising high.

When it approaches the slope, drive carefully down to the ground; (13) If the motor grader should be transported to another one for a short distance on public ways after

finishing working in one construction site, please do by following ”preparations before transportation’ in part 4of this chapter.

Figure1-21 Requirements for Loading Preparations 3.

Points for Attention of Motor Grader Hoisting Attention: (1) examine the hook of the motor grader (figure 1-22) and the cable of the crane; (2) the robs fixing the front and rear frames should be locked before being hoisted to avoid the swinging of the frames while hoisting; (3) make sure that the cables will not touch the motor grader while hoisting.

Figure1-22 (4) Please make sure that hoisting is carried out in a proper way. (Figure1-23) And nobody is allowed to stand near while hoisting lest that one might be hurt by the broken cables.

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Figure1-23 (5) The center of gravity of the motor grader should be coincide with that of the truck. The truck is not allowed to carry irrelevant things of the motor grader. The height, width and length of the carried commodity should be within the indicators of local transportation laws and regulations. The truck should run at a proper speed. As the center of gravity of the motor grader is high, special attention is required to avoid turnover while turning a corner. Enough space and distance should be left while crossing the underground passages, bridges tunnels or passing high-latitude pipes and cables.

4.

Safe stopping To avoid accidents: (1) Stop the motor grader on horizontal ground; (2) If the motor grader should be stopped on a slope, thighs like pegs should be put under its front and rear wheels to avoid sliding; (3) Lower the shovel, front blade (optional) and rear scarifier to the ground; (4) Gear selector should be in neutral position. Put the button of parking brake, making it in the position of “P”.

(5) Run the engine at an idle speed and without load for 5 minutes (6) Turn the key switch to “OFF” to stop the engine; (7) Get the key from the key switch.

5.

Storage When the motor grader is in storage for a ling time, the water in the water tank of the diesel engine should be drained off and anti-rust measures should be adopted. It should be placed in ventilated and dry storehouse. If placed outdoors, it should be placed in a high terrain, and supported over the ground, making its tyres above the ground and covered with rainproof cloth.

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Chapter 6 Re-sale Notice following items if the motor grader is resold: 1.

All documents about motor graders must be handed over to new operator, such as operating regulations, maintenance guide, diagram, nameplate and certificate of inspection. Without these files, motor graders cannot be re-sold.

2.

You will obtain data about modification on safety and updating function as soon as you submit the re-sale report to Sany Company.

3.

Cautions for operating motor graders shall be told to new operators.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter II Utilization of New Machine

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Chapter 1 Cautions for Utilization The driver of motor grader is suggested to be guided by our operation technician, so as to make full use of the motor grader. The cautions for utilization are as follows: 1.

Correctly choose the slewing angle and scraping angle of shovel, it is better to adopt a larger slewing angle, so as to achieve stronger excavation force in unit working width; the small scraping angle can reduce cutting resistance, while the large scraping angle can improve flatness and effect.

2.

Tilt the front wheel to the side with material discharged, and make the front wheel plumb when working on the slope, so as to achieve a better adhesive force with support from tilted front wheel.

3.

When the motor grader is running, the shovel can be extended by operating shovel pulling device, while its height will not be changed.

4.

The motor grader is inapplicable for underground working condition or bad ventilated environment.

5.

The function of motor grader can be improved by installing such devices as front blade, rear scarifier and snow blade.

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Chapter 2 Cautions for Utilization of New Motor Grader I.

Debugging before Utilization Before utilization, the motor grader shall be checked, especially whether broken during transportation.

Contents to be checked: 1.

Check the illumination and horn systems and the fastening of nuts.

2.

Check the tyre pressure. The normal pressure is 0.2 Mpa for front wheel and 0.25 Mpa for rear wheel.

3.

Check the oil level in engine, reduction tandem, shovel slewing worm gear case, hydraulic oil tank and fuel tank.

4.

Check the water tank: fill it with non-freezing solution.

5.

If the signal lamp for working braking pressure fails to give out light after initiation of engine, check the braking and steering functions.

6.

One week after operation of motor grader: fill butter in accordance with schematic diagram for lubrication (see Figure 9-8).

7.

II.

Antifreezing: Use antifreezing diesel if necessary.

Commissioning of New Motor Grader All moving elements from engine, travel hydraulic system, reduction tandem to wheel shall experience commissioning. During such a period, the motor grader shall not work under full load.

1.

Within the first 50 operating hours, only 75% of rated power of motor grader can be used.

2.

During the 50-100 hours, full power can be used, but the continuous working hour under full power condition shall not exceed 2 hours.

III. Cautions for Safety during Commissioning and Operation (I) Carefully read and comply with all safety symbols on the machine, and learn how to correctly and safely operate the machine and controller; (II) Only allow to initiate the engine on the operating mat (on the ground is forbidden), and make sure that all control levers are at neutral position before initiating the engine; (III) Before back swing of the shovel or transfer and operation of the machine, make sure the position of personnel around, and especially be careful to not collide with them; (IV) Keep the alarm for backward running and the horn in working state all the time, and whistle to alarm the personnel around when the machine starts to move; (V) If the running and slewing or the operation of machine is conducted in narrow area, it is suggested to employ the signaler and harmonize the meaning of gesture signals before initiation of machine.

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Only one signaler is allowed, and it is forbidden to employ two signalers or above at the same time to give guidance; (VI) If the engine shall be initiated by cross-cover method, it shall be conducted by two persons, and it is forbidden to use frozen storage battery. The breach of proper cross-over initiation procedure will result in battery explosion or machine out of control; (VII) The passenger may block off the sight line of operators, and hence result in operation of machine under the unsafe condition. Therefore, only the operator is allowed to appear in the cabin, other passengers are forbidden; (VIII)The cabin bears the capacity for FOPS and ROPS, but the assessment shall be conducted in advance to ensure the safety of operators and machine, if the operation is conducted at the place to be fallen with stone block or macadam; (IX) Prevent other personnel from access to working area, warn the person around by pressing horn or sending out other signals when the machine is moving forward, seek help from the signaler if your sight line is blocked during backward running, and the signaler shall send out the gesture signals in accordance with local regulations. It is allowed to move the machine only when the signaler and the operator clearly understand the signals. During backward running, turning or operation, prevent the people from access to the machine as much as possible, from collision with the machine, and from severe casualty accident; (X) Keep the window in good condition and the rearview mirror and light clear; (XI) Dust, heavy rain and mist will reduce visibility. Slow the speed and properly turn on the illuminating light if the visibility is reduced; (XII) Prevent the machine from working on the slope with the gradient over 14°; (XIII)If clearing snow on a frozen ground, the vehicle shall be equipped with antiskid chain and prevented from overturning due to too rapid speed.

IV. Precaution against Emergency (I) Wear working clothing and safety articles, and do not take a change; (II) Avoid wearing of loose clothing, jewelry or other things that will hook the control lever or parts of machine; (III) The operator shall be absorbed in safe operation, and not listen to the radio or music during operation.

(IV) Be caution to the fire or accident; (V) Equip with first-aid box nearby.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter III Overall Parameters

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Chapter 1 Main Technical Parameters Length Width Height Wheel Base between Front and Rear Axles Overall (mm) Parameters Wheel Base between Middle and Rear Wheel (mm) Wheel Track (mm) Ground Clearance of Machine (mm) Complete Basic Machine Operating Type Front Axle Quality (kg) Rear Axle Minimum Turning Radius (m) Tyre Specifications Wheel Tyre Pressure (Mpa) Basic Type (mm)

9095 2648 3218

Traveling Speed (km/h)

Diesel Engine

Rated Power (kW) Maximum Output Torque (Nm) Start Mode

10450 2740 3218

Steering Angle of Front Wheel (°)

±45

1522

Inclined Angle of Front Wheel (°)

±17

2196

Steering Angle of Frame Hinging (°) Front Axle Swing Tandem ±15 (°) (°) Complete Model with Front Scrape Machine Board and Rear Ripper Front Axle (kg) Rear Axle

±25

420 16050 4230 11820

±15 16920 4380 12540

7.9 17.5-25PR12-EM Two Front Wheels

Inclined Angle of Shovel (°) Maximum Tractive Force (kN) Forward D (Automatic Gear) First Speed Second Speed Manual Gear Third Speed Fourth Speed Model Type

Length Width Height

6208

Shovel Length (mm) Working Performance Parameters

Model with Front Scrape Board and Rear Ripper (mm)

Basic Type 90

Felloe 14/1.5-25(TB) 0.2 Four Rear Wheels 0.25 Optional 3660 3965 Type Turning Angle of Shovel 360 (°) 86

Backward 0~31.6 R(Automatic Gear) 0~31.6 6.3 First Speed 6.3 9.9 Second Speed 9.9 Manual Gear 14.9 Third Speed 14.9 31.6 Fourth Speed 31.6 QSB6.7-C192 In-line six cylinders, water cooled, 4-stroke, overhead valve direct injection, turbo charged 145(PQ190II), 2300(PQ190II) Rated Rotation Speed(r/min) 2500(PQ190IIA) 149(PQ190IIA) 702(PQ190II), Max. Torque Rotation 1400(PQ190II) 1500(PQ190IIA) 814(PQ190IIA) Speed(r/min) 24V.DC Electrical Starting

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Chapter 2 Structure of Complete Machine 1.

Structure of Complete Machine (See Fig. 1-24)

Fig. 1-24 Full Hydraulic Motor Grader Model PQ190IIIA

L 10450

H 3218

B 2648

1-Blade (optional);

2-Carriage;

6-Control console;

7-Cabin assembly;

L1 9095

3-Brand;

L2 6208

H1 628

B1 2196

B2 2000

B3 3660

B4 2740

5-Swing frame;

8-Operating control device;

10-Seat;

12-Diesel engine and accessories;

13-Engine cover;

16-Wheel;

L4 1588

4-Working device hydraulic system;

9-Engine speed governing device; 15-Scarifier (Optional);

L3 2705

11-Air conditioning system; 14-Motor grader electrical system;

17-Traveling brake system;

18-Reduction tandem assembly;

19-Rear axle frame; 20-Oil tank assembly;

21-Traveling hydraulic system; 22-Hydraulic power control system;

23-Hydraulic angular device;

24-Shovel;

25-Worm gear case;

27-Steering hydraulic system;

28-Front axle assembly

31

26-Working device;

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

2.

Product Nameplate

3.

Main Components

Sany Heavy Industry Co., Ltd.

(1) Engine Motor Grader Model Manufacturer Model Diesel Engine

Type Rated Power (kw) Rated Rotation Speed (r/min)

PQ190IIIA USA CUMMINS QSB6.7-C192 In-line six cylinders, water cooled, 4-stroke, overhead valve direct injection, turbo charged 144 2200

(2) Carriage The front and back carriages are hinged with each other and the left and right hinging steering angle is 25° respectively, the front carriage is of box beam structure, and the back one is of frame structure welded with solid beam.

(3) Working Device The shovel, slewing mechanism, angular device, blade, and scarifier (optional) are all hydraulically controlled; and the slewing mechanism is driven by hydraulic motor---worm gear case.

(4) Control Console The control console can be inclined backward or forward, with a regulation range of 65°~90° and a head regulation angle of 15°.

(5) Cabin The cabin is of steel-welded structure, equipped with air conditioner and damping rubber pad on 32

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the bottom.

(6) Front Axle The front axle is of steel-welded structure, with a swing angle of ±15°, a front-wheel inclined angle of ±17°, and a steering angle of ±45°.

(7) Reduction Tandem The reduction tandem is of a swing type, interior parts are driven by gear, and its swing angle is ±15°.

(8) Front Blade (Optional) It has a maximum underground depth of 205 mm and a maximum ground clearance of 500 mm.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter IV Transmission System

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Chapter 1 Transmission System 1.

Transmission Route (See Fig.1-25) Engine 1→Hydraulic pump 2→Hydraulic motor 3, 6→Reduction tandem 4, 7→Wheel 5, 8, 9, 10.

1-Engine;

2-Hydraulic pump;

3, 6-Hydraulic motor;

4, 7-Reduction tandem 5, 8, 9, 10-Wheel;

11-Shaft coupling

Fig. 1-25 Static Hydraulic Transmission Schematic Diagram The engine 1 drives the hydraulic pump 2 to operate, and the hydraulic pump 2 drives the hydraulic motors 3 and 6 to operate, and through the reduction tandems 4 and 7, the motors 3 and 6 drive the wheels 5, 8, 9, and 10 to rotate. Thus the dynamic transmission of the motor grader from the engine 1 to the wheels 5, 8, 9, and 10 is completed.

2.

Shifting (Steering) Principles The traveling direction (forward or backward) and the traveling speed of the motor grader will be controlled by changing the inclining direction of the inclined plate of the hydraulic pump 2 and the discharge capacity of the hydraulic motors 3 and 6 respectively.

3.

Structure and Working Principles of Reduction Tandem Assembly See Fig. 1-26 for details of the structure of the reduction tandem.

The full hydraulic motor grader has two reduction tandem assemblies in the left and right, installed at the left and right side of the rear axle frame respectively. Each tandem has front and rear output shafts, which are equipped with wheel hub and wheel.

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The reduction tandem is two groups of same deceleration gears in the front and back side, the moment which is outputted from the hydraulic motor will be inputted from the gear bearing end in the middle of the tandem, via two groups of same grade III gear deceleration in the front and back side, it will be transmitted onto the last grade deceleration gear, then, the power will be transmitted onto the wheel through the wheel shaft, which drives the motor grader move forward or backward.

One side of the tandem is equipped with one hollow columniform convex platform outwards, the exterior surface of the convex platform is inserted into the hole of the lubrication-free abrasion proof sleeve which is installed in the rear axle frame, the outer end face of the convex platform is equipped with one round flange disc, which makes the tandem locate in the left and right axial direction, and one abrasion proof copper mat is installed between the rear axle frame and tandem as well as flange disc and rear axle frame respectively.

1- Locking nut;

2-Brake drum

6- Grade II driving gear;

3-Brake;

4-Connecting disc;

7-Shaft;

8-Brake;

10-Copper mat;

11-Lubrication-free abrasion proof sleeve;

13-Flange disc;

14-Rear axle frame;

5-Grade II driven gear; 9-Grade I driving gear shaft; 12-Hydraulic motor;

15- Grade I driven gear;

16- Grade III driving gear shaft; 17- Grade III driven gear; 18-Wheel shaft;

19-Tandem

Fig. 1-26 Reduction Tandem Assembly During working of the motor grader, as the tandem could swing with a front and back angle of 15° around the convex platform, which will abrade the lubrication-free abrasion proof sleeve and copper mat, when having been abraded to a certain degree, they should be replaced immediately.

The hydraulic motor is installed on the flange disc, its output shaft connects with the high-speed gear shaft in the tandem through the spline set, in addition, the gear shaft joggles with two front and rear driven gears simultaneously, which delivers power to front and rear directions respectively.

The gears 6,15 connect with shaft 7 by the flat key, the component 16 is a gear shaft with outer 36

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

spline, thus, it not only owns the gear effect, but also possesses the shaft function. The gear 5 connects with the gear shaft 16 through the spline, and, the grade III transmission gear17 is also connected with the wheel shaft through the spline.

The output end of the wheel shaft and the brake hub is cooperated by the tapered bore, in addition to that, they are connected by one flat key, the locking nut presses the conical surface cooperation between the wheel shaft and brake hub in the axial direction, then certain shrink range will be produced, which drives the traveling output torque of the motor grader to deliver mainly by the shrink cooperation of the conical surface, moreover, flat key also delivers part torques.

Each tandem is equipped with two connecting discs, it could support the wheel shaft, and, the brake is equipped on the connecting disc.

In addition, in the place on the tandem which is symmetrical to the motor, the brake is equipped.

The structure and working principles of the brake will be introduced in the brake system.

(1) Structure of Tandem As the reduction tandem is of the functions of transmission, deceleration, bearing, and balance, it is required that the tandem should possess the characteristics of compact structure, high processing precision, strong bearing capacity, and large rigidity. The tandem is the gear shaft system of the transmission system, and the installation carrier of the brake, wheel, driving motor, and other parts, accordingly, it is one of the traveling and transmission core structural components of the full hydraulic motor grader.

The tandem is a kind of box structure welded by the steel plate, by means of the movement simulation of the computer as well as the calculation and analysis by the finite element to the strength and rigidity when it is under stress, it could meet the demand of the above working conditions completely.

(2) Lubrication During operation of the reduction tandem, the operation of the gear and shaft should ensure its abundant lubrication. The splash lubrication mode is adopted for the tandem gear and bearing of the full hydraulic motor grader. When the gear rotates, the gear tooth in the lubrication oil brings oil into the gear joggle area, thus, the joggle tooth face will be lubricated. In addition, when the gear rotates, lubrication oil in the oil basin will be swung to all directions, then, lubrication oil will flow downwards from the upper part of the box and enters into the bearing part, thus, the rotary bearing could be lubricated.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter V Hydraulic System

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1.

Sany Heavy Industry Co., Ltd.

Descriptions The hydraulic system of the full hydraulic motor grader is composed of the traveling hydraulic system, traveling brake system, steering hydraulic system, and the operating hydraulic system.

2.

Traveling Hydraulic System (See Fig.1-27) The traveling hydraulic system is a closed system and composed of one pump and two motors, including the brake hydraulic circuit.

The principle of the traveling hydraulic system is shown in Fig. 1-27, the traveling pump 1 is a variable plunger pump, and oil pumped out from the pump will directly drive the two traveling motors 3 fixed on the deceleration balancing box. Through the alteration of the discharge capacity and direction of the high pressure oil which is caused by the changing of the angle of the inclined plate, the traveling direction and speed of the motor grader will be changed; oil for the brake cylinder 10 is from the oil fill circuit in the traveling system, and is controlled by the electromagnetic steering valve 8.

1. Traveling pump

2. Oil filter

6. Pressure measuring adaptor

3. Traveling motor

4. Air cleaner 5. Liquid level and temperature gauge

7. Radiator 8. Steering valve

9. Pressure relay

10. Brake cylinder

Fig. 1-27 Traveling Hydraulic System Schematic Diagram

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

3.

Sany Heavy Industry Co., Ltd.

Traveling Brake System The double-circuit full hydraulic dynamic brake system is adopted for the traveling brake, and the hub type brake is adopted.

The principle of the traveling brake system is shown in Fig. 1-28.

①Gear pump ② Prefill valve ⑤Main oil pump

③Pressure measuring adaptor

④Low-pressure alarm switch

⑥Accumulator ⑦Brake valve ⑧Brake light switch adaptor

⑨Brake cylinder

Fig. 1-28 Traveling Brake System Schematic Diagram The accumulator will always conserve enough pressure oil, so that in case some malfunctions occur and the prefill valve stops working, the conserved pressure oil will be enough for the execution of 6 times effective brakes. If the pressure of the accumulator is not enough for a brake and the low-pressure alarm switch (4) is switched on, the traveling brake low-pressure alarm light on the gauge board in the cabin will light, and the driver shall immediately stop and check the machine.

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4.

Sany Heavy Industry Co., Ltd.

Steering Hydraulic System The full hydraulic dynamical steering is adopted for the steering hydraulic system, and even the dynamical oil is cut off, the steering still can be realized by manual force.

The steering hydraulic system principle is shown in Fig. 1-29. The gear pump is fixed on the force-take mouth of the engine. The oil pumped out from the pump will flow through the retaining valve and into the steering device. While the driver turns the steering wheel, the steering device will accordingly send the pressure oil into the steering oil cylinder, thus make the two front wheels turn as required.

The measuring motor in the steering device will automatically switch to the pumping working conditions when too few oil is supplied. Driven by the steering wheel, the measuring motor will pump the pressure oil into the steering cylinder; restricted by the operator’s force, the steering by manual force can only execute limited control to the steering of the motor grader.

1. Steering oil cylinder 2. Pressure measuring adaptor 3. Shock valve 4. Oil suction valve 5. Diverter 6. Safety valve 7. Retaining valve 8. Radiator 9. Pump 10. Oil filter

Fig. 1-29 Steering Hydraulic System Schematic Diagram

41

Fig. 1-30 Working Hydraulic System Schematic Diagram

42 8. Hinging steering oil cylinder 11. Oil cylinder of the blade

7. Shovel swing oil cylinder

10. Inclined oil cylinder of the front wheel

13. Rotary adaptor

14 Hydraulic motor

15. Shovel lead-out oil cylinder

5. Balanced valve

4. Left multi-port steering valve

12. Oil cylinder for the changing of the shovel angle

2. Oil tank

16. Right shovel poppet cylinder

9. Oil cylinder of the scarifier

6. Left shovel poppet cylinder

3. Right multi-port steering valve

5.

1. Double-gear pump

PQ190IIIA Full Hydraulic Motor Grader User’s Guide Sany Heavy Industry Co., Ltd.

Operating Hydraulic System

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

The principle of the operating hydraulic system is shown in Fig. 1-30. The double-gear pump is fixed behind the traveling hydraulic pump, two gear pumps connect with the left or right multi-port valve to form two separate circuits respectively. The parallel oil circuits are adopted to connect the units in the multi-port valve, and each single valve can work independently. Once the driver operates the multi-port valve handle, the corresponding execution component element will begin to work and make the operation mechanism work too.

The scarifier oil cylinder (optional), the inclined oil cylinder of the front wheel, the oil cylinder of the blade (optional), and the shovel poppet and swing oil cylinder are all equipped with balanced valves, which can prevent the settlement of the device caused by the internal leakage of the oil cylinder and keep the stable motion of the oil cylinder.

6.

Hydraulic Oil Tank The traveling hydraulic system, traveling brake system, steering hydraulic system, and the operating hydraulic system share one hydraulic oil tank. The hydraulic oil is a working medium with extremely high cleanliness, so the oil tank shall be kept clean and it’s not allowed to open it randomly. The hydraulic oil shall be replaced once its color changes or it becomes opaque. No un-filtered oil is allowed to be filled into the oil tank, neither is the oil with the dustiness not better than the Level 18/15 regulated in the GB/T14039-1993 and JG/T70-1999 standards or the NAS Level 8.

The hydraulic oil tank is equipped with following components:

(1) Air cleaner: to filter air and keep the foreign matters away.

(2) Liquid level meter: to measure the volume of oil in the oil tank and observe whether the oil has deteriorated. When the machine is in operation, the oil level shall be between the upper and lower limits of the liquid level meter.

(3) Temperature sensor: the temperature of the hydraulic oil in the hydraulic oil tank shall be within 30-65℃, and the maximum temperature can’t exceed 80℃.

(4) The hydraulic system is equipped with two oil filters: high-pressure oil filter and oil return filter, which are used to filter the oil. When there are too many impurities in the filter core, which may make the pressure difference of the filtered oil too high, the by-pass valve in the oil filter will open to let the oil flow through it, so the hydraulic system can still work normally. The color of the light given off by the contamination indicator fixed on the high pressure oil filter will change from green to red when pressure difference of the filtered oil is over a certain value, in this case, the oil filter core shall be replaced immediately.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter VI Electrical System

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide

I.

Sany Heavy Industry Co., Ltd.

Summery The electric system of grader is controlled based on PLC of SIEMENS S7-200. It also includes TD200 text display, VDO combined meters and warning unit (man-computer interface). It is easy for operation and highly automatic. Multi-gear moving can be achieved through the control handle and accelerating pedal. The technology is in the leading place of this field.

The electric system includes the operator interfaces, power of system, startup of engine, traveling control, electric control box, illumination alarm, air conditioner and auxiliary circuit etc.

Please refer to Fig.1-31 for details.

45

accumulator

starter

enrichment electromagnetic valve

starting switch

braking

starting relay

Braking electromagnetic valve

lock electromagnetic valve

preheating device

power supply relay

46 working light

front

generator

rear traveling light

lower beam

low pressure of engine oil Braking

Turning and parking light

left right brake turning turning relay

brake light

side light

PLC constant voltage power

rotate speed signal of drive motor

Side left and right non-slip Box alarm light valve

block of charging high temperature of low brake air pressure failure cooling water cleaner

hydraulic oil preheating turning signal temperature signal

valve

right

trackslip

recorder

gear

engine speed

forward

alarm buzzer

back window screen-wiper

horn

backward electromagneti c valve

air conditioning system

pressure switch

forward electromagnetic valve

clutch

main frame of air condition

brake engine oil stopping pressure pressure brake

backward

Cigar front window Syringe lighter screen-wiper

PLC signal input

charging

gear selector

conditions adjustment

diesel moisture power content supply

front working light

left

gear signal

valve

PLC signal output startup

Fig.1-31 Schematic of Electric System of Grader

cooling water temperature

combined meters

engine oil pressure

high beam

fuel oil level

right

electromagnetic electromagnetic

left

PQ190IIIA Full Hydraulic Motor Grader User’s Guide Sany Heavy Industry Co., Ltd.

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

II.

Sany Heavy Industry Co., Ltd.

Operator Interface of Grader The operator interfaces of grader include the front operator interface, right operator interface, operator interface of text display, operator interface of air conditioner and operator interface of radio recorder.

(I) See Fig.1-32 for front operator interface

1-Fuel oil level; 2-Cooling water temperature thermometer; 3-Turning indicator light; 4-Charging indicator light; 5-Warming indicator light; 6- Warning light for high pressure of liquid filtering; 7-Swithch of turning light; 8-Switch of working light;

9-Switch of front light;10-Switch of traveling light; 11-Warning light of brake pressure;12- Warning

light for Low pressure of liquid filtering;13-Indicator light of manual brake; 14-Warning light of air filtering malfunction; 15-Horn button; 16-Pressure gauge of engine oil; 17-Hydraulic oil temperature gauge; 18-Text display

Fig.1-32 Front Operator Interface (II) See Fig.1-33 for right operator interface

1-Gear selector;

2-Swich of parking light; 3-Switch of lock-pin oil cylinder; 4-Switch of working light; 5-Switch of

syringe ;6-Switch of front windscreen wiper;7- Switch of rear windscreen wiper; 8-Cigar lighter; 9-Switch of manual brake(emergency stopping); 10-Startup switch

Fig.1-33 Right Operator Interface 47

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(III) See Fig.1-34 for operator interface of air condition (on the control box)

1-Air condition mode switch;

2-Air quantity switch;

3-Display of temperature

Fig.1-34: Operator Interface of Air Condition (IV) See Fig.1-35 for operator interface of radio (at the upper front of cabin).

The radio can receive AM and FM. And it can search and save the bands automatically. The sound it utters is clean and mellow. The air conditioner serves for the purpose of heating and cooling, and it can be directly controlled by the control panel of front seal plate at the top of cabin ceiling.

1-Power supply;

2-Sound effect;

6-Fast forward; 7-Previous track; 11-Automatic play; 12-Preset;

3-Backward; 8-Next;

4-Casette deck;

9-Automatic saving;

5-Fast backward;

10-Band;

13-Crystal screen; 14-Volume up; 15-Volume down

Fig.1-35: Operator Interface of Radio

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(V) See Fig. 1-36 for operator interface of text display (on the front control console)

Text Displaying Area

Mark Position Function Button

Data Decreasing Button

Function Shift Button

Data Increasing Button

Menu Button Confirmation Button

Fig 1-36 Text Display 1.

Display of data The data can be displayed on the text display as following: (1)Charging malfunction (2) Air filtering malfunction (3) Low braking pressure (4) Warning for diesel moisture content (5) Information of gear and speed D —— Forward automatic gear

R —— Backward automatic gear

N —— Neutral gear

FS —— Forward manual gear

RS —— Backward manual gear Format: D

23.6 km/h ;

FS 2

12.5 km/h

(6)Clock (7) Hour meter Each page of text display can display two pieces of information. The sequence listed above is the one of display. When the information to be displayed are more than two pieces, the sign “↓” at the right and lower part of display area will flash. You may page down more information through the data descending key. In one minute after stopping paging down, the text display shall reset to initial state.

2.

Time setting (refer to fig.6-6) 49

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(1) Entering the Menu of TD200 by pressing “ESC”; (2) Entering the setting mode of time and date by pressing “↓” or “↑”; (3) Pressing “ENTER”; (4) Setting the character indicated by cursor through pressing “↓” or “↑” Set the next character by pressing “ENTER”. After finishing setting, press “ENTER” to return to the display menu. When setting, in order to return to the display menu, you may press “ESC” or wait for one minute.

III. Power Supply of System The power supply of system is provided by two batteries of 12V in series (DELPHI 6-QW-100).

Voltage of the system is DC 24V. Its cathode shall be earthed. Power supply of the system can be disconnected by DC contactor or power supply switch.

The main parameters are as follows: Type of Grader

PQ190IIIA

Starting motor

3.7kW,24V

Generator

24V,70A

Voltage of system

24VDC

Capacity of accumulator

2×100Ah

IV. Electric Control Box Assembly As shown in fig.1-37, the switching control box is considered as the control core of the whole electric system. It receives the signal sent from the sensor of operation system, transfers the signal to PLC module after being processed (magnifying, filtering wave and clearing). Then, the processed signal will be output after being calculated. After the signal goes through the relay, corresponding load can be driven by relay and magnifier, and then the requested operation can be achieved. The constant power supply requested by PLC and sensor should be provided and the protection should be given to short circuit. In addition, the communication interface for uploading and downloading program should be offered so as to possess the capacity of remote monitoring and data maintenance.. The primary parts are as followed: (I) Micro breaker DZ47, switching on or off the circuit and protecting the circuit when it is under overload; (II) Central module CPU224: 14 Switch quantity input, 10 switch quantity output (including two high-speed pulse output of 20KHz), working voltage 20.4 VDC~28.8VDC, load capacity 750m, No.1 logic signal >15VDC and working temperature 0℃~50℃; 50

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(III) Relay: working voltage 16 VDC~30VDC, load capacity 30/20A and working temperature -40℃~100℃; (IV) Flash relay: working voltage 16 VDC~30VDC, load capacity 10W~110W and working temperature -40℃~100℃; (V) Assembly of circuit board: self-made; (VI) Fuse block: assembling sheet fuse; (VII) Sheet fuse: Provide various fusing current according to different circuit mode.

Fuse block Circuit Board

1-Micro breaker DZ47; 2-Central module CPU224;3-Relay ;4-Flash relay; 5-Circuit board assembly;

6-Fuse block;

7-Sheet fuse

Fig 1-37 Electric Control Box Assembly V.

Control of Engine When the electric control engine starts up or stops, the accumulator shall be charged so as to supply working power source to whole machine. The electric controller of engine mainly includes ignition switch S1, DC contactor K0, accumulator G1, starting motor M1, generator G2, starting relay K1, preheat controller and thickened electromagnet valve Y1 and oil-cutting electromagnet valve Y2.

When the key switch is placed at “0”, power supply of overall system is cut off.

(I) When the key switch is at “I”, current passes by the F1 and 104 relay K0 so as to get them 51

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attracted, and the normally contact of K0R (100,101) is turned on, thus the overall system gets electrified. Meanwhile, the braking electromagnetic valve Y2 gets electrified and attracted, and oil circuit is closed to prepare for the start of diesel engine; PLC tests over the input terminal and determine the logics of system, and the protective starting relay K2 is attracted to prepare for turning on Y1 and K1. In order to start up the machine successfully under the condition that temperature is below -5℃, the automatic preheating device is designed for the system. When at “I”, the preheating controller shall test if preheat is necessary. If necessary, the systems shall get preheated and the combined warning lights shall be lit up. When the preheating indicator light is off, preheating has been finished and the machine can be started up at this time. If the testing over system shows preheating is not necessary, the machine can be started up directly.

(II) If the system is confirmed to be at normal state, place the start switch at “Ⅲ”. Since K2 is galvanized, thickened electromagnetic valve Y1 and start relay K1 get electrified so that the starting motor starts the diesel engine. Then the generator works under the drive of diesel engine. The generator supplies electricity to the system and accumulator as well. As shown in fig.6-1, when starting the diesel engine, in order to keep the starting motor from being burned due to long-time ignition, the protective starting circuit is designed for the system. After the diesel engine is started, PLC can automatically cut off the protective starting relay K2 by analyzing the generator D+ voltage value. Meanwhile, Y1 and K1 disconnected so as to cut off the ignition circuit to protect the starting motor. In addition, starting under protection of neutral gear is designed for the system. When the gear selector is only placed at neutral one, PLC Q0.3 could output the signal that relay K2 is turned on, and in such condition the machine could be started.

(III) Extinguishing of generator When the system is working, as shown in fig.3-60, turn left the start switch to the position. At this time, the current through braking electromagnetic valve is cut off so as to stop the diesel engine.

The remanence shall keep the terminal of generator D+ operating for some time, and the voltage UD+ shall keep the power relay K0 attracted so that the accumulator could supply electricity to system until UD+ is too insufficient to keep K0 attracted. Meanwhile, since the power relay is inlaid with backward diode, UD+ will not supply the electricity to Y2 through K0, which can ensure successful braking. Generally, before normally operating braking, the gear selector should be placed at neutral gear.

(IV) Function of electromagnetic valve When being electrified during starting and operating, the diesel oil circuit is switched on. When stopping, electricity over winding is cut off and so is the fuel oil circuit of engine, thus the diesel engine extinguishes.

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Caution: 1. Before starting the engine, check if the surroundings of the diesel engine are safe, then, turn on the key switch and whistle it, start it if safe.

2. After the system is switched on, the text display is initialized, and no abnormal condition occurs, the key switch could be rotated rightwards from position 1 over position 2 and 3 to start the engine.

3. The residence time of the key switch in position 3 should not exceed 5s, and the interval should not be less than 1min, if consecutive three starts are unsuccessful, the reasons should be found out, and restart it after troubles are eliminated.

4. If the gear selector is not set to the neutral gear, the engine could not be started.

VI. Traveling Control (I) Gear control As shown in fig.1-31, fully hydraulic grader is jointed with PLC through the gear selector to be made up from 11 gears, i.e. forward auto-gear D, forward manual gears from 1 to 4, neutral gear, backward auto-gear R, backward manual gears from 1 to 4. The signal from gear selector is sent to five input points of PLC, i.e. I0.3, I0.4, I0.5, I0.6 and I1.1. I0.3 and I1.1 are direction-optional signals, and I0.3 stands for “forward” and I1.1 stands for “backward”. By collecting the signals of I0.3 and I1.1, PLC could automatically identify the direction of movement of system. Meanwhile, the forward relay K3 of Q0.6 output terminal and backward relay K4 of Q0.7 output terminal can get electrified to drive the corresponding forward and backward electromagnetic valves Y5 and Y6. Thus, the corresponding oil circuit is closed off and the machine moves according to the required direction and gear. I0.4, I0.5 and I0.6 make up of binary encoding. By means of various coders and code signals, PLC can automatically adjust the exhausting volume of the traveling motor and shift various gears.

The system program designs several automatic gears for option. PLC can automatically select the appropriate gear according to the throttle of diesel engine and load. In the course of working, the load of system varies from time to time. PLC can detect the signals of rotate speed of left and right driving motors through access switch so as to adjust the current of left and right electric proportional valves and to control the exhaust volume of left and right traveling motors, by which the traveling of machine can be ensured and trackslip over wheels can be well controlled.

When adjusting gears, time delay for shifting gear is considered and designed for system. For protecting the hydraulic system, limit for reversely shifting gear is arranged in the system. When the speed is only at “zero”, reversely shifting gear is allowed.

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In the course of operation, the operator should hold the gear selector with his/her right hand and lift the locking mechanism of neutral gear with middle finger and index finger. Pushing forward is at the forward automatic gear and manual gears 1 to 4 (slow to fast) respectively; pulling backward is at the backward automatic gear and manual gears 1 to 4 (slow to fast) respectively. When backing the grader, the backing alarm will give alarm. The locking mechanism of neutral gear can be released after pulling over the neutral gear, and the gear selector can be locked at any gear. When the gear is at its real place, a “crack” can be heard.

(II) Trackslip adjustment As shown in fig.1-31, when the machine is traveling, the signal of traveling speed of left and right motors are output to I0.0 and I0.1 of PLC. PLC will compute the traveling speed of left and right motors, and the fast one will be considered slippy by PLC. Then, the relay K8 or K9 over the output terminal Q0.4 or Q0.5 will be electrified and so will the electromagnetic valves Y6 and Y7 under the control by K8 or K9. Resultantly, part of hydraulic oil of the fast one will flow to the other side. When the speed ratio between both sides is returned to a specific range, the adjustment will be at normal working state again. Take the slippy left side for instance, the ratio between the speed computed by PLC from the signal of left 10.0 and the one from right 10.1 is more than 1, if this value is above a specific range (for example, if it is above 1.2 that is speed ratio between two sides when the turning radius of the grader is minimum), the relay K8 over Q0.4 will get electrified and so will the electromagnetic valve controlled by K8. At this time, the hydraulic oil of left one whose speed is faster will flow to the right side so that the power supply of right side is increased and its speed is also rising. Till the speed ratio is returned to within a specific range, the current of K8 over Q0.4 will be cut off and Y6 losses electricity. Thus, normal working state is resumed. The slippy condition for right side may be deduced by analogy.

Caution: 1. It should be cautious when operating gear selector. Do not pull hard so as not damage the operational mechanism or put into the over gear; 2. When the engine is started and the gear is put into for traveling, the braking button should be released. After traveling is proved safe by whistling, the gear selector should be put into the necessary gear. Step the accelerating pedal and then the grader can start traveling.

VII. Control by operational device As shown in fig.1-31, by switching on the switch S4 over the right console, the electromagnetic valve on the operational device can get electrified. Pull out the lock pin, the operational device and shovel are put into the specified place, and then the lock pin on the operational device gets into the 54

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jack to close off switch S4 on the right console and the electromagnetic valve Y9 losses current, thus the operational device is fixed. By such operation, the shovel can be used for scraping slope and shoveling channels VIII. Instrument Display and Malfunction Warning Monitoring the working condition of system depends on an analog combined meters, a switch combined alarm light, buzzer and text display. The analog value includes fuel oil level, cooling water temperature, hydraulic oil temperature and pressure of diesel oil. The switches are involved in turning, preheating, charging, hydraulic filter cleaner, braking and braking pressure.

The indicator signal for charging malfunction is taken from D+ terminal of generator. Before starting generator, since D+ terminal is virtual, the charging indicator light will be on. After the generator is started, the indicator light will become off gradually as the electric potential of D+ terminal is rising, If the generator is out of order when working, along with falling of voltage of D+ terminal, the indicator light will be on again so as to send out signal to 11.0 port of PLC, and then the buzzer will give an alarm.

The signals indicating water content of diesel oil, pressure of engine oil and braking shall correspond to the input terminals of PLC, i.e. I0.7, I1.4 and I1.5. When the corresponding sensor is working, the indicator light will be on. Meanwhile, PLC shall make control over the others of system, and the corresponding state and parameters shall be viewed on the text display.

(I) Engine Start If the start preparations are in place, insert the key into the start switch of the right control panel, turn it rightwards to the “1” position to turn on the power of main engine, and observe if the system is normal. At this time, the monitoring instrument should display as follows: Hydraulic Oil Thermometer ……

deviates from the start position to indicate the actual oil

temperature; Steering Indicator Light ……

is off;

Pre-heating Indicator Light ……is on if the environmental temperature is lower than -10℃, and automatically off after the pre-heating (The pre-heating time is 3-10 seconds); Hand Brake Indicator Light ……

is on, and the buzzer doesn’t alarm;

Charging Indicator Light ……

is on, and the buzzer doesn’t alarm;

Brake Pressure Alarm Light …… is on, and the buzzer doesn’t alarm; Air cleaner Blocking Alarm Light …… is off; Liquid Filtration Low Pressure Alarm Light …… is off; Liquid Filtration High Pressure Alarm Light …… is off.

Cautions: when the pre-heating indicator light is on, do not start the engine, after the pre-heating is 55

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finished and the pre-heating indicator light is off, restart the engine.

(II) Set the gear selector to the neutral gear. If the pre-heating indicator light is off, turn the key switch rightwards from the “1” position, and start the engine over the “2” position and the “3” position.

Release the key right away after the engine is started, and the key switch will be back to the “1” position automatically and the start is completed. Other operations could be carried out.

After the engine is started, the monitoring instrument shall display as follows in normal conditions: Fuel Oil Level Meter ……

displays the actual oil level;

Cooling Water Thermometer ……

begins to rise to indicate the actual water temperature;

Engine Oil Pressure Gauge ……

rises to 1bar~4bar;

Hydraulic Oil Thermometer ……

begins to rise to indicate the actual oil temperature;

Steering Indicator Light ……

is off;

Pre-heating Indicator Light ……

is off;

Hand Brake Indicator Light ……

is off;

Charging Indicator Light ……

is off;

Brake Pressure Alarm Light …… is off; Air cleaner Blocking Alarm Light …… is off; Liquid Filtration Low Pressure Alarm Light …… is off; Liquid Filtration High Pressure Alarm Light …… is off.

(III) Use of Monitoring Instrument: During engine operation, monitor the working conditions and eliminate troubles according to the following items: Fuel Oil Level Meter ……

displays the actual oil level, and add oil in the proper time;

Cooling Water Thermometer ……

indicates the actual water temperature with an allowable

temperature of 108℃; Engine Oil Pressure Gauge ……

0.8bar~5bar;

Hydraulic Oil Thermometer ……

indicates the actual oil temperature with an allowable

temperature of 80℃; Steering Indicator Light …… is on when the steering light is on; Pre-heating Indicator Light ……

is on in automatic pre-heating;

Hand Brake Indicator Light …… is on when the hand brake switch is pressed ; Charging Indicator Light ……

is on during malfunction, and the buzzer alarms;

Brake Pressure Alarm Light … is on during malfunction, and the buzzer alarms; Air cleaner Blocking Alarm Light … is on during malfunction, and the buzzer alarms; Liquid Filtration Low Pressure Alarm Light … is on during malfunction, and the buzzer alarms; 56

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Liquid Filtration High Pressure Alarm Light … is on during malfunction, and the buzzer alarms.

IX. Control Switch and Handle (I) Start Switch of Engine As shown in Fig. 1-38, the start switch of engine is on the right control panel. There are 4 positions and the functions are as follows: “0” position——cut off the main power supply; the engine stalls;; “1” position——the main power supplies are switched on completely, the pre-heating power of the cold start is on, and the pre-heating is carried out before the engine is started. The orange indicator light is on;

Fig. 1-38 Ignition Switch

“2” position——vacancy; “3” position——start the engine.

(II) Gearshift and Operational Handle

As shown in Fig. 3-40, the operation of the automatic stepless shifting and hand step shifting can be adopted in the gearshift system; the gearshift between the automatic stepless shifting and the hand step shifting can be controlled by an operational handle.

FS4 (Hand Forward 4th Gear)

Handle Ball

FS3 (Hand Forward 3rd Gear)

Forward Direction

Backward Direction

FS2 (Hand Forward 2nd Gear)

Lock Sleeve

FS1 (Hand Forward 1st Gear)

Operational Lever of Gearshift

D (Forward Automatic Gear) N (Neutral Gear) R (Backward Automatic Gear) RS1 (Hand Backward 1st Gear) RS2 (Hand Backward 2nd Gear) RS3 (Hand Backward 3rd Gear) RS4 (Hand Backward 4th Gear)

Fig. 1-39 Gear

Fig. 1-40 Gear Selector

As shown in Fig. 3-39, 11 gears are set for traveling totally: the middle N is the neutral gear; D is 57

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the forward automatic gear; FS1, FS2, FS3 and FS4 are respectively the hand forward 1st, 2nd, 3rd and 4th gear; R is the backward automatic gear; RS1, RS2, RS3 and RS4 are respectively the hand backward 1st, 2nd, 3rd and 4th gear.

Operation of gear selector is as follows: Take hold of the operational lever by the right hand and lift the lock sleeve of neutral gear with the middle finger and forefinger; pushing forward is respectively the forward automatic gear, hand 1st-4th gear (slow-fast); pulling backward is respectively the backward automatic gear, hand 1st-4th gear (slow-fast) and the reversing alarm device sounds during backing. Release the neutral gear lock mechanism for operation after passing the neutral gear, the gear selector can be self-locked in any gear, and when the gear is in place, the crack sound could be heard. Please be cautious in operation, and do not be too forcible to damage the operational mechanism or result in over gearing. The gearshift operation shall be carried out one by one, and the gear skipping operation is forbidden; the information of gear and speed will be displayed on the text display.

Cautions: 1. Only when the gearshift operational handle is in the neutral

Press

Brake

gear position, can the engine be started; 2. The operational handle has a gear-locking device in the neutral gear, lift the lock sleeve under the operational handle ball when the operational handle is passing the neutral gear.

3. The brake is locked with the traveling gear. Only when the brake is released and the traveling gear is used, can the machine be driven.

Horn and Brake Button Operation Device Horn Button Press the button in the middle of the steering wheel, the horn begins to sound and stops sounding as soon as the button is released.

See Fig. 3-41 for details of the brake button.

Brake: the brake button is installed on the right control console, press the button and the brake works.

Brake Releasing: turn the button to make it skip according to the arrow direction shown in Fig.3-41 and the brake is released.

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X. Illumination and Signal Lights (I) The motor grader is equipped with traveling light, working light, steering light, reversing light, and carriage light, which are controlled by the switch control mounted in the front and right consoles.

The reversing light is controlled by the reversing relay K$ of Q0.7 outputted by PLC, and the carriage light is controlled by the switch on the carriage light within the cabin. In addition, the power of the night view light in the combination meter of the front console is supplied by No. 514 wire of the front working light, namely, it is on when the front working light is on. See Fig. 6-1 for details.

(II) The alarm signal light is controlled by pre-heat signal 110, steering signal 519, engine oil pressure I1.4, brake I1.5, charging malfunction 113, air-cleaning block IX.2, cooling water temperature IX.1, and brake pressure switch signal I1.3 respectively. See Fig. 6-1 for details.

1.

When the temperature is low (lower than -5℃), 110 supplies +24V, and the pre-heat indicator light is on (red);

2.

When the steering light S8 is pressed, No. 519 wire is switched on, and the steering indicator light is on (green);

3.

When the pressure of the engine oil is too high, I1.4 sends the signal, and the indicator light is on (yellow);

4.

During brake, I1.5 sends the signal, and the indicator light is on (red);

5.

When charging is in trouble, 113 is switched on, and the indicator light is on (red);

6.

When the air cleaner is blocked, the indicator light is on (yellow);

7.

When water temperature is high, IX.1 sends the signal, and the indicator light is on (red);

8.

When the brake pressure is low, I1.3 sends the signal, and the indicator light is on (yellow).

XI. Air Conditioner of Electric System As shown in fig.3-31, the voltage shall be transmitted from the micro breaker Q3 to the air conditioner, and then the control lines 707 and 707 are placed over the compressor and pressure switch of diesel engine. With this means, air conditioning can be realized.

(I) Operation of air conditioner: 1.

Firstly, select refrigeration or warm up according to the requirements.

2.

When the refrigeration system is put into use for the first time, set the air volume switch to the high gear after starting the engine, and operate it for about 5 minutes, after that, adjust the temperature control knob to refrigeration position. At that time, the temperature within the cabin will come down, the indoor temperature will be viewed on the screen. Till the temperature you feel become comfortable, turn the adjusting knob at right lower side of seat so as not to let out cold wind, when the compressor will stop working. If the temperature in the cabin is higher than this one, the compressor will start automatically, and the system will carry out refrigeration. If the temperature in 59

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cabin is lower this one, the system will stop working.

3.

When using air conditioner, do not turn the knob at right lower side of seat to minimum so as to set the air quantity switch at low gear. If in that case, the evaporator will be frosted, and the refrigerating effect will be reduced.

4.

Control of heating temperature: Till the temperature reaches to the necessary one, close off the air quantity switch; if the indoor temperature is lower than then necessary one, restart the air quantity switch.

5.

Adjusting the air angle can change the angle and direction of cold and heated air. Adjust the air volume switch, so as to obtain high, middle, and low gears air output.

Cautions: 1. Only when the engine is operated, can the air conditioner work normally.

2. As the heating system is connected with the water tank of the engine, when the environmental temperature is lower than 0℃ and the engine can’t work for a long time, the water tank of the engine should be emptied or filled antifreezing solution, so as to avoid cracking the heating radiator by frosts.

XII. GPRS/GPS Remote Monitoring System Taking the artificial intelligence engineering and mechanical telecommunication developed independently by SANY and position module SYMT as core, the current advancing wireless telecommunication technology and control technology are adopted, which builds up the remote monitoring system of grader. The hardware structure of main machine is referred to fig. 6-12.

Primary functions: (I) Positioning of machine. Wherever the grader is, the appropriate position of the machine can be find out through the monitoring and positioning by GPS center of SANY; (II) Locking control. Those graders that are stolen or whose payments are owed can be locked so as not to be moved; (III) Remote monitoring on working condition. By data request, GPS center of SANY can upload the relevant data of working condition to the headquarters for data analysis and malfunction diagnosis; (IV) Notice. The existing hidden troubles of machine and periodic maintenance will be reminded of in text on the man-machine interface; (V) Updating of remote program. It can remotely upload and download the controlling program.

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GPRS Antenna

SYMT Movable Terminal

GPS Antenna

Fig. 1-42 Structure of Remote Monitoring System XIII. Signal Detection Sensor The signal detection sensors include fuel oil level sensor, water temperature sensor, hydraulic oil temperature sensor, diesel pressure sensor, left/right motor sensor and W terminal of rotate speed signal of generator. Among them, the fuel oil level sensor, water temperature sensor, hydraulic oil temperature sensor and diesel pressure sensor are directly connected with the combined meterss of front console, having the characteristics of resistance. The resistance of temperature sensor falls down as its temperature rises; rising diesel oil pressure can minish the resistance and rising fueling oil level can raise the resistance. The sensors of both motors output the square wave pulse electricity to the input terminals 10.0 and 10.1 of PLC so that PLC can compute the traveling speed.

W terminal of generator sends out the rotate speed pulse signal to the input terminal 11.2 of PLC via resistance and audion, thus, PLC can compute the rotate speed of engine. The following measured parameter is provided for reference.

System voltage: 0V~36V voltage signal Water temperature of engine: for signal of resistance, when at 40℃, 80℃ and 100℃ and 120℃, the corresponding resistance value is 494.4Ω, 117.1Ω, 63.5Ω and 38.7Ω respectively.

Pressure of diesel oil: for resistance signal, 0bar~10bar correspond to 10Ω~184Ω Rotate speed of engine: for pulse signal, the crest value of around 28V corresponds to frequency of 0Hz~2000Hz. Diesel oil level: by resistance signal, 0~1 correspond to 78Ω~0.7Ω Temperature of hydraulic oil: by resistance signal, when at 20℃, 90℃ and 120℃, the resistance 61

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is 750Ω, 51.2Ω and 36.5Ω respectively.

Traveling speed: by pulse signal, when the crest value is around 22, the frequency is from 0Hz to 2000Hz XIV. Auxiliary Electric Appliance (I) The illumination unit is composed of front combined lights, working light, rear combined light(brake, turning and backing), indoor light. The turning light does not have the control unit for near or remote beam. When parking, the four turning light flash to serve as warning.

(II) The front screen wiper has automatic zero reset. When switch off the switch, the screen wiper reset and stop automatically.

(III) The horn is fixed at the front bottom of cabin; the backing buzzer is fixed at the back of rear carriage; the acoustics is fixed at the front top of cabin and cigar lighter is at the control panel at the right side in the cabin.

(IV) The electromagnet of lock-pin oil cylinder is installed at the bottom of cabin.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter VII Driving and Operation

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Chapter I Driving and Operation I.

Driving and Operation For the positions of the operation parts in the cabin, see Fig. 1-43.

1. Operation Control Handle;

2. Front Operator Interface;

3.Touch Screen;

4. Steering Wheel;

5. Control Footplate of Control Console;

7. Traveling Brake Footplate;

8. Gear Selector;

9.Hand Throttle;

10. Right Operator Interface;

11.Brake Button;

12.Operator Interface for Air Conditioner;

13. Control Box;

14.Seat;

15. Stating Switch of Engine;

16. Air Conditioner;

17.Front Control Console;

18. Bottom Board of Cabin

6.Throttle Footplate;

Fig. 1-43 Brief Diagram of Operation in Cabin

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1.

Sany Heavy Industry Co., Ltd.

Adjustment of the Control Console (See Fig. 1-44) Adjustment of the Console: During adjustment, step on the footplate 2 of the lower part of the control console firstly, pull and push the steering wheel to the required position and release the footplate thus to fasten the console body.

Head Adjustment: Release the handle 1 on the right side of the control console, and adjust the inclined of the steering wheel to the required position and then screw down the handle.

2.

Start and Stall

2.1 Checking before Starting Engine

Fig. 1-44 Console

(1) Firstly, confirm that the gear selector is in the neutral gear, and the brake button is pressed; (2) Check if tire pressure is normal; (3) Check if the fastening bolts of the tire, front and rear carriage, axle frame and frame, and the working device are loose; (4) Check if the reduction tandem, connecting copper sleeve of the axle frame and frame, working device and its worm gear case, front and rear bearings, and all lubrication points are lubricated completely; (5) Check if the hydraulic pipelines are damaged or leaks, and if the electric connecting lines are reliable; (6) Check if the engine oil level is proper; (7) Check fuel oil level; (8) Check if all cleaners (air cleaner, engine oil cleaner, diesel cleaner) of the engine, and the fuel oil pipeline are sound; (9) Check the oil level indicator of the hydraulic oil tank; (10) Check if the water tank is filled with water.

2.2 Engine Start (1) Release the brake, and set the gear selector to the neutral gear position (if the gear selector is not set to the neutral gear, the engine could not be started); (2) Ring the horn to remind the staff around;

Fig. 1-45 Ignition Switch

(3) Insert the key into the ignition switch, and rotate to the position 1 (See Fig. 1-45). Check all indicator lights and instruments to see if the display is normal; 65

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(4) Rotate the start-up key switch to position 3, when the engine starts, release the start-up key switch immediately; (5) In order to prevent damaging the starter, the following should be done: (a) In order to prevent damaging the starter, the time to start the motor each time should not exceed 10s, if the engine cold not be started, turn the key switch to the close position, and restart it after 30s; (b) After the start fails, if rotating the key switch before engine stops, the starter will be damaged; (c) In order to prevent the storage battery, the interval of 1min~2min should be reserved between each start; (d) When the engine is of low temperature, avoid running with high speed; (e) After the system is switched on, the text display is initialized, and no abnormal condition occurs, the key switch could be rotated rightwards from position 1 over position 2 and 3 to start the engine; (f) The residence time of the key switch in position 3 should not exceed 5s, if consecutive three starts are unsuccessful, the reasons should be found out, and restart it after troubles are eliminated.

3.

Travel and Stop Working Device

3.1 Steering Wheel (See Fig. 1-43) Turn the steering wheel and the front wheel is turned.

3.2 Horn Button Press the button in the middle of the steering wheel, the horn begins to sound and stops sounding as soon as the button is released.

3.3 Throttle Footplate (See Fig. 1-43) This footplate controls the rotation speed of the engine.

3.4 Traveling Brake Footplate (See Fig. 1-43) The footplate affects the brake of the 4 rear wheels through the

Press

brake

hydraulic system. The strength of brake depends on the stroke of the stepped footplate.

3.5 Brake Button (See Fig. 1-46) Brake: the brake button is installed on the right control console (See Fig. 1-43), press the button and the brake works.

Brake Releasing: turn the button to make it skip according to the arrow direction shown in Fig. 1-46 and the brake is released.

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Fig. 1-46 Brake Button

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

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Cautions: ¾ The brake can be also used as the emergency brake, which can only be used under the emergent conditions that the traveling brake doesn’t work. If the traveling brake works, it is forbidden to use the brake in the traveling status of the motor grader. ¾ As the constantly-close brake is adopted for stop, that is, the brake works without hydraulic oil in the brake. If the motor grader is driven to the dangerous places (at the railway crossing or on the railway), the brake hydraulic oil pipe is broken or the engine burns out, and the brake is decompressed to make the brake work, the motor grader can’t be driven or trailed. At this time, the method to release brake is as follows: screw off the outer sleeve (Sequence 2) of the brake installed on both sides of reduction tandem (between 2 rear wheels), screw down the nut (Sequence 3) with a spanner (about 2-3 rounds) to extend the piston lever about 3-4mm, and the brake is released.

4.

Use of Electric Apparatus and Instrument (Design in accordance with Standard EN60204:1993)

4.1 Front Operator Interface (See Fig. 1-47)

1. Fuel oil Level;2. Cooling Water Thermometer;

3. Steering Indicator Light;

4. Charging Indicator Light;

5. Pre-heating Indicator Light;

6. Liquid Filtering High Pressure Alarm Light;

7. Steering Light Switch;

8. Working Light Switch;

9. Head Light Switch;

10. Traveling Light Switch;

11. Alarm Light for Low Brake Pressure;12. Liquid Filtering Low Pressure Alarm Light;

13. Manual Brake Indicator Light; 16. Engine Oil Pressure Gauge;

14. Air-Filter Trouble Alarm Light;

15. Horn Button;

17. Hydraulic Oil Thermometer;

Fig. 1-47 Front Operator Interface 67

18. Text Display

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

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4.1.1 Use of Monitoring Instrument (See Fig. 1-47) During engine operation, monitor the working conditions and eliminate troubles according to the following items: Fuel Oil Level Meter ……displays the actual oil level, and add oil in the proper time; Cooling Water Thermometer ……indicates the actual water temperature with an allowable temperature of 108℃.

Engine oil pressure gauge …… 0.8-5bar.

Hydraulic Oil Thermometer ……indicates the actual oil temperature with an allowable temperature of 80℃.

Steering Indicator Light ……is on when the steering light is on.

Pre-heating Indicator Light ……is on in automatic pre-heating.

Charging Indicator Light ……is on and the buzzer alarms in trouble.

Brake Pressure Alarm Light ……is on and the buzzer alarms in trouble.

4.1.2 Horn Switch Operation (See Fig. 1-47) Press the switch in the middle of the steering wheel and the horn begins to sound and stops sounding as soon as the switch is released.

4.2 Right Operator Interface (See Fig.1-48) Press the left steering light on

Stop in the middle position

Press the right steering light on

Press the working light on

Press the working light off

Stop in the middle position Press the travel light for the near light

Press the travel light for the distance light

Press the head light off

Press the head light on

Fig. 1-48 Control Switches on Front Operator Interface 4.3 Right Operator Interface (See. Fig. 1-49)

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1. Gear Selector;

2. Parking Light Switch;

3. Locking-pin Oil Cylinder Switch;

4. Working Light Switch;

5. Washer Switch;

6. Front Windscreen Wiper Switch;

7. Rear Windscreen Wiper Switch;

8. Cigar Lighter;

9. Manual Brake (Emergency Brake) Switch;

10. Start Switch

Fig. 1-49 Right Operator Interface Cigar lighter operation: press the middle raised part of the cigar lighter, 5-8 seconds later, push outward the cigar lighting part and use it; after using, install the cigar lighting part in the original position.

Brake (emergency brake) switch operation: press this switch, the brake works, the traveling hydraulic system stops driving and the machine can’t move or work, but the engine continues running; turn it counterclockwise for reposition.

4.4 Operation of Switches on Right Operator Interface (See Fig. 1-50) Press for parking light off

Press for parking light on

Press for locking-pin closing Press for washer stopping Press for front windscreen Press for back windscreen wiper stopping wiper stopping

Press for locking-pin on

Press for washer working

Press for front windscreen wiper working

Press for rear windscreen wiper working

Fig.1-50 Control Switches on Right Operator Interface 69

Rear working light off

Rear working table light on

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

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4.5 TD200 Text Display 4.5.1 Operation Interface (See Fig.1-51) Text Displaying Area

Mark Position Function Button

Data Decreasing Button

Function Shift Button

Menu Button

Data Increasing Button

Confirmation Button

Fig. 1-51 Text Display 4.5.2 Data Display The text display can display the following data: ¾ Rotation speed of the engine ¾ Time ¾ Timing ¾ Malfunction information ¾ Information on gear and speed Sample 1: D

23.6 Km/h indicating: forward automatic gear with a speed of 23.6 Km/h

Sample 1:FS

2

12.5 Km/h indicating: forward hand gear II with a speed of 12.5 Km/h

D ——forward automatic gear

R ——backward automatic gear

N——neutral gear

FS ——forward hand gear

RS ——backward hand gear Each page of the text display can display 2 pieces of information, and the ranked order above is the display prior order. When the information to be displayed are more than 2 pieces, the “↓” (“↑”) will flash on the right lower part of the text display area. The information can be read by turning pages through the “Data decreasing (increasing) button”, 1 minute after pages are turned, the text display will return to the primary display status automatically.

There are Chinese and English in the information display. Press “F1”, information is displayed in 70

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Chinese; and press “F1”, information is displayed in English.

4.5.3 Clock Setting (See Fig. 1-51) ¾ Press “ESC” to enter the Menu mode of TD200. ¾ Press “↓” or “↑” to enter “setting of time and date”. ¾ Press “ENTER”. ¾ Press “↓” or “↑”, and set the cursor-indicated character. ¾ Press “ENTER” to set the next character. Press “ENTER” to return after setting. During setting, press “ESC” to return to the display interface, and, one minute after pressing is stopped, return to the display interface.

5.

Others

5.1 Opening of Positioning Lock of Door of Cabin: 5.1.1 Turn the rotary handle near to the side window in the cabin and the door positioning lock is opened.

5.1.2 Outside the car, there is a handle on each lower side of the cabin. Pull the handle, the door positioning lock is opened.

5.2 Driver’s Seat (See Fig.1-52) 5.2.1 Adjustment of Bearing Capacity Turn the Handle Wheel (1) to adjust the bearing capacity of the seat.

5.2.2 Adjustment of Backrest Adjust the backrest angle with the Lever (2), and make it embed with the lever properly after adjustment.

5.2.3 Adjustment of Height and Angle of Seat Adjust the height and angle of the seat cushion and backrest with the Lever (3).

5.2.4 Adjustment of Seat Position Adjust the seat to move forward and backward with the Lever (4). And make it embed with the Lever (4) properly after adjustment.

Fig. 1-52 Driver’s Seat

5.3 Radio The cabin is equipped with slewable stereo acoustics with

large power and auto-searching radio that can serves as music player, radio and clock. See use and operation of the accessories for details of the instruction.

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Chapter 2 Driving 1.

Check before Starting

1.1 Check the oil level indicator of the hydraulic oil tank (it should be carried out after the hydraulic system and the hydraulic cylinder are filled with oil); 1.2 Check if each air cleaner of the engine is good (the alarm indicator lights of the air cleaner and engine oil filter should be off and the text display doesn’t display troubles); 1.3 Check if the engine oil level is proper; Figure 1-53 Traveling Status Figure

1.4 Check if the tank is filled with water; 1.5 Check the fuel oil level; 1.6 Check if the air pressure of the tyre is normal.

2.

Preparations Before Starting:

2.1 Release the brake; 2.2 Inspect if every meter, light indicator and operation is in order; 2.3 Inspect if the traveling brake system and the steering system are effective and reliable; 2.4 Turn the shovel to the operation position, and lift it higher as much as possible (see Fig. 1-53); 2.5 Lift the blade and back scarifier completely (if the users have opted this component); 2.6 Check the following items in the conditions of the engine are of idle speed operation: 2.6.1 Steering: Turn the steering wheel deasil and widdershins. The steering wheel should be flexible, and the front wheel should rotate with it.

2.6.2 Brake system: The brake working pressure indicator light shall not be displayed.

Cautions: The shovel, blade and the scarifier should be lifted to the highest position when the motor grader is running.

3.

Start the Engine

3.1 Start the engine in normal conditions 3.1.1 Release the brake, turn the gear selector to the neutral position (or else, the engine can’t be started) 3.1.2 Put the key to the ignition switch, turn to “1”position (Fig. 1-46). Inspect to see if the display of all 72

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the indicator lights and meters are normal.

3.1.3 Turn the starting key switch to “3”position. Release the starting key switch immediately when the engine starts.

Cautions: ¾ Each successive starting time couldn’t exceed 15 seconds, and the interval of every starts should be 1~2 minutes in order to protect storage battery; ¾ Avoid operating at high speed when the temperature of the engine is low; ¾ The engine will not be started if it is not at neutral position before starting.

3.2 Start of the engine when the environment temperature is low 3.2.1 When the environment temperature is near or below 0℃, after the engine starting switch is switched on, if the engine should be preheated, the preheating yellow indicator light of the engine should be lit, the preheat should be about 1 minute.

3.2.2 The preheat indicator light should be off when the preheating is finished.

3.2.3 If the engine can’t start steadily, the starting should be stopped, and restart it after 2 minutes. If many null starts happen, the engine will not be started, and the air heater system of the engine should be inspected.

4. Start the Motor Grader 4.1 Start the motor grader 4.1.1 Turn the gear selector to the position of “forward automatic gear” or “backward automatic gear”.

4.1.2 Ring the whistle, release the brake and step on the throttle footplate then the motor grader can start its traveling.

4.2 Display of the meter in traveling The following meters, displays should be inspected in the traveling: 4.2.1 The pressure of the engine oil (See Fig. 1-47); 4.2.2 The cooling water temperature of the engine (See Fig. 1-47); 4.2.3 The temperature of the hydraulic oil (See Fig. 1-47); 4.2.4 Step on the traveling brake footplate after traveling certain distance, and inspect the braking performance.

When the motor grader is in the traveling operation, the engine oil pressure should not be lower than 0.8 ba, the water temperature should not be higher than 113℃, the oil temperature should not be higher than 85℃, or else, the working should be stopped.

4.3 Steering 4.3.1 Operate the steering wheel, the front wheel steering can be realized;

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Operation Essential: The front axle is the box or plate alignment welding structure, in order to adapt to different working conditions, the front wheel could be steered (with a steering angle of about ±45°), inclined (with an inclined angle of about ±17°), and swung (with a swing angle of about ±15°) to realize different functions. During above operations, the motor grader could absorb impacts from part exterior loads.

Manipulate the steering wheel rightwards, the motor grader will steer rightwards, if leftwards, the motor grader will steer leftwards.

During steering of the front axle, if inclination is necessary, firstly, incline it with an angle of±17°, then turn it with an angle of ±45°. Steering before inclination is forbidden, for it will prevent damages of the inclined connecting rod of the motor grader effectively. See Fig. 1-54 for details.

Incline firstly

Steer lastly

Fig. 1-54 Operation Instruction of Front Axle of Motor Grader 4.3.2 The steering of the articulation frame will be controlled by one control lever (See Fig. 1-43).

Operation Essential: The front frame could steer leftwards and rightwards with an angle of ±25°, when on the ground, the connecting rod for articulation steering should be released to avoid damaging the steering oil cylinder on the ground or during the rapid commissioning due to unreleased steering and fixing connecting rod. During conveyance, the articulation steering connecting rod should be fixed to avoid safety accidents due to frame slide. See Fig. 1-55 for details.

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Articulation steering and fixing connecting rod

Fig. 1-55 Front and Rear Frame Articulation 5.

Operation Essential for Rapid Commissioning

(1) Before rapid commissioning, the axle steering should be checked, articulation steering action should be sensitive, the traveling brake should be reliable and steady, and horn sound should be loud; (2) In order to prevent possible safety accident, it is forbidden to turn to articulation steering during the rapid commissioning course, if articulation steering is required, it should be slowed down; (3) The shovel should be put in the traveling status; (4) During turning, whistle to warn others; (5) It is forbidden to travel with high speed in the narrow section.

6.

Brake

6.1 Brake (Fig.1-56) The brake is a constantly-close wet-type multi-disc brake. That is, when hydraulic oil effect exists, the brake should be released. The brake would be effective with the effect of the disc spring, and the pressure oil can also be removed. The

1-Adjustable shim 3-Nut 5-Bolt

brake is respectively installed in the middle of the outside of the left and right

2-Outer Protective Sleeve 4-Hand Brake 6-Piston Rod Fig. 1-56 Brake

deceleration reduction tandems.

See section 4 of this chapter for the operation of

the brake. The braking performance of the brake should be usually inspected.

The friction disc should be inspected to see if it is damaged after the brake is adopted as the emergency brake. The clearance should be adjusted when the friction disc is replaced. The adjustment of the clearance is finished through increasing or decreasing the adjustable shim 1.

The operation procedures are as follows: 6.1.1 Loosen the bolt 5 (six pieces); 75

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6.1.2 Remove the adjustable shim 1. Shake the hand brake lightly, and put it inside with a little force; 6.1.3 Measure the clearance between the brake 4 and tandem; 6.1.4 Subtract 2mm from the measured clearance, it is the required thickness of the shim; 6.1.4.1 Remove or increase adjustable shim 1 according to the required thickness of the shim; 6.1.4.2 Tighten the bolt 5 after it is adjusted.

7.

Parking and Trail

7.1 Parking 7.1.1 Release the throttle footplate; 7.1.2 Turn the gear selector to the neutral position, step on the foot brake, until the motor grader is steady; 7.1.3 Press the hand brake button.

7.2

Engine Stall Turn the starting switch key to the “0” position, and then the engine will be off.

Cautions: It’s not allowed to close the engine under the conditions of full load, make it idle running for 1~2 minutes. If it is temporarily parked and the machine is not in the safe place, we should deasil turn the key switch to the 1 position, open the parking alarm light switch, and make the alarm light flash, for avoidance of accidents.

7.3 Park the Motor Grader 7.3.1 Press down the brake button; 7.3.2 Put the working device on the ground; 7.3.3 Take off the ignition key, and lock the door of the cabin.

Cautions: If the motor grader has been parked at the steep-slope for a long time, the wheels should be parked to avoid sliding. If the motor grader has been parked for a long time, the wheels should be hoisted.

7.4 Trail The motor grader should be trailed when the engine is broken. The following operations should be performed before the trail: 7.4.1 If the parking time of the motor grader is too long (≥3 months), the hydraulic oil should be filled in the traveling hydraulic motor shell, so as to avoid burning the lubrication due to oil shortage of hydraulic motor; 7.4.2 The brake should be released according to the caution requirements of the section 4 of this 76

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chapter before the trail of the motor grader; 7.4.3 The hydraulic steering will not be appeared because of the out of work of the steering pump. The steering will be difficult when the motor grader is trailed, we had better not trail it in a long distance.

The speed of the trailed motor grader should not be more than 5km/h.

Cautions: ¾ The brake should be released before the motor grader is trailed; ¾ The friction disc of the hand brake should be inspected to see if it is damaged or not after the brake is adopted as the emergency brake. The friction disc should be replaced and its clearance should be adjusted.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter VIII Operation of Working Device

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I. Driving Oil Cylinder and Hydraulic Motor of Working Device (See Fig. 1-57)

1. Front blade oil cylinder;

2. Front wheel inclined oil cylinder;

3. Rotary gear ring hydraulic motor;

4. Blade angle adjusting oil cylinder; 5. Shovel lifting oil cylinder;

6. Locking-pin oil cylinder;

7. Shovel swing oil cylinder;

9. Carriage hinging oil cylinder;

8. Shovel lead-out oil cylinder;

10. Scarifier lifting oil cylinder

Fig. 1-57 Position of Hydraulic Oil Cylinder and Motor of Working Device II. Operation Control Device (See Fig. 1-58)

1. Declination of the shovel left side

2. Lift of the shovel left side

3. Shovel swing leftward

4. Shovel swing rightward

5. Leftward steering of the wheel hinging

6. Rightward steering of the wheel hinging

7. Declination of the back scarifier

8. Lift of the back scarifier

9. Leftward of the wheel inclined

10. Rightward of the wheel inclined

11. Declination of the blade

12. Lift of the blade

13. Increase of the blade angle

14. Decrease of the blade angle

15. Shovel widdershins rotates

16. Shovel deasil rotates

17. Shovel lead-out leftward

18. Shovel lead-out rightward

19. Declination of the shovel right side

Fig. 1-58 Operation Control Devices

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III. Swing Frame Operation In normal conditions, the swing frame is locked at the horizontal position 3 (see Fig. 1-59). When separately swing the shovel to the left and right erect, we should separately lock the swing frame at the position 6 of Fig. 7-4 and position 1 of Fig.1-59. Manipulate the locking of the different positions of the swing frame through the following steps.

1.

Put the shovel at the level by lifting oil cylinder (the hydraulic system is idle load)

2.

Press down the locking-pin oil cylinder switch (See Fig. 1-49), pull the cross pin out of the cross pin hole when the switch indicator light is lit.

3.

Operate the contraction of the left and right lifting oil cylinder of the shovel and the swing oil cylinder of the shovel. The counterforce from the ground by the shovel will affect the swing frame and put forward its rotation.

4.

Press down the locking-pin oil cylinder switch when the swing frame rotates to the locked position (the cross pin of the swing frame just aims at the cross pin hole of this position). The switch indicator light will be off, insert the cross pin into cross pin hole and lock the swing frame.

Cross Pin Oil Cylinder

Fig. 1-59 Displacement of the Swing Frame a

Fig. 1-60 Displacement of the Swing Frame b Operation Essential for Swing Frame Slewing When the shovel swings to left and right and erects, the left and right lifting oil cylinder of the shovel and the shovel swing oil cylinder should be operated at the same time, it is forbidden to solely operate one or two oil cylinders to move to the limit, while another oil cylinder does not move, for interference will happen and damage the oil cylinder.

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IV. Adjustment of the Shovel 1.

Rotation of the Shovel Manipulate the shovel rotary control handle (See Fig. 1-58), which can make the shovel separately rotate in left and right direction 360 °.

2.

Swing of the Shovel Manipulate the shovel rotary control handle (See Fig. 1-58), which can make the shovel separately swing in left and right direction.

3.

Lead-out of the Shovel Manipulate the shovel lead-out control handle (See Fig. 1-58), which can make the shovel separately lead out in left and right direction.

4.

Change of the Blade Angle Manipulate the blade angle change control handle (See Fig. 1-58), which can make the blade angle change in the range of 36 °~66°.

5.

Lifting of the Shovel Manipulate the left and right shovels lifting control handle (See Fig. 1-58), which can make the left and right side of the shovel separately lift, descend or lift and descend at the same time.

V.

Back Scarifier (Optional)

Fig. 1-61 Back Scarifier

Fig. 1-62 Operating Conditions Installation Position

The back scarifier has 5 or 3 gears. Under normal conditions, 3 gears will work on the hard ground.

In order to ensure the balance of the stress, the gears should be symmetrical to the allocation operations during the utilization process.

1.

Position of Scarifier Two kinds of installation positions of the scarifier:

5.1.1 The installation position of the conveyance operating conditions, see 1-61; 81

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5.1.2 The installation position of the operating conditions gear, see Fig. 1-62.

2.

Loosing Operation Control the lifting of the scarifier by the control lever. The hard degree of the earth can decide the number of teeth of the scarification, the underground depth, and traveling speed.

Cautions The back scarifier should be lifted before turning and reversing the motor grader.

VI. Operation Essential for Leveling Operation (I) During leveling working, select correct shovel slewing angle and scraping angle according to the soil structure; (II) In order to obtain optimal working efficiency, proper leveling working speed and backward speed should be selected; (III) When working begins, adjust the shovel and machine center to form certain angle, if it is advantageous to sand, soil, stone, or snow, drain it to both sides of the machine; (IV) During leveling course, generally, adjust and fix the steering wheel, hold the control lever of left and right poppet oil cylinders by hands, and stare at the shovel, in addition, based on the underground depth of the shovel and the flatness of the ground, constantly adjust the lifting height of the shovel.

If hill appears, the front blade (if installed) could be used to push it, if the ground is hard, the rear scarifier (if installed) could be used to dig soil, and then use the shovel for flatness; (V) As roots and stones will exist in the lower part of the sandy gravel pavement, cement mixed ground, or loose ground, please be cautious during the leveling course, if leveling with high speed, when shovel meets the hard substance, it will decelerate abruptly, due to inertial effect, the driver will show the forward movement tendency, therefore, the driver should be cautious to avoid injury; (VI) During left and right side lead-out of the shovel, if meeting hard substance, it should be stopped. It is forbidden to operate ferociously, for it will bend the side lead-out oil cylinder; (VII) During slewing of the shovel, operation should be cautious, so as to prevent scraping the wheel and damaging the frame and front axle steering connecting rod; (VIII) If the motor grader is of rapid working speed, staff will be knocked down by the shovel, wheel, and frame, or pushed onto other objects, then, serious injury and death will happen, therefore, all staff should be away from the working area; (IX) In order to avoid lubrication interruption and shortage of the engine, the working gradient of the motor grader should not exceed values stated in the following table. If exceeding, engine will be dangerous due to bad lubrication.

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Name

Transversal slope

Moving direction Allowable angle

Left or right 20°

83

Longitudinal slope Forward 25°

Backward 25°

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter IX Use and Operation for the Accessories

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Chapter 1 Air Conditioner 1.

Air Conditioning System Figure

Fig. 1-63

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1.A221600000048

Air conditioner KGP3103F.1

2.A210891000005

Throat collar 442.025.8

3.A210741000003

Rubber hose d=16L=3.2m GB7548-87.1

4.A210741000002

Rubber hose d=16L=2.8m GB7548-87.1

5.A210434000013

Spacer27 JB982-77.3

6.A820205000095

YZ18.9-2. adaptor.

7.A210111000079

Bolt M6×16 GB5783-00.10

8.A210405000006

Spacer6 JB97.1-02.10

9.A210401000016

Spacer6 GB93-87.10

10.A210111000003

Bolt M10×120 GB5783-00.1

11.A210307000017

Nut M10×120 GB5783-00.1

12.A210405000011

Spacer10 GB97.1-02.4

13.A210401000001

Spacer10 GB93-87.4

14.A210111000038

Bolt M12×30 GB5783-00.6

15.A210405000001

Spacer12 GB97.1-85.6

16.A210401000002

Spacer12 GB93-87.6

17.A810505019001

PQ190A.18.2 support stay.1

18.A210111000027

Bolt M10×40 GB5783-00.3

19.A820301014728

PQ190A.18-5. flexible bolt.1

20.A210111000333

Bolt M12×50 GB5783-00 grade 12.9.1

21.A820101318416

PQ190A.18-6. flexible pile.1

22.A210307000040

Nut M16 GB6170-00.2

23.A210401000004

Spacer16 GB93-87.2

24.A810505011041

PQ190A.18.3. compressor support.1

25.A210111000293

Bolt M8×30 5783-00 grade 10.9.4

26.A210405000007

Spacer8 GB97.1-02.2

27.A210401000017

Spacer8 GB93-87.2

28.A810505990025

PQ190.18B.1. connecting tube.1

29.A820699000228

PQ190.18B-1.packingI.2

30.A820699000160

PQ190.18A-3 packing II.4

31.A210855000029

Throat collar 442.080.4

32.A210202000009

Screw M3×8 GB67-00.8

33.B230106000052

Triangle belt 6460.1

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2. Air Conditioner Operator Interface (On the Control Box)

1. Mode Switch of Air Conditioner;

2.Air Volume Switch;

3. Temperature

Fig. 1-64 Operator Interface of Air Conditioner 3. Operation of Air Conditioner 3.1 Mode Switch of Air Conditioner (Fig. 1-64, 1): The mode switch of air conditioner is a three-position self locking switch, pressing the upside for the warm mode, pressing the underside for the refrigeration mode, and setting in the middle for closure.

3.2 Air Volume Switch (Fig. 1-64, 2): The air volume switch is a three-position and self locking switch, including high, middle, and low gears.

3.3 Hot Water Valve and Wind Outlet Operation (Fig. 1-65) When the handle of the hot water valve (Fig. 1-65, 1) is in vertical status, it means opening, and when it is in the horizontal status, it means closure. When the hot water valve is opened, hot water in the engine will flow through the evaporator, and then the air conditioner switch mode should be set in the warm up mode, accordingly, the cabin will receive hot wind. During refrigeration, the handle of the hot water valve should be set in the horizontal position (namely turn off hot water), so as to avoid simultaneous refrigeration and warm-up. The wind direction controlling handle (Fig.1-65, 3) is used to control air conditioning wind come from the top of the cabin or the bottom of the seat, and the cold wind coming from the top and the hot wind from the bottom could achieve a best effect.

When the environmental temperature is lower than 15℃, the air conditioning system will stop refrigeration automatically.

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1- Hot water valve;

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2- Refrigeration control

3- Wind direction valve;

Fig. 1-65 Air Conditioner Adjusting Valve 3.4 Instruction 3.4.1 Firstly, select refrigeration or warm up according to the requirements.

3.4.2 When the refrigeration system is put into use for the first time, set the air volume switch to the high gear after starting the engine, and operate it for about 5 minutes, after that, adjust the refrigeration control knob to a proper range. At that time, the temperature within the cabin will come down, when it reaches 15℃, the compressor will stop working. When the temperature in the cabin is higher than 15℃, the compressor will start automatically, and the system will carry out refrigeration again.

3.4.4 Adjust the air volume switch, so as to obtain high, middle, and low gears air output.

Cautions: ¾ Only when the engine is operated, can the air conditioner work normally. ¾ When the air conditioner is used, the temperature and air volume should not be adjusted to the minimum simultaneously, so as to avoid frosting of the evaporator, for it will affect the refrigeration effect. ¾ As the heating system is connected with the water tank of the engine, when the environmental temperature is lower than 0℃ and the engine can’t work for a long time, the water tank of the engine should be emptied or filled antifreezing solution, so as to avoid cracking the heating radiator by frosts.

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Chapter 2 Radio 1. Operator Interface of Radio (Front Top of the Cabin)

1-Power;

2-Sound effect;

3-Backward;

4-Casette deck;

6-Fast forward; 7-Previous track;

8-Next track;

9-Automatic saving track; 10-Band;

11-Automatic play;

13-Crystal screen;

12-Preset track;

14-Volume up; 15-Volume down

Fig. 1-66 Operator Interface of Radio

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5-Fast backward;

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Chapter 3 Windscreen Wiper I.

Switch of Front Window Washer (See Fig. 1-67) The switch of the front window washer is a warp-plate switch. When the warp is pressed down, the switch indicator light will be on. After slacking up, the switch can reposit itself automatically. Turn on the switch and then the injection nozzle will eject the cleaning fluid.

The container for the cleaning fluid is installed on the framework of the engine cover. In winter, the anti-freeze fluid or the acid alcohol shall be added to the water.

II.

Switch of Rear Windscreen Wiper (See Fig. 1-68) The switch of the rear windscreen wiper is a two-position self locking switch. When pressed from the above, the windscreen wiper begins to work and the indicator light will be on. When pressed from the below, it will stop working.

1-67 Washer Indicating Card

1-68 Rear Windscreen Wiper Indicating Card

1-69 Front Windscreen Wiper Indicating Card

III. Switch of Front Windscreen Wiper (See Fig.1-69) This is a two-position three-wire self locking switch. When the switch is pressed from the above, the indicating will be on. When the switch is pressed from the below, the windscreen wiper comes back to minimum angle before stopping working.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Part II Maintenance

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter I Periodic Technical Maintenance

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(I) Technical Maintenance for the Motor Grader after 50h’s running-in Before utilization, the motor grader shall experience the commissioning for 50h, otherwise it is forbidden to put into formal utilization. The 50h’s commissioning shall be conducted in accordance with relevant specification in the user’s guide for the engine. After commissioning, it shall be maintained based on following specifications: 1.

Repeat all items of routine technical maintenance;

2.

Check the tyre pressure and the wheel’s nut (use the torque spanner with the moment of 450N.m);

3.

Replace the engine oil, discharge former engine oil when warming up the motor grader, fill with fresh engine oil, and check whether the engine oil level is at the specified height after short-time operation;

4.

Check the hydraulic oil level, and fill with hydraulic oil to specified volume;

5.

Check the coolant level in the engine, and fill with coolant to specified volume;

6.

Check whether there is any leakage of tandem and hydraulic system, and eliminate it if necessary; fill with hydraulic oil to specified volume;

7.

Clean the air cleaner once per 50h’s operation of the engine.

(II) Technical Maintenance for the Motor Grader after 100h’s Operation 1.

Repeat all items of routine technical maintenance;

2.

Replace the lubrication oil in tandem, discharge former lubrication oil when warming up the motor grader, and fill with fresh lubrication oil;

3.

Clean the engine oil filter;

4.

Clean the diesel oil filter;

5.

Check the air-in system and exhaust system, make sure the adaptor firmly fastened, and rinse the air-in and exhaust pipelines if necessary;

6.

Maintain the engine in accordance with technical maintenance for the motor grader after 100h’s operation as specified in the user’s guide for the engine;

7.

Check the parking braking system, and adjust it if necessary;

8.

Check whether the steering gear is loose, including the groove shaped nuts of steering rod, and screw down if necessary;

9.

Check the oriented gap of shovel, and adjust it if necessary;

10. Screw down the wheel’s nut (use the torque spanner with the moment of 450N.m).

(III) Technical Maintenance for the Motor Grader after 250h’s Operation 1.

Repeat all items of technical maintenance for the motor grader after 100h’s operation;

2.

Maintain the engine in accordance with technical maintenance for the motor grader after 250h’s operation as specified in the user’s guide for the engine; 93

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3.

Rinse the fuel tank and pipeline;

4.

Check the axle frame and the oil level in tandem, and fill oil for maintenance;

5.

Blow off the accumulated dust in the motor by compressed air, check whether the parts are abnormal, and eliminate it if necessary;

6.

Check the oriented gap of steering ring, and adjust it if necessary.

(IV) Technical Maintenance for the Motor Grader after 500h’s Operation 1.

Repeat all items of technical maintenance for the motor grader after 250h’s operation;

2.

Maintain the diesel engine in accordance with technical maintenance for the motor grader after 250h’s operation as specified in the user’s guide for the engine;

3.

Check the gasket of rim brake, and replace with a new one if the thickness is less than 3mm;

4.

Check whether the switch and the electric circuit of control monitoring device is normal, and immediately repair it if broken.

(V) Technical Maintenance for the Motor Grader after 1000h’s Operation 1.

Repeat all items of technical maintenance for the motor grader after 500h’s operation;

2.

Maintain the engine in accordance with technical maintenance for the motor grader after 500h’s operation as specified in the user’s guide for the engine;

3.

Replace the core of hydraulic oil filter;

4.

Check the abrasion of the transmission shaft’s bearing of fan and the tension wheel’s bearing of belt;

5.

Provide special maintenance for the engine in the case of the temperature below 5℃: (1) Use winter fuel and pay attention to the water content of fuel, so as to avoid blockage of oil circuit; (2) Fill the cooling system with antifreezing fluid, otherwise discharge the cooling water when the temperature falls to 40℃~50℃ after parking; (3) It is better to not park the motor grader in the open air in cold seasons and districts, otherwise the cooling water shall be heated for warming up the machine when initiation.

(VI) Technical Maintenance for the Motor Grader after 2000h’s Operation 1.

Repeat all items of technical maintenance for the motor grader after 1000h’s operation;

2.

Replace the lubricating grease in front axle hub, and adjust the bearing gasp of front wheel;

3.

Check the axial gap of transmission gear of reduction tandem, and readjust it if it is over 0.1mm.

(VII) Technical Maintenance for the Motor Grader after 3000h’s Operation 1.

Repeat all items of technical maintenance for the motor grader after 1000h’s operation;

2.

Rinse the cooling system;

3.

Rinse the engine oil cooler; 94

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Check the inner water sealing in water pump, and fill the operating bearing with fresh lubricating grease;

5.

Replace the core of air cleaner.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter II Check of Fastening Pieces

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Check the fastening before the initial 50h, and then check each 250h. See Table 2-1 and Table 2-2 for details of fastening torque.

(I) Fastening bolt of front and rear wheels; (II) Lock nut of wheel shaft; (III) Fastening bolt and tension bolt of sliding board of working device; (IV) Installation bolts of engine and its accessories; (V) Air conditioner and installation bolts of swing frame.

If necessary, the torque spanner shall be used to check and fasten bolts and nuts as required in the following tables; in case of damage, new bolts or nuts of same or higher grade shall be used for replacement.

Table 2-1 Technical Specification of Fastening Torque Dimension of Screw Thread

Metric Nuts and Bolts Standard Fastening Torque Dimension of Value (N.m) Screw Thread

Standard Fastening Torque Value (N.m)

M6 M8

12±3 28±7

M14 M16

160±30 240±40

M10 M12

55±10 100±20

M20 M30

460±60 1600±200

Table 2-2 Fastening Torque Values for Bolts on Main Parts (N.m) Dimension of Bolt M20 fastening bolt of traveling motor

Recommended Fastening Torque Value (N.m) 580

M22 wheel hub bolt M24 fixed bolt of slewing bearing

550 590

M16 fixed bolt of traveling motor connecting board M72 fastening nut of wheel shaft

295 2300~2800

(VI) Remarks 1.

Make sure bolts and nuts of clean threads;

2.

Fill bolts and nuts with lubricant to stabilize their frictional coefficient;

3.

Screw down loose assemble bolts, and contact the nearest dealer appointed and SANY company;

4.

The required fastening torque shall in N.m: For example: When using 1m-long spanner for fastening bolts or nuts and turning the end of spanner with a force of 120N, the following torque will be produced: 1m×120N=120N.m.

If using 0.25m-long spanner to produce a same torque as above: 0.25m×y=120N.m, the force should be: y=120N.m÷0.25m=480N.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter III Maintenance of Hydraulic System

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The full hydraulic motor grader is high-tech product. When using it, the routine inspection and maintenance is very important. Any improper using or maintenance, or absent routine maintenance would cause failures and bring damages to user, operator and environment.

Such actions of full hydraulic motor grader as traveling, working, turning and brake are under the control by means of static pressure transmission. So, it is very important to maintain the hydraulic system as follows: (I) Maintenance to Working Medium of Hydraulic System Before starting motor grader, check hydraulic oil level in oil tank normal or not, and keep it always in normal condition: 1. Check pipeline filter blocked or not, and if necessary, replace the core of filter; 2. Check hydraulic oil in oil tank normal or not, and if it is emulsified or unclean, replace it; 3. Check the working oil temperature of working mediums.

(II) Maintenance to Pipeline The operator shall often check pipeline with oil leakage or not, especially at adaptor junction and valve sealing surface to ensure cleanness of pipeline and security of hydraulic system.

(III) Inspection and Maintenance to Pressure of Hydraulic System The operator shall often inspect The operator shall often inspect security pressure of each system, such as traveling pressure, oil fill pressure in traveling system, and security, brake, steering pressures of traveling system to well and timely know their changes and the status of hydraulic parts, accordingly to ensure security and reliability for using motor grader.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter IV Maintenance of Engine

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See user’s guide for engine for details of maintenance of engine.

(I) Content of Regular Maintenance The preventative maintenance of diesel engine begins from knowing its working conditions. Before starting, it is required to regular maintenance, including checking engine oil and cooling liquid level, looking over parts with leakage, loosening or damage or not, belt abraded or damaged or not, and there is any change of diesel engine or not.

1.

check engine oil level Only after at least 5 minutes after stopping the diesel engine when engine oil flows back to drain pan can oil level be checked. When oil level is lower or higher than set mark, it is forbidden to start diesel engine.

2.

check cooling liquid level For checking cooling liquid level, the operator shall open water fill cover or liquid level inspection port of radiator or expansion water tank.

Caution: only when the temperature of cooling liquid of diesel engine falls down below 50℃ can the water fill cover of radiator be opened. If it is opened at once after diesel engine is stopped, water and steam with pressure and high temperature would burst out to damage persons. When adding cooling liquid, air in cooling system shall be fully exhausted.

3.

check transmission belt Check belt with cross crack or not and check the tension of belt by hand. If the belt is found of any abrasion or exfoliation, the replacement is required.

4.

check cooling fan It is required to check cooling fan with failures or not every day, including crack, rivet loosening, vane loosening or bending to ensure the security and reliability of cooling fan. If necessary, operator shall screw down fastening bolts or replace damaged fan.

5.

remove water and sediment in fuel-water separator It is required to remove water and sediment in fuel-water separator every day, if necessary, as follows: open bottom valve of fuel-water separator or fuel filter to remove water and sediment until there is clean fuel flowing out, and then shut up bottom valve.

6.

notices If too much sediment is found, the fuel-water separator and also all the fuel shall be replaced, if necessary to ensure the normal working of diesel engine.

(II) Content of Maintenance Each 250h or 3-month Besides the content of regular maintenance, it also includes such maintenance items as follows (the maintenance period shall be shortened properly according to working environment or using 101

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status of engine, even if the diesel engine is under use, any delay of maintenance is forbidden).

1.

replace engine oil or engine oil filter During the use of diesel engine, the engine oil will become dirty and engine oil additive decrease, it is required to periodically replace engine oil or engine oil filter to clear pollutants floating on engine oil.

Steps for Replacement: For the replacement of engine oil, when engine oil is warm and pollutants are floating and when the water temperature of diesel engine reaches 60℃, dismount oil drain screw plug to drain out all the engine oil; while for the replacing engine oil filter, clear dirty matter around engine oil filter, dismount rotary-typed engine oil filter and clean the surface of O-seal ring at filter seat.

Cautions: Before installing engine oil filter, the operator shall fill clean engine oil into its chamber fully, smear the surface of seal ring with a thin layer of clean engine oil, and then install engine oil filter according to instructions of manufacturer.

If the engine oil filter is screwed down too much, the deformation of screw thread or the damage of seal ring would occur. Operator shall install oil screw plug back, fill diesel engine with clean engine oil to proper level, start diesel engine and make it run at idle speed, and then check there is any oil leakage at engine oil filter and oil drain screw plug, and after 15min stopping for engine oil to flow from upper parts, check oil level again, if necessary, add engine oil to set mark.

2.

check air intake system Operator shall check air intake rubber hose with crack or perforation or not, and clamping collar loose or not, and if necessary, screw down or replace it to ensure no air leakage in air intake system, or else diesel engine would be damaged.

Steps: Inspection and Maintenance of Intermediate Cooler (if necessary): operator shall inspect by eye air intake/outlet chambers of intermediate cooler with crack, perforation or other damages or not, check tube, radiator and welding joint with crack, unsoldering or other damages or not; if engine oil or rubbish is found in intermediate cooler due to failure of charger or other reasons, operator must dismount the intermediate cooler and clean it, and it is forbidden to clean it with corrosive agent, or else serious damage would be caused.

3.

check air cleaner If the resistance of air cleaner exceeds the following values, the air cleaner shall be replaced: for charged or charged intercooled type, it is 6.2kPa, while for natural air suction type, it is 5.0kPa, and its resistance shall be checked under standardized working condition for diesel engine. If a 102

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resistance indicator is matched with air cleaner, the resistance indicator shall be checked periodically. When the red mark rises up to inspection port or in case of resistance alarm, the air cleaner shall be replaced. After the completion of replacement, the alarm indicator shall be reset.

Cautions: it is forbidden to start the diesel engine without air cleaner. Before entering into diesel engine, the air must be cleaned to avoid dust or rubbish in the diesel engine, leading to untimely abrasion of diesel engine.

(III) Content of Maintenance Each 500h or 6-month Beside the content of regular maintenance and previous periodical maintenance, it also includes such maintenance items as follows: 1.

replace fuel filter Clean around the fuel filter seat, dismount fuel filter and towel the sealing surface of fuel filter seat; add clean diesel into new fuel filter, lubricate rubber seal ring with clean engine oil, and then install the new fuel filter according to user’s guide of manufacturer. To prevent fuel against leaking, screw down fuel filter tightly but not too much, or else it would be damaged.

2.

exhaust in fuel system If an overflow valve is set in oil-in chamber of fuel spray pump, during the replacement of fuel filter as required above, a little of air into fuel system can be exhausted automatically. However, in case of following conditions, the man-power exhaust is required: (1) fuel filter not fully filled in installation; (2) replacement of fuel spray pump; (3) initial startup or no continuous running of diesel engine after starting; (4) diesel in fuel tank sucked dry; (5) exhausting steps: ① exhausting of low-pressure fuel oil tube and fuel filter: open exhaust screw on fuel filter, press manual pump for oil pumping until no air is found in the diesel drained at exhaust screw, and then screw down the exhaust screw. ② exhausting of high-pressure fuel oil tube: loosen the adaptor nut at oil sprayer, start diesel engine with startup motor to exhaust the air in high-pressure oil tube and then screw down the adaptor nut; start diesel engine, exhaust air in each high-pressure oil tube one by one until the diesel engine can run normally and stably.

3.

check antifreezing fluid Operator shall check the enrichment of antifreezing fluid by using ice point instrument. Under any weather condition, the antifreezing fluid is required because it can increase the boiling point of cooling fluid and decrease its freezing point, accordingly enlarging the running scope of diesel 103

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engine. Of the antifreezing, there are lots of elements that can protect diesel engine and also enhance the service life of diesel engine. If antifreezing fluid is found too little or degenerative, it shall be added or replaced.

(IV) Content of Maintenance Each 1000h or 1-year Beside the content of regular maintenance and periodical maintenance items mentioned above, it also includes such maintenance items as follows: 1.

adjust petcock gap Operator shall dismount cylinder cover, plug jigger tool into jigger hole to meet with gear ring of flywheel, slowly turn crankshaft to seek the compression dead point of the first cylinder by hand, and then, according instructions in user’s guide, check and adjust petcock gap by using petcock gap plug gauge. When checking and adjusting petcock gap, the diesel engine shall be cooled below 60℃. Operator shall check and adjust petcock gap at the piston dead point of the first cylinder according to the steps stated in user’s guide. After screwing down the lock nut of rock boom, operator shall recheck gaps of each petcock to ensure no change of its value. Operator shall mark at belt plate damper and turn crankshaft by 360° to check and adjust gaps of each petcock as stated in user’s guide. After screwing down the lock nut of rock boom, operator shall recheck gaps of each petcock to ensure no change of its value, and then reinstall cylinder cover.

2.

check tightness of belt Operator shall measure its deflection at the maximum span to ensure the deflection not more than the value limited in user’s guide.

3.

check belt, tension wheel bearing and fan rotary shaft bearing Operator shall dismount transmission belt to check it damaged or no, turn tension wheel bearing in normal condition or not to ensure it can rotate freely without any block or radial, axial cross action, turn fan to check its rotary bearing in normal condition or not to ensure it without any vibration or too much cross action, and then reinstall the transmission belt.

(V) Content of Maintenance Each 2000h or 2-year Beside the content of regular maintenance and periodical maintenance items mentioned above, it also includes such maintenance items as follows: 1.

clean cooling system After long-terming working of diesel engine, under the effect of heating oxygenation, antifreezing fluid would become organic acid, which has serious corrosion to engine, and more and more sediment would be accumulated in antifreezing fluid, leading to the preservative activity reduced and the flow tube of cooling fluid jammed. In addition, with the enhancement of using of diesel engine, the content of mineral materials in antifreezing fluid would increase gradually, and the 104

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engine oil and waste gas would seep into and pollute the cooling fluid. To ensure the cooling and preservative activities of diesel engine, the cooling system must be cleaned periodically, and be replaced every two years.

2.

check torsional vibration damper Operator shall check reticle at internal/external ring of torsional vibration damper shifting or not, and if a deviation more than 1.6mm, the damper shall be replaced. Operator shall check rubber parts of damper aged or not, and if rubber chip is found or rubber ring is lower than the metal surface over 3.2mm, the damper shall be replaced.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter V Maintenance of Electrical System

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(I) Battery 1.

Storage battery used for motor grader is the one free of maintenance. It is required to fix firmly storage battery on motor grader, and often check its tightness to avoid any loosening.

2.

If the motor grader is left without working for a long term, the electric quantity of storage battery shall be check as follows: observing from the window of densitometer (slight green means fullness, heavy black means shortage and requires charging, and light requires replacement.

3.

For installation, the storage battery shall be well connected with power supply with positive pole (+) first and then negative pole (-), and a little of Vaseline shall be smeared at wire holders. While take the storage battery out, operator shall cut off negative pole (-) from power first and then positive pole (+).

(II) Check illumination system and the tightness of connections and nuts; (III) Check the tightness of connections of sensors; (IV) Check the electric control box with dust or not, and clean it if necessary; check the tightness of electric parts; (V) After starting engine, keep working brake pressure signal lamp off; check functions of brake and steering; (VI) Check power supply relay with water log or not, and dismount it for toweling, if necessary.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter VI Maintenance of Worm Gear Case

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(I) Oil Replacement 1

To speed up oil draining, incline shovel to the side of oil drain plug (①), and set it against the ground;

2

Just as show in Fig. 6-1, dismount oil drain plug (①) to let oil flow into container, also to speed up oil draining, dismount oil drain plug (②), and after all the oil is drained out, clean oil drain plugs, replace seal rings and screw down plugs;

3

Adjust the lifting oil cylinder to set shovel level;

4

Add oil from oil fill hole (②) to mid position of observation hole (③);

5

Clean oil drain plug (②), replace seal ring and screw down plugs;

6

Capacity: at the mid position of observation hole, the oil volume is about 2.5L.

(II) Oil Level Inspection 1

The shovel slewing turbine tank shall be set level;

2

The maximum oil level must be set at the mid position of observation hole (③);

3

If necessary, oil shall be added from oil fill hole (②).

Fig.2-1

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter VII Maintenance of Reduction Tandem

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The reduction tandem assembly is an important part of the transmission system of PQ series motor grader, proper utilization and maintenance will effectively improve reliability and service life of the motor grader.

The utilization and maintenance of the reduction tandem includes utilization and maintenance of tandem, traveling brake, and parking brake.

The figure for dismantling the reduction tandem is shown in next page.

1.A210206000019

Screw M16×50GB77-00

2.A820301014883

PQ190A.16-4 Locking Nut

3.A210509000036

Key 22×80 GB1096-79

4.A820210000111

PQ190.16A-19A Gear

5.A820301020171

P190.19-1 Hub bolt

6.A210308000016

Nut M22×1.5 GB6171-00 Grade 10

7.A210403000008

Spacer22GB849-88

8.A820401000166

PQ190A.16-3 Brake drum

9.A210204000232

Screw M16×45 GB70.1-00 Grade 10

10.A820102010206

P190.19-2 Pad

11.A810201092001

P190.19.1 Brake

12.B230101000805

Oil seal BAUSL90×110×12

13.A820201000820

PQ190A.16-5 Cover

14.A210111000090

Bolt M8×25 GB5783-00

15.A210401000017

Spacer8 GB93-87

16.A210604000012

Roller bearing 32018 GB297-94

17.A820402000158

PQ190.16B-1 Connecting disc

18.A820301021034

PQ190A.16-15A Wheel axle

19.A210608000147

O-ring 315×5.3 GB3452.1-92

20.A810421000003

PQ190A.16.3 Right Tandem

21.A210604000054

Roller bearing 32020 GB297-94

22.A820210000105

PQ190.16A-21A Gear

23.A820201000824

PQ190A.16-9 Bearing Cover

24.A210111000037

Bolt M12×25 GB5783-00

25.A210622000020

Roller bearing NJ218 GB283-94

26.A820201000825

PQ190A.16-13 Bearing cover

27.A210111000018

Bolt M10×25 GB5783-00 111

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28.A210401000001

Spacer10 GB93-87

29.A210111000289

Bolt M20×45 GB5783-00 Grade 10.9

30.A210401000006

Spacer20 GB93-87

31.A820210000113

PQ190.16A-16A Gear

32.A820301020240

PQ190.16A-11 Gear shaft

33.B221500000022

Bearing NJ315

34.A820201000826

PQ190A.16-14 Bearing cover

35.A210111000081

Bolt M6×25 GB5783-00

36.A210401000016

Spacer 6 GB93-87

37.B230101000339

O-ring 192×4FREUDENBERG

38.A210609000112

O-ring 212×5.3 GB3452.1-92

39.A820201000880

PQ190A.16-10 Connecting plate

40.A210204000273

Screw M16×35 GB70.1-00 Grade 12.9

41.A210401000004

Spacer16 GB93-87

42.A820204000166

P190.19-25 Plug

43.A210434000018

Spacer42 JB982-77

44.A810201990003

P190.19.7 Oil level indicator

45.A820201000821

PQ190A.16-6 Bearing cover

46.A820301020242

PQ190.16A-18 Gear shaft

47.A820202000875

PQ190.16-20 Separating collar

48.A820102010295

PQ190.16B-24 Adjusting pad

49.A820102010296

PQ190.16B-25 Adjusting pad

50.A820102010297

PQ190.16B-26 Adjusting pad

51.A820201000822

PQ190A.16-7 Bearing cover

52.A820301020420

PQ190.16A-15A Shaft

53.A820210000114

PQ190.16A-17A Gear

54.A210509000077

Key 22×100 GB1096-79

55.A210509000108

Key 25×100 GB1096-79

56.A810201080016

PQ190.16B.2 Parking brake

57.A210622000019

Roller bearing NJ213 GB283-94

58.A820201000823

PQ190A.16-8 Bearing cover

59.A210203000008

Screw M6×25 GB68-00

60.B221500000021

Bearing NJ412

61.A820102010607

PQ190A.16-30 Adjusting pad 112

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62.A820102010608

PQ190A.16-31 Adjusting pad

63.A820102010609

PQ190A.16-32 Adjusting pad

64.A810103990020

PQ190.16A.4 Small cover plate

65.A210434000015

Spacer 33JB982-77

66.A810103990024

PQ190.16B.5 Screw plug

67.B210852000001

Double clamp SP112/12-PP GD-AS

68.A820101319903

PQ190A.16-12 Cover plate

69.B210851000001

Single clamp SP112A-PP-DP-AS

70.A210111000203

Bolt M12×35 GB5783-00 Grade 10.9

71.A210401000002

Spacer 12 GB93-87

72.A820101016175

PQ190.16-8 Small cover plate

73.A820202004452

PQ190A.16-36 Sleeve

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Fig. 2-2 Reduction Tandem

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Maintenance of Tandem, Travelling Braking and Parking Braking

(I) Maintenance of Tandem As shown in Figure 2-3, during operation process of the tandem, it shall often check the oil level of the lubrication oil in the box.

When the motor grader is parked, the oil level shall be between the middle level and the top level of the oil level indicator ③ at the tandem tail.

1. Oil Replacement Period The first oil replacement time for tandem is 100h after operation of new machine, and henceforward once every 1000 operation hours.

2. Brand and Quantity The brand of the lubrication oil is Mobil gear oil 629, and oil consumption of every tandem is about 35L.

Fig. 2－3 Lubrication of Tandem

3. Method Tilt the tandem to the oil drain plug direction, screw off the oil drain plug ④, and drain oil into the container till completely drained; 4. Screw down the plug again; 5. Screw off the screw plug ① on the cover plate of tandem, and fill fresh oil from the installation orifice of screw plug ①; the oil level shall between the middle and the top level of the oil level indicator ③; 6. Install and screw down the screw plug①.

(II) Check the abrasion of braking liner of traveling brake

Brake hub

Cam

Cam

Adjustable bolt

Adjustable bolt Brake liner Brake shoe

Screw off

Screw down

Screw off

Screw down

Fig. 2-4 Schematic Diagram for Adjustment of Braking Liner of Traveling Brake

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When the motor grader has been operated for a period, its braking performance will be weakened due to abrasion of braking liner. Accordingly, the brake should be adjusted as figure 2-4, the method is as follows: 1. Screw down the bolt according to the “screw down” direction shown in the figure (direction shown in the figure is that the operator stands at the outside of the motor grader, over against the brake) with a spanner, till the bolt is immovable, at that time, the liner of the brake shoe should touch the brake hub; 2. Screw off the bolt about 30° according to the screw-off direction in order to ensure that the clearance between the liner on the brake shoe and the brake hub is 0.75mm.

3. Adjust another brake shoe in the same way; 4. Adjust 4 wheel brakes at the same time; 5. Special caution: Do not adjust the bolt with too strong force, or it will damage the cam.

(III) Check the abrasion of friction disc of parking brake As shown in Figure 2-5, the friction disc of parking brake will be worn after the motor grader has been used for some time, so the brake effect will be not very good. Therefore, the brake shall be adjusted according to following methods and procedure: 1. Loosen the bolt (No.4) (unnecessary to take it off); reduce the thickness of adjustment spacer (No.3) according to actual situation; 2. Re-screw the bolt (No.4); (IV) If the parking brake can't be released

normally

due

to

decompression in parking brake that caused by malfunction of the engine or the hydraulic system, the manual release can be adopted: 1. Screw off the outer sleeve (No.6) on the brake 2. Take out the split pin (No.7); 3. Screw down the nut (No.8) to pull

Fig. 2-5 Adjustment of Parking Brake

out the piston rod about 3~4mm, then the brake is released.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter VIII Utilization and Maintenance of Copper Sleeve of Rear Axle Frame

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Maintenance The tandem (No.1) and the rear axle frame (No.5) are connected by the copper sleeve (No.3) (See Fig.2-6), and lubricated by the lubrication grease. As the tandem will swing forward and backward when the motor grader travels on rugged road, so good lubrication is important to prolong the service life of copper sleeve, and ensure the long and reliable operation.

1.

Maintenance Requirements During the motor grader’s operation, the copper sleeve of rear axle frame should be lubricated with the lubrication grease once a day.

2.

Maintenance Methods (1) Use the doper to inject the lubrication grease into the grease nipple (No.4) in the front and back of the rear axle frame, till the lubrication grease overflows at the both sides of the copper sleeve.

(2) When injecting with the lubrication grease, in order to ensure the lubrication effect and make the grease equably injected along the axial and radial directions of the copper sleeve, the operator can land the Shovel of motor grade, operate the left (right) lifting cylinder of the Shovel to jack up the left (right) side of the motor grader, lift up the wheels on the left (right) tandem, and then inject the lubrication grease.

II.

Methods and Procedure for Copper Sleeve Replacement If the tandem swings severely leftward and rightward due to the abrasion of the copper sleeve, even the interference occurs between the top of the tandem and the rear axle frame, the copper sleeve (No.3) and spacer (No.6) shall be replaced.

1.

Necessary spare parts: Copper sleeve (No.3), spacer (No.6) and О-ring (No. 10 and 11) Forward Direction

1- Tandem

2-Gear shaft

7-connecting board

8-Screw

3- Copper sleeve

4-Grease nipple

9-Hydraulic motor

10-О-ring

5- Rear axle frame 11-О-ring

Fig. 2-6 Connecting Figure of Tandem and Rear Axle Frame 118

12-Screw

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Sany Heavy Industry Co., Ltd.

Methods for Dismantling Copper Sleeve:

2.1 Support the Rear Axle Frame Jack up the rear axle frame (No.5) of the motor grader with a jack (load of the rear axle is 12000kg), so as to lift up the wheel at the side where the cooper sleeve of the motor grader should be replaced, and then lay the crosstie or other reliable spacer under the bottom of rear axle.

2.2 Dismantle the wheel at the brake hub of the tandem 2.3 Disconnect the hydraulic pipeline and the electric circuit Dismantle the hydraulic pipeline. Disconnect the hydraulic pipes at the tandem and hydraulic motor from the connector, jam the connectors of each pipeline with clean plug and seal well. As the oil return hose of the motor connects straightly to the oil case, so the hose’s mouth at this place should be well plugged to prevent plentiful hydraulic oil from leakage.

Take out the wire plug on the electromagnetic valve of the hydraulic motor, and wrap it up.

2.4 Dismantle the hydraulic motor Screw out the mounting screw (No.8) of the hydraulic motor, and take out the hydraulic motor (No.9).

2.5 Screw out the mounting screw (No.12) of the connecting board (No.7), and take out the connecting board and the copper washer (No.6).

2.6 Dismantle the tandem Lift the tandem (1500kg in weight) with hoisting equipment, and move slowly outward to separate the tandem and the rear axle frame.

2.7 Knock out the broken copper sleeve from the inner side of the rear axle frame with a copper stick.

Pay attention to not damage the surface of inner holes on the rear axle frame spare part for the copper sleeve.

3.

Methods for Installing Copper Sleeve The installation methods are just adverse to the order of dismantling.

3.1 Rinse of Components z

Rinse the silt or oil stain on the surface of dismantled components that need reassembly.

z

Rinse the spilliness on the assembly or moving surface.

3.2 Installation of Copper Sleeve z

Daub a little lubrication grease on the excircle of copper sleeve and the surface (Place A in Fig.2-6) of inner holes in the rear axle frame to be assembled.

z

Press the copper sleeve into the rear axle frame. After the assembly, the copper sleeve and the terminal face (Place B in Fig.2-6) of rear axle frame should be integrated tightly.

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z

Sany Heavy Industry Co., Ltd.

Daub the lubrication grease in the inner holes of copper sleeve, and on the excircle’s surface on the tandem spare part for the copper sleeve.

z

Lift the tandem and slowly put it in the rear axle frame.

3.4 Installation of Copper Spacer z

Daub a proper amount of lubrication grease on the two terminal faces of the copper sleeve;

z

Install the copper spacer as Fig.2-7 showed, and pay attention to the installation direction of the copper spacer that the terminal face with 8 oil grooves on the copper spacer should direct towards the hydraulic motor.

3.5 Installation of Connecting Board z

Replace the O-ring 220×5.7GB1235-76(No.11) on the connecting board, and daub a proper amount of lubrication grease on the O-ring;

z

Install the connecting board as Fig.2-6 showed, and pay attention to not to damage the O-ring;

z

Fasten the connecting board with the screw (No.12), and the fastening moment is 295N.m.

3.6 Installation of Motor z

Replace the O-ring 192×4FREUDENBERG (No.10) on the hydraulic motor, and daub a proper amount of lubrication grease on the O-ring and the spline of motor output shaft;

z

Install the hydraulic motor as Fig.2-6 showed. During the installation, the motor can be shaken gently to insert the outer spline of motor to the inner spline of gear shaft (No.2) in the tandem.

Meanwhile, pay attention to not to damage the O-ring.

z

Fasten the hydraulic motor with screw (No.8), and the fastening moment is 580N.m.

3.7 Connection of Pipeline (Circuit) Connect each hydraulic pipeline and the electric circuit as the original installation was.

3.8 Filling of Lubrication Grease Fill the lubrication grease following the maintenance requirements.

3.9 Installation of Wheel Remount the wheel with the fastening moment for the wheel nut being 550N.m.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter IX Adjustment and Maintenance of Working Device

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Working Device of Motor Grader (Fig. 2-7)

1.A820205001447

P190.2-2A Outer ring of spherical bearing

2.A820102010216

P190.2-17Shim

3.A820101322617

PQ190A.2-1Seat board

4.A210401000008

Spacer 24GB93-87

5.A210204000253

Screw M24x50GB70.1-00

6.A810312012012

PQ190A.2.2 Traction frame

7.B210840000006

Single clamp SP763.5-PP DP-AS

8.A210399000020 Nut M24x1.5GB1337-88 9.A210199004056

Bolt M24m6x1.5x85GB27-88 122

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10.A210401000001 Spacer 10GB93-87 11.A210204000009 Screw M10x45GB70.1-00 12.A820101322503 PQ190A.2-19 Liner plates 13.A210111000091 Bolt M8x30GB5783-00 14.A210405000007 Spacer 8GB97.1-02 15.A820103020015

PQ190A.2-18 Wearing plate

16.A210111000065 Bolt M20x90GB5783-00 Grade 10.9 17.A210307000005 Nut M20GB6170-00 18.A210113000239 Bolt M24x2x160GB5785-00 Grade 10.9 19.A820101322622 PQ190A.2-12 Spacer 20.A820101010021 P190.2-11 Shim 21.A820101010022 P190A.2-16 Shim 22.A210405000009 Spacer 24GB97.1-02 23.A820101010023 P190.2-15 Shim 24.A210334000014 Nut M24x2GB1337-88 Grade 10 25.A820402000209

P190.2-9A Sliding board

26.A210307000012 Nut M8GB6170-00 27.A210401000017

Spacer 8GB93-87

28.A820101322482 PQ190A.2-5Cover plate 29.A820101322618 PQ190A.2-4Connecting plate 30.A829900000011

P190.2-6 U-bolt

31.A210122000001 Bolt M24h9x160GB28-88 32.A210501000010 Pin 5x50GB91-00 33.A820102010057 P190.2-13 Adjusting ring 34.A210350000003 Nut M24GB6181-86 35.A210491000028 Pin 8x80GB91-00 36.A820102010019 P190.2-14 Shim 37.A820102010004

P190.2-7 Shim

38.A820202000230 P190.2-8 Bush 39.A210406000003 Spacer 42GB97.1-02 40.A820204000286 P190.2-18 Groove Nut 41.A810312011014 PQ190A.2.1Slewing ring 42.A820101322480 PQ190A.2-3 Support 43.A210111000088 Bolt M8x16GB5783-00 123

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Maintenance of Working Device

(I) Adjustment of Slewing Ring Gear of Shovel If the radial jumping exceeds 3mm and the axial gap exceeds 2.5mm, the sliding board of slewing ring gear shall be adjusted. If it is the disc-type ring gear, the above adjustment is unnecessary.

Methods: 1.

Axial Adjustment of Sliding Board (1) As shown in Fig. 2-8, measure the axial gap between ring gear (No.1) and four sliding boards (No.2) by feeler gauge, and ensure the gap

Fig. 2-8 Adjustment of Slewing Ring Gear of Shovel

between 0.6mm~0.8mm; (2) After screwing off nut (No.4), take off four guide boards to add or withdraw shim (No.3), so as to make the gap conform to the requirement, and reinstall the guide boards.

2.

Radial Adjustment of Slewing Ring (1) Lift the shovel of motor grader to keep the traction frame in balance; (2) Loosen nuts (No.5 and 4), and screw the bolt (No.6) outward slightly, so as to make sliding board (No.2) in relatively free state; rotate the slewing ring for 360° and 2~3 circles, and measure the gap between sliding board and slewing ring (No.1) by feeler gauge; (3) Symmetrically adjust the fit clearance between sliding board and slewing ring based on measurement result, and ensure the gear side clearance between driving wheel and slewing ring within 1mm~2mm when adjustment. Slightly screw down the bolt (No.6) and nuts (No.4 and t); (4) Rotate the slewing ring for 360° and 2~3 circles again. Re-measure it by feeler gauge based on running situation, symmetrically adjust the fit clearance between sliding board and slewing ring based on measurement result, and ensure the gear side clearance between driving wheel and slewing ring within 1mm~2mm; (5) Repeat the above adjustment procedures till the fit clearance between sliding board and slewing ring reaches the minimum value and the slewing ring will not be blocked and interfered during operation. Screw down the bolt (No.6) and nuts (No.4 and 5) with the fastening moment of 590N.m. Conduct the rotation test, the slewing ring shall freely rotate 360°.

Fig. 2-9 Replacement of Shovel’s Bush 124

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(II) Check and Adjustment of Shovel As shown in Figure 2-9, after being used for some time, the shovel will shake due to the abrasion of bush (No. ①) and guide board. If the shovel shakes greatly, the guide board and bush should be replaced at both sides. If the guide rod is rugged or scratched, it shall be trimmed by a file, and then replace the guide board and the bush. Detailed operating methods are as follows: (1) Lay wood under the both ends of shovel; (2) Put the shovel on the wood in natural state (under slight stress); (3) Dismantle the baffle ②; (4) Slide the shovel to the other end, and dismantle the bush ①; (5) Replace with a new bush and fasten the baffle; (6) Replace the bush at the other end in the same way.

(III) Replacement of Guide Board As shown in Figure 2-10, the guide board shall be replaced in accordance to following methods: 1.

Lay wood under the both ends of shovel, put the shovel on the wood in natural state (under slight stress), and loosen the

Fig. 2-10 Replacement of Shovel’s Guide Board

fastening bolts of board guide ①; 2.

Dismantle the guide board ②, replace with a new one, and screw down it with bolts;

3.

Replace the guide board at the other end in the same way.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter X Maintenance of Front Axle

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(I) Check whether the front axle is blocked or interfered under such operating conditions as swing, inclination and steering limit, and find out reasons and rectify malfunctions if necessary; (II) Check ball pivots of steering connecting rod and steering oil cylinder, lubricate them in proper time; check whether bolts and nuts are loose after long working hours, find out reasons and rectify malfunctions if necessary;

1-Fixing screw; 2-Needle bearing; 3-Bearing cover; 4, 5-Hub bearing; 6, 7-bolt

8-cover; 9-end cover; 10-adjusting pad

Figure 2-11 Partial Structure of Front Axle before Change (III) Check and lubricate the copper sleeve of front axle, the bearing of inclined connecting rod of front axle, the bearing of steering knuckle and the bearing of inclined knuckle of wheel in specified term; check the dust boot of ball pivot, and place it if broken or worn due to rubber aging; find out malfunctions in time and rectify them; (IV) During the process of routine maintenance of motor grader, the needle bearing of front axle shall be periodically dismantled, rinsed and refilled with lubricating grease. When filling of the lubricating grease, the fixing screw of bearing cover is always loosened due to great pressure in inclined knuckle hole of wheel, so it is better not to fill the lubricating grease with high pressure doper and better to frequently check the fastening of the fixing screw of bearing cover. When assembling the needle bearing, put it forward by hand, and tap it by copper hammer. It is forbidden to fiercely beat the needle bearing by iron rod, otherwise it will be broken.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter XI Maintenance of Air Conditioner

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(I) Normal Utilization of Air-conditioning System In order to keep favorable technical state and working reliability of air conditioning system, to make full use of its working efficiency, and to prolong its service life, following items shall be paid 在 when using the air conditioner: 1.

Maintain it in accordance with manufacturer’s instruction;

2.

Initiate the engine before using air conditioner, turn on the air conditioner after a few minutes’ stable operation of engine, choose the proper wind rate and refrigeration degree: when the refrigeration degree reaches the maximum, the wind rate shall be turned to the maximum value, so as to prevent the evaporator from icing due to supercooling;

3.

Close the ventilator scoop, window and door when using air conditioner, so as to achieve satisfied temperature as soon as possible and to save energy;

4.

Do not open the window and door of vehicle when ventilation only, allow to turn on the warming switch rather than hot water switch, namely do not initiate the engine and supply hot water either.

5.

In the process of refrigeration, close the hot water valve to avoid concurrence of refrigeration and warming.

6.

In case that the engine ceases running, it is better not to use the air-conditioning system too long, so as to avoid using up the battery’s power and difficult initiation of the engine;

7.

In the season when the air conditioner is unnecessary or if the vehicle shall be parked for a long time, the engine shall be initiated once per half-month, and the air-conditioning system shall run for 5min~10min each time.

(II) Routine Maintenance of Air-conditioning System 1.

Keep the condenser clean, for its cleanness is correlated with heat exchange, so it is necessary to often check that whether there is oil stain and silt stain on its surface, and whether the cooling fin is bent or blocked. If the surface of condenser is dirty, immediately use compressed air or clean water to rinse it, so as to keep sound condition for heat emission and guard against overhigh pressure and temperature of condenser and weakened capacity for refrigeration due to its poor performance of heat emission. During the rinsing of condenser, do not collide with the cooling fin and damage the refrigeration pipeline;

2.

Keep the air cleaner in air delivery duct clean. As the air entering the cabin shall be filtered by air cleaner, so it is necessary to often check that whether the air cleaner is jammed by dust or foreign substances and cleaned if necessary, so as to ensure sufficient wind. In order to prevent the air duct of evaporator’s core from jamming and avoid the influence on wind rate, it is necessary to check and clean up the inside and outside air cleaners once a week;

3.

Periodically check the utilization and tension of compressor’s belt. Tension the belt in time if it is 129

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loose, or replace it with the special belt for vehicle-used air conditioner if it has chink or is damaged.

The new belt will stretch after being used for 36h~48h, so it shall be tensioned again with the tension force of 160N~200N in general; 4.

Frequently check whether the pipeline’s adaptor, junction part, bolt and screw of refrigeration system is loose or collides with surrounding machine parts, whether the rubber hose is aged, and whether the shock isolation rubber pad at the thread board hole falls off or is damaged;

5.

In such cold seasons as spring, autumn or winter when air conditioner is unnecessary, the compressor of air conditioner shall be initiated once per half-month for 5 min~10min each time, because the refrigerant, during circulation, can bring the refrigerator oil to each part in the system, and hence prevent the sealing rubber ring, compressor’s shaft seal and other parts in system’s pipelines from poor sealing and leakage of refrigerant due to lack of oil, and keep the compressor, expansion valve and other moving parts in the system move and free of binding or rusting.

Additionally, the maintenance shall be conducted under the ambient temperature over 4℃, otherwise the low temperature will result in poor fluidity due to viscous frozen oil. It is forbidden to immediately bring the oil to the parts to be lubricated when the compressor is initiated, otherwise the compressor will be greatly attrited or damaged even more.

(III) Periodic Maintenance of Air-conditioning System For the important air conditioning system, some necessary periodic maintenance and check, except for the foresaid routine maintenance and check conducted by the driver, shall be carried out by professional maintainers during the process of using air conditioner, so as to better guarantee the service life and work reliability of air conditioner. The periodic maintenance for air conditioning system covers following main items: 1.

Check and Maintenance of Compressor: Generally conducted once per three years. Mainly check that whether the air-in and exhaust pressures conform to the requirement, and whether the fastening piece is loose or leaks air; dismantle the compressor to check that whether the air-in valve and exhaust valve are damaged or distorted, and repair or replace them if necessary; replace the sealing ring and shaft seal if the compressor is dismantled and repaired, otherwise the leakage will occur at the sealing place of compressor;

2.

Check and Maintenance of Condenser and Cooling Fan: Generally conducted once a year.

Thoroughly clean or rinse the foreign substances and dust on the surface of condenser, rectify and rehabilitate the cooling fin of condenser by flat-nosed pliers, carefully check that whether the surface of condenser is abnormal, and whether there is any leakage of refrigerant by leak detector; recoat the antirust painting if peels off, so as to prevent leakage due to rusting and perforation; check whether the cooling fan of condenser can normally run, the electric brush of fan’s motor is 130

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overly worn; 3.

Check and Maintenance of Evaporator: Generally, the leakage check shall be conducted once a year by leak detector, and the evaporator’s tank cover shall be dismantled once per 2~3 years to clean the inner of evaporator, and to get rid of the foreign substances in air delivery duct;

4.

Check and Maintenance of Electromagnetic Clutch: Conducted once per 1~2 years. Mainly check that whether its motion is normal, whether the wheel spins, whether the junction surface is worn, and whether the clutch’s bearing is severely worn. And use the feeler gauge to check that whether the gap of electromagnetic clutch conforms to the requirement;

5.

Replacement of Liquid Storage Drier: Under normal condition, one liquid storage drier shall be replaced every 3 years, but timely replacement is necessary if water enters the system due to improper utilization; and the liquid storage drier shall be also replaced if the pipeline is opened and ventilated for over 30 mi.

6.

Maintenance of Expansion Valve: Generally in every 1~2 years, check that whether its motion is normal, whether the openness is proper, and whether the filter mesh is jammed, and replace or properly adjust it if abnormal.

7.

Maintenance of Pipelines of Refrigeration System (1) Adaptor: Check it once a year, and check its sealing by leak detector; (2) Piping: Check that whether it collide with other parts, whether the rubber hose is aged and has crack, and replace the rubber hose every 3~5 years.

8.

Check and Maintenance of Drive Mechanism (1) Triangle Belt of Compressor: Check its tension and abrasion after every 100h’ operation, and replace with a new one after being used for about 3 years; (2) Tension Gear and Bearing: Check them once a year, and fill lubricating oil.

9.

Replacement of Frozen Oil: In general, check or replace it about every two years, and timely check or refill frozen oil in case of great leakage of pipeline.

10. Check and Replacement of Safety Device: Check the pressure switch, temperature control device and other safety device that relates to safe and reliable work of air-conditioning system once a year, and replace such devices every five years.

The foresaid period for periodic check and maintenance shall be fulfilled in accordance with actual operation condition of air conditioner, which can be shorten in southern districts and prolonged in northern districts.

(IV) Others: 1.

The fastening pieces, such as bolt and nut, shall be fastened once per three months;

2.

The shockproof and insulation rubber pad shall be checked whether aged or distorted, and shall be 131

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replaced in time if necessary; 3.

Check that whether the heat insulating material for pipeline loses its efficacy due to aging once a year;

4.

Check the refrigeration once every two years, and keep the temperature difference between air inlet and outlet within 7℃~10℃.

(V) Maintenance Period Table Item Pipeline adaptor

Condenser

Evaporator

Liquid receiver Refrigerant

Compressor

Contents Check whether the locking nut of adaptors is loose, make sure that the rubber hose and the adaptor are free of oil stain due to refrigerant leakage, the rubber hose and the pipeline are free of crack, aging, embrittlement, compression damage, and collapsing.

Make sure that the fin of condenser isn’t distorted, otherwise make it in order; and make sure the core isn’t blocked by foreign substances, otherwise clean it.

Make sure that the fan of condenser isn’t broken and can run normally Clean foreign substances in air-in and air-out ducts of evaporator’s core, check whether the drain tube below the condensed water is blocked, and smoothen it if necessary Check whether the splicing pieces of pressure switch are firm.

Replace the liquid receiver after the air conditioner has been used for some time Only slight or no air bubble is visible from inspection window when the air conditioner runs, otherwise the refrigerant shall be filled.

Period Once/month

Once/month Once/month Once/year Once/quarter Every 1000h Once/month

Firmly fix the installation bolt Make sure that the spare part surface for compressor assembly and the rotary shaft sealing of main axle are free of oil stain due to leakage of refrigerant

Once/month

Check the abrasion of compressor’s belt, and replace it if severe Check the tension of belt, and tension the belt if the tension force is insufficient

Once/month

Initiate the air conditioner to run a few minutes in unused seasons

Once/week

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter XII Wheel Maintenance

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Maintenance of Tyre a. Examine whether there is the incised wound or the crack daily. b. Frequently examine the air pressure of the tyres (in cold state): the fore tyre-0.2Mpa and the back tyre-0.25Mpa c. The erosion against the tyres from the fuel oil, engine oil and grease lubricant must be avoided. d. The net cap must be installed on the degassing valve to avoid input of feculences. e. Replace the valve core with air leakage.

II.

Fastening of Wheel When the working time of the new machine is close to 100 hours, the nuts of the wheel rim shall be examined every day. In the coming days, fasten them once every 50 hours. And the tightening torque is 450Nm.

III. Dismantlement and Installment of Tyres

Fig. 2-12 Wheel 1. A210881000017 2. A210854000001

Tyre 17.5-25-12PR Felloe 14/1.5-25 (TB)

Tyre or fellows will explode if they are dismantled in an improper way, and hence result in severe physical injury. Do not dismantle tyres unless you have rich experience and proper tools to guarantee security. Make full preparation before dismantling tyres.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter XIII Lubrication

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The motor grader should be maintained and lubricated regularly during the process of use, only in this way, the normal use of the machine can be ensured. For the interval and position of the lubrication of every part, please see following figure for details.

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PQ190 II Motor Grader Lubrication Point (Maintenance) Schematic Diagram

1. Blade oil cylinder bearing 3places 2. Blade bearing 4 places (the position is symmetrical) 24. Front wheel inclined oil cylinder bearing

3. Front axle copper sleeve 2 places

4 places (the position is symmetrical)

4. Front wheel inclined coupling bar 2 places (the position is symmetrical)

25. Front wheel bearing 2 places (the position is symmetrical)

5. Front wheel steering joint 2 places (the position is symmetrical) 6. Front wheel inclined hinge 2 places (the position is symmetrical)

26. Front wheel steering oil cylinder 4places (the position is symmetrical)

7. Hauling frame bearing 1place

27. Worm gear case charging mouth 1place

8. Swing oil cylinder copper sleeve and ball pin 3places

28. Swing frame copper sleeve

9. Worm gear case oil level window 1place

4places

10. Tray-shaped turning circle 9 places Rolling-tray-shaped turning circle 4 places

29. Oil cylinder bearing 4places (the position is symmetrical)

11. Shovel guide rail 2 places 12. Shovel lifting oil cylinder bearing 3 places

13. Swing frame cross pin 1place 14. Turning joint 1place 30. Articulating oil cylinder bearing

15. Shovel lifting oil cylinder copper sleeve and ball pin 3 places

8 places (the position is symmetrical)

16. Articulating bearing 2 places

17. Fuel oil tank oil level window 1place 18 Hydraulic oil tank 1place 31. Balancing box charging mouth

19. Rear axle frame copper sleeve 2 places (the position is symmetrical)

2places (the position is symmetrical)

20. Engine lubricating oil 1place 21. Engine oil staff guage

1place 32. Balancing box oil level window 2places (the position is symmetrical)

22. Blower, tension wheel, driving shaft bearing 3 places

33. Scarifier bearing 2places (the position is symmetrical)

23. Scarifier oil cylinder copper sleeve, bearing 3 places

34. Water tank 1place

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Chapter 1 Lubrication (Maintenance) Table for PQ190IIIA Motor Grader No.

Lubrication (Maintenance) Item

1 2 3 4 5 6 7

Blade oil cylinder bearing Blade bearing Front axle copper sleeve Front wheel inclined coupling bar Front wheel steering joint Front wheel inclined hinge Hauling frame bearing Swing oil cylinder copper sleeve and ball pin Worm gear case oil level window

8 9

10

16 17 18

Hydraulic oil tank

19

Rear axle frame copper sleeve

20

Engine lubricating oil

21

Engine oil staff gauge Blower, tension wheel, driving shaft bearing Scarifier oil cylinder copper sleeve, bearing Front wheel inclined oil cylinder bearing Front wheel bearing Front wheel steering oil cylinder Worm gear case charging mouth Swing frame copper sleeve

15

22 23 24 25 26 27 28

Working Time (h) 50 100 300 ● ● ● ● ● ● ●

1000

Remarks

● ☆

Tray-shaped turning circle Rolling-tray-shaped turning circle Shovel guide rail Shovel lifting oil cylinder bearing Swing frame cross pin Turning joint Shovel lifting oil cylinder copper sleeve and ball pin Articulating bearing Fuel oil tank oil level window

11 12 13 14

10

Every shift should clear sandy soil on the matching surface, and the lubrication grease should be added according to the actual conditions

● ● ● ● ●

The first maintenance is 50 h

● ● ●

The first maintenance is 50 h

☆ Filter and charge oil at every operation 2000h It should be conducted by every shift Every shift should check the oil level, and oil should be added according to the checking conditions.

●

☆ ● ● ● ● ● ★ ● 138

The first maintenance is 50h

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29 30 31 32 33

Oil cylinder bearing Articulating oil cylinder bearing Tandem charging mouth Tandem oil level window Scarifier bearing

☆ ●

34

Water tank

☆

●oil mouth charging ★filtering and charging

● ● ★

The replacement period of the non-freezing solution is 2 years

☆checking oil level, and filling it at any moment once

the oil level is insufficient Remarks: 1.

The above time indicates the operation time of the motor grader;

2.

If the motor grader has been parked for a long time (above 30 days), the complete machine should be maintained before storage. When it is restarted, it should be checked carefully and maintained according to the actual conditions.

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Chapter 2 Consumed Materials Filter core of high-pressure oil filter: HYDAC filter core 0240D010BN3HC Filter core of oil return oil filter: STAUFF filter core SFC-5810E Air cleaner: STAUFF Air cleaner SES3-10-S080-O-L Mobil gear oil 629 (Grade ISO VG150): 70L Used in Deceleration Tandem APIG L-5 gear Oil (SAE 85W-140): 2.5L

Used in Worm Gear Case

Mobil abrasion-proof hydraulic oil AW68 (AW46): 285L Used in Hydraulic System Mobil Heibawang 1300 diesel lubricating oil (0#): Diesel oil GB252 (0#) 380L

21L

Used in Engine

Used in Fuel Tank (in summer)

Diesel oil GB252 (-10#) 380L Used in Fuel Tank (in winter) Mobil nonfreezing solution: 40L Mobil lubrication grease EP2: 4Kg

Used in Water Tank Used in Return Ring and Articulating Oscillating Bearing

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Part III Analysis on Malfunctions

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter I Analysis on Malfunctions for the Mechanical Part

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Chapter 1 Summary I.

Malfunctions caused by Inappropriate Maintenance

(I) The slewing ring with big running clearance After working for a period of time, the slewing rings have a bigger clearance, which needs the adjustment made by the after-sales personnel. The bigger clearance of the slewing rings will be resulted from the following situations: 1.

After the operation of the motor grader, if the sand, gravel and mud isn’t cleared away from the slewing ring timely, they will mix with the lubricating grease, accordingly accelerating the abrasion of the slewing ring; under such circumstance, the lubricating grease slowly becoming dry will result in the blockage of the slewing ring, at this moment, a big change will befall for the clearance between the 4 slide boards and the slewing ring, especially the uneven clearance and large displacement when slewing result in the blockage, serious abrasion of the gears or broken gears.

2.

If working under the bad environment, the motor grader is used as the bulldozer for long time, if without normal maintenance and frequently rotating with heavy loads, the slewing ring will be abraded seriously with large displacement.

3.

The explanation of the Fig.3-1 is as follows: In the wok of the motor grader, due to the gradual impact from the outer load, the slewing ring strikes the slide plate 3 when working, resulting in the looseness of the fastening bolt of the slide plate 3 and the clearance enlarged between the slewing ring 1 and slide plate 3, when the drive wheel 2 drives the slewing ring 1 to run, the displacement or blockage of the slewing ring 1 will occur, resulting in the rupture of the slide plate 3 and serious abrasion or crack of the gear of the slewing ring 1. Therefore, the clearance between the slewing ring 1 and slide plate 3 must be regularly checked and adjusted.

4.

The adjustment methods refer to “Maintenance of the Work Device”.

1

2

3

1-Slewing ring; 2-Drive wheel; 3-Slide plate

Fig.3-1 Slewing Ring Adjustment Schematic Diagram 143

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(II) Quick abrasion of the slide plate (as shown in Fig.3-1) The slide plate is a wearable part, after the operation of the motor grader, if the sand, gravel and mud isn’t cleared away from the slewing ring timely, they will mix with the lubricating grease, accordingly accelerating the abrasion of the slewing ring, thus, the slide plate shall be replaced after running for 2000h; but if the sand, gravel and mud isn’t cleared away from the slewing ring timely, and the running clearance between the slewing ring and the slide plate can be timely adjusted, the slide plate can work with service lifetime of over 5000h. Thus, the clients should be well trained by the salesmen and after-sales personnel, making them operate in strict accordance with the requirements stated in the User’s Guide and timely maintain the machine.

(III) The tandem blocked, with abnormal noise and inclined abrasion (as shown in Fig.3-2) 1.

The tandem blocked and with abnormal noise (1) Malfunction: after being used for a period of time, the tandem swings inflexibly, sometimes accompanying with noise.

(2) Analysis on causes ① If the outer annular of the copper sleeve is blocked or the filling hole of the lubricating grease just aligns with the lubricating hole, the filled lubricating grease will go to the two ends of the copper sleeve, and then the tandem will rub the axle frame accompanying with abnormal noise; ② The client doesn’t fill lubricating grease timely.

(3) Troubleshooting ① If the copper sleeve is seriously abraded, replace it and instruct the client to fill clean lubricating grease timely; ② If the copper sleeve isn’t seriously abraded, clean it and instruct the client to fill clean lubricating grease timely; ③ Adopt the lubricating-free composite material sleeve remedied in line with the design.

2.

The inclined abrasion of the copper sleeve of the axle frame and the spacer results in the interference of the tandem and the frame (as shown in Fig.3-2) (1) Malfunction: after being used for a period of time, the inclined abrasion of the copper sleeve and spacer at the connection between the tandem and the axle frame results in the interference of the balancing box with the frame when swinging.

(2) Analysis on causes ① When the tandem swings, the relative rotation exists between the installation round table and copper sleeve on the tank body, and abrasion also exists; ② The lubricating grease is not filled timely in line with the requirements, resulting in bad 144

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lubrication of the interface with relative rotation and accelerating the abrasion of the copper sleeve; ③ The interface loads are distributed unevenly with inclined abrasion; when the copper sleeve is abraded excessively, the clearance of the interface is large, the top of the tandem slantingly swings inward and interferes with the rear frame.

(3) Troubleshooting ① Replace the copper sleeve and spacer; ② Fill clean lubricating grease in the rear axle frame copper sleeve each day in line with the requirements; ③ Adopt the lubricating-free composite material sleeve remedied in line with the design.

3.

The method and procedure for replacing the copper sleeve (as shown in Fig.3-2) If the copper sleeve abraded results in the tandem swinging seriously, even the top of the tandem interferes with the rear frame, replace the copper sleeve (No.3) and spacer (No.6).

The spare parts needed: copper sleeve (No.3), spacer (No.6), O-ring (No.10 and 11).

(1) Dismantling method of the copper sleeve: ① Support the rear axle frame Jack the rear axle frame (the rear axle has a loan weight of 12000kg) with a jack (No.5), making the wheel at one side of the copper sleeve to be replaced leave the ground, and then place a sleeper or other reliable cushion block beneath the bottom of the rear axle frame. ② Dismantle the wheel on the tandem brake hub; ③ Break the hydraulic pipeline and electrical lines a. Dismantle the hydraulic pipeline, break the hydraulic tube on the tandem and hydraulic motor, plug up the interfaces of pipelines with clean plugs and seal them. The oil return rubber hose of the motor is straight through with the oil tank, so the rubber hose inlet must be plugged to prevent hydraulic oil from leakage in large amount; b. Pull out the electrical plug on the hydraulic motor electromagnetic valve and bind it up. ④ Dismantle the hydraulic motor Screw off the installation screw of the hydraulic motor (No.8), and take out the hydraulic motor (No.9); ⑤ Screw off the installation screw (No.12) of the connecting board (No.7), and take out the connecting board and copper pad (No.6); ⑥ Dismantle the tandem Hoist the tandem (with a weight of 1500kg) with a crane, slowly move outward to separate the tandem and the rear axle frame; 145

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⑦ Knock the copper sleeve damaged out of the inner side of the rear axle frame with a copper bar. Note: no damage of the inner hole surface matched with the copper sleeve on the rear axle frame.

Forward direction

1-Tandem; 2-Spline shaft; 3-Copper sleeve; 4-Grease nipple; 5-Axle frame; 6-Spacer; 7-Connecting board; 8-Bolt;

9-Travel motor;

10.11-O-ring;

12-Screw

Fig.3-2 Assembly of the Tandem Axle Frame Copper Sleeve (2) The installation method of the copper sleeve: The installation sequence is reverse with that of dismantling. ① Wash the spare parts: Clear away the mud, sand or smear on the surface of spare parts dismantled and to be re-assembled; eliminate the burrs on the surface of assembly or moving parts. ② Install the copper sleeve: a. Coat the outer ring of the copper sleeve and the inner hole of the rear axle frame to be assembled with some lubricating grease (A in the figure); b. Press the copper sleeve into the rear axle frame, after being assembled, make sure the copper sleeve and rear axle frame end surface (B in the figure) integrate closely. ③ Install the tandem Coat the inner hole of the copper sleeve and the outer ring surface matched with the copper 146

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sleeve on the tandem with lubricating grease, hoist the tandem and then install it slowly into the rear axle frame. ④ Install the copper pad Coat the two ends of the copper pad with appropriate amount of lubricating grease and install the copper pad in line with the figure. In the installation, attention should be paid to the direction of the copper pad: the end of the copper pad with 8 oil trunks shall face the hydraulic motor; ⑤ Install the connecting board a. Replace the O-ring 220×5.7GB1235-76 (No.11) on the connecting board, and coat the O-ring with appropriate amount of lubricating grease; b. Well install the connecting board in line with the figure, no damage of the O-ring; fasten the connection board with screws (No. 12) with a screw-down moment of 295N.m. ⑥ Assemble the motor a. Replace the O-ring 192×4FREUDENBERG (No.10) on the hydraulic motor, and coat the O-ring and motor output shaft spline with appropriate amount of lubricating grease, well install the hydraulic motor in line with the figure; in the installation, lightly shake the motor in order to make the outer spline of the motor inserted into the inner spline of the gear shaft (No.2) on the tandem, at the same time, no damage of the O-ring; b. Fasten the hydraulic motor with screws (No.8) and a screw-down moment of 580N.m; ⑦ Connect the tube (pipeline) Well connect the hydraulic pipelines and electrical lines in line with the original assembly relation. ⑧ Add the lubricating grease

Fig.3-3 Front Axle Steering Schematic Diagram

Add the lubricating grease in line with the maintenance requirements; ⑨ Install the wheels

Re-install the wheels with a nut screw-down moment of 550N.m.

II.

Malfunctions Caused by Inappropriate Operation

(I) The front axle steering rod bended (as shown in Fig.3-3) 1.

Malfunction The front axle steering rod is bended frontward or upward; 147

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Analysis on causes When the shovel slews for 360°, the inappropriate operation will result in the tyre scratched by the shovel and the front axle steering rod bended;

3.

Prevention Method Be careful to slew the shovel for 360° passing by the tyre and front axle.

(II) The lifting oil cylinder bended 1.

Malfunction The shovel lifting oil cylinder is bended;

2.

Analysis on causes In the hauling of the motor grader with truck, support it with the shovel, in the transportation, the shovel lifting oil cylinder is gradually impacted by the outside force due to the vibration, resulting in the piston rod bended;

3.

Prevention Method In the hauling of the motor grader with truck, the shovel must be laid down with a sleeper or rubber placed beneath.

III. Differentiation of Normal Losses and Malfunctions (I) The shoveling blade seriously abraded 1.

Malfunction: the shoveling blade is used for 100h with serious abrasion.

2.

Analysis on causes: the service lifetime of the shoveling blade is related with the working conditions of the usage, if the motor grader is used on the sandy gravel or cement ground, the shoveling blade only has a service lifetime of 100h due to serious friction heating and accordingly quick abrasion; if the motor grader is used on the Grade II soil, the shoveling blade can be used for 800h.

(II) The tyre scratched and abraded seriously 1.

Malfunction: after used for 500h, the tyre is seriously abraded

Fig. 3-4 Tyre Pattern Direction Schematic Diagram

with a lot of points cracked or disjointed.

2.

Analysis on causes: when working on the uneven sandy gravel or cement ground, the tyre will be damaged by pointed stone, iron sheet and piton.

3.

Troubleshooting (1) Prior to the work of the motor grader, clear away the sharp stones, iron sheet and piton on the surface of the subgrade; (2) Replace the tyre with the following procedures: 148

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① Press down the brake before changing the wheel; ② Firstly loosen the felloe nut for a circle before jacking the motor grader; ③ To replace the rear wheel, one side of the motor grader can be supported hydraulically. The end angle of the shovel shall be placed in front of the tandem wheel propped up, and then the motor grader can be supported with the lifting oil cylinder at one side of the wheel to be replaced; ④ Prop up the front wheel with mould board or shovel; ⑤ Loosen the felloe nut and dismantle the wheel.

Special notices: ① Before dismantling the wheels, support the motor grader steadily; ② When dismantling the wheels, no damage of the screw thread of the wheel hub bolt; ③ After assembling the wheels, screw down the wheel hub nuts symmetrically and crosswise; ④ Within 100h after each wheel is replaced, the wheel hub nut shall be re-screwed down each day with a specified screw-down moment of 550N.m; ⑤ The direction of wheel thread When installing the tyre, attention should be paid to the thread direction on the tyre, we recommend that the tyre thread of the drive wheel should be installed along the direction indicated in the figure to get the max. tractive force in the driving direction (as shown in Fig.3-4); while the thread of the non-driving front wheel has the reverse direction with that of the rear wheel.

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Chapter 2 Common Malfunctions and Troubleshooting for the Mechanical System I.

Malfunction of Shovel Bush

(I) Malfunction The insufficient strength of the support board results in the bush sliding out.

(II) Analysis on causes A little lubricating grease on the shovel guide bar stuff with sandy soil is brought into the guide sleeve, making the shovel difficultly stretch and the bush baffle with insufficient strength, thus resulting in the bush sliding out (as shown in Fig.3-5); (III) Troubleshooting 1.

Adopt the 16mm-thick baffle to promote the elimination function of mud and sand, and reduce the abrasion of the baffle and bush.

2.

Strengthen the daily maintenance of the machine, timely clean the sand, stone and earth on the guide bar and then coat it with lubricating grease.

Bush sliding out

Support board

Fig. 3-5 Damaged Shovel Bush II.

Oil Leakage of the Interface between Brake Hub and Brake Interface

(I) Malfunction As shown in Fig.3-6, after running for a period of time, the wheel hub is of oil leakage. The possible two conditions may result in it after dismantled for checking: 1.

The edge of the seal ring is abraded;

2.

The bearing is not abraded but with fine scrap.

(II) Analysis on causes 1.

The unclean lubricating oil in the tandem or joggling of the gear produce scrap, thus resulting in the seal ring abraded;

2.

The seal ring’s quality is unstable.

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Oil leakage part

Fig.3-6 Brake Hub with Oil Leakage (III) Troubleshooting 1.

Choose the seal ring with good quality;

2.

Replace the gear lubricant.

III. Traveling brake Failed or with Bad Braking Effect (I) Malfunction 1.

Step on the brake pedal with a brake distance not up to the design requirement;

2.

The 1~2 traveling brakes fails in braking.

(II) Analysis on causes 1.

As shown in Fig.3-7, the braking pump of the brake is

Fig.3-7 Braking pump

damaged and of leakage; 2.

It’s service lifetime is basically over, the brake hoof is seriously abraded or damaged.

(III) Troubleshooting 1.

Replace the braking pump;

2.

Replace the brake spacer of the traveling brake; If the traveling brake still has bad braking effect, with abnormal noise when working or too high temperature after made adjustment, the brake spacer should be checked and replaced. When the brake spacer is less than 3mm thick, it must be replaced.

(1) When replacing with new brake spacer, hone and planish it together with the brake hub to make sure the contact area; in addition, in order to avoid the unbalance of the brake force, the 151

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brake spacer of the symmetrical wheel should be replaced together; (2) When replacing the parts related with the brake hoof, the 4 brakes should be adjusted together; the two brake hoofs of a brake should be adjusted together.

(3) After the oil in the hydraulic oil tank changed, the adaptor in the pipeline loosened or repaired, the hydraulic system may mix with air, at this moment, the traveling brake hydraulic pipeline should be deflated. After the hydraulic oil tank is full of oil, the deflation of the brake system can start (all of the 4 brakes must deflate) as shown in Fig.3-8.

(4) The operation technique is as follows (operated by 2 persons simultaneously):

1-Deflation bolt;

2-Hose;

3-Vessel

Fig.3-8 Traveling Brake Hydraulic System Deflation Schematic Diagram

① Ignite the engine; ② Take out the rubber cap of the deflation bolt;

③ Place one end of the hose on the deflation bolt and the other end in a clean vessel; ④ Loosen the deflation bolt for half a circle, and step on the brake pedal; ⑤ When oil flowing out of the deflating valve doesn’t bubble, immediately screw down the deflation bolt and loosen the brake pedal.

IV. Brake Failed or with Bad Braking Effect (I) Malfunction After being used for a long period of time, it parks on a slope with certain gradient, which slowly or quickly slides after pressing down the parking brake. Check the hydraulic pipeline and electric wires of the parking brake for being normal.

(II) Analysis on causes The inner and outer friction sheets of the brake are abraded seriously, and cannot reach the braking effect.

(III) Troubleshooting Replace the friction sheet of the parking brake with the following procedures: 1.

Screw off the bolt as shown in Fig.3-9 (No.4);

2.

Take out the parts of the parking brake (No.2.5.6.7.8.9.10) and friction sheet;

3.

Clear away the smear on the outer hub of the brake (No. 11) and brake;

4.

Install the new friction sheets in the sequence of outer blade—inner blade---outer blade---inner blade onto the outer hub of the brake and the gear shaft (No.13); 152

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Replace the O-ring (No.10) on the brake and coat the O-ring with appropriate amount of lubricating grease in the installation;

6.

Re-install the parts of the brake (at this moment, firstly don’t install the adjusting spacer No.3), screw down it with the bolt (No.4), get rid of the clearance between interfaces of the friction sheet and piston rod (No.5), and then loosen the bolt (No.4) till without pull;

7.

Measure the clearance δ between the pressure cover of the brake (No.9) and the installation surface of the brake outer hub (No.11);

8.

Assemble the adjusting spacer (No.3) with a thickness of δ- (2~2.5) mm;

9.

After making adjustment, screw down the bolt (No.4).

Note: After the parking brake is used as the emergency brake, check its friction sheet for being damaged, if it is damaged, make adjustment in line with the foregoing requirements.

1-Friction sheet;

2-Dish spring;

6-Outer protective sleeve;

7-Pin;

11-Outer hub of brake; 12-Tandem body;

3-Adjusting spacer; 8-Nut;

4-Bolt;

9-Brake pressure cover;

5-Piston rod; 10--ring;

13-Transmission shaft

Fig.3-9 Assembly of Parking Brake V. Traveling brake with High Temperature (I) Malfunction When the motor grader travels under rarely or not using the traveling brake, the brake hub will heat with high temperature.

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Brake pump

Brake hoof

Resilience spring

Fig.3-10 Assembly of the Traveling brake (II) Analysis on causes With little or no clearance between the brake spacer and the brake hub, when the motor grader travels, they are in a state of contact and friction all the time, thereby resulting in the brake heating and with the temperature rising. There are 3 factors resulting in the reduction of the clearance between the brake hub and the brake spacer as follows: 1.

The clearance between the brake hub and the brake spacer is not well adjusted in line with the requirements;

2.

The traveling brake hydraulic pipeline or valve is blocked or the valve core is blocked, resulting in that the piston of the brake pump cannot draw back;

3.

The resilience spring on the brake is damaged, so cannot draw back the two brake hoofs stretched.

(III) Troubleshooting Shoot the troubles one after another in accordance with the foregoing analysis for causes: 1.

Adjust the clearance between the brake hub and brake spacer by the means stipulated in “Traveling brake failed or with bad braking effect”;

2.

Check the traveling brake hydraulic pipeline or valves for blockage, and the hydraulic valve core for blockage, and then shoot the troubles.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter II Malfunctions Analysis on Diesel Engine System

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In order to make troubleshooting easy and reduce the time it costs, the following procedures should be followed: (I) Before dealing with the malfunction, its details should be found out first: for example, the working conditions of the diesel engine before malfunction appears - loading statement, the elevation and the dust of the surroundings; the quality of the malfunction- worsening gradually, appearing suddenly, appearing intermittently or appearing after replacing fuel or engine oil; the phenomenon of the malfunction-the color of the exhaust gas, the temperature and consumption of the coolant and whether seeping occurs to it, the temperature and consumption of the engine oil and whether seeping occurs to it, the consumption of fuel, the noise of the diesel engine and so on; whether the coolant has been polluted by such substances as engine oil, rust and solidifying precipitate; whether the engine oil has been polluted by water, fuel or other substances; the vibration of the diesel engine and other cases; (II) Make tight and systematic analysis on the malfunctions; (III) Make an organic connection between the omens of the malfunctions and the diesel system and its spare parts; (IV) Connect the present malfunctions with the recent maintenance and repair of the motor grader; (V) Examinations should be done repeatedly before disassembling the diesel engine; (VI) To deal with the malfunctions, one should start with the easiest and most obvious problems; (VII) Define the reasons for the malfunctions and make thorough repairs; (VIII) Start the diesel engine after repairing to make sure that the malfunctions have been properly resolved.

I.

Diesel Engine Can’t Be Started

(I) Malfunction 1.

The engine can’t be started or is hard to be started after trying for several times;

2.

The engine stops working immediately after being started with difficulty.

(II) Analysis on Reasons The supplying system of diesel engine is an independent one, mainly composed of the tube, filter and oil conveying pump, and its relevant starting appliances mainly include the circuit, storage battery and starting motor. Generally speaking, malfunctions occurring in starting are out of the following reasons: 1.

The diesel is of poor quality, with lots of drifts and impurities;

2.

Diesel oil filter core is blocked;

3.

Air leakage in oil-in tube;

4.

Damage of diesel conveying pump; 156

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5.

Low in electric quantity of the storage battery;

6.

Damage of the electromagnetic valve while parking.

(III) Troubleshooting First, the storage battery should be checked; if it is low in electric quantity, it should be charged quickly or connected with the storage batteries of other equipment in a parallel way. Then, examine the filter core to see whether it has been stopped up; if it is so, the old one should be replaced; fill up the new one with clean diesel, stall it in the right place and drain off the air; as the oil circuit has not been completely filled up with fuel, a little more time is required for the initiate starting, but within 10 minutes; if the engine fails to be started, it should stop running for 2 minutes and be restarted when the motor is completely cool, otherwise, the starting motor is easily destroyed. If it is in winter when starting is difficult, more examinations should be done to the oil gear rack to see whether it is in the oil-supplying position and whether the heat-supplying system is working properly.

If the engine fails to be started continuously for three times, other reasons should be taken into consideration. Disassemble the electromagnetic valve when necessary and reset the gear rack.

II.

Diesel Engine Can’t be Started (Part 1)

(I) Malfunction Press the power source switch to start the diesel engine, but it runs slowly or can’t be started.

(II) Analysis on Reasons According to the above phenomenon, examination is made in the following aspects: 1.

Whether the batteries are charged with enough power; and whether the connector lug of the power source is loose;

2.

Whether the oil conveying pump is blocked or damaged;

3.

Whether there are some mechanical problems with the diesel engine which cause stops;

4.

Whether the oil circuit is blocked.

If all the above problems can be excluded, the starting motor should be disassembled for examination, to see whether slow speed or imbalance are caused because teeth of the gear are destroyed. If it is so or the engine has been started for many times and for a long time, the bearings at the ends of the motor rotor will be seriously worn and torn, and short circuit of the earth and reduction of voltage will occur inside, thus the output of the motor will not be enough and the diesel engine can be started.

(III) Troubleshooting First, the storage battery should be checked; if it is low in electric quantity, it should be charged quickly or connected with the storage batteries of other equipments in a parallel way. If the oil conveying pump or starting motor is damaged, it should be replaced. And the working statement of 157

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the oil circuit should be checked and the air drained off.

III. Diesel Engine Can’t be Started (Part 2) (I) Malfunction Start the diesel engine, the motor is working properly, but the diesel engine can’t be started as the air in the oil circuit can not be drained out.

(II) Analysis on Reasons Examinations should be done to the oil circuit of the diesel engine, which is such a procedure that the diesel is drawn out from the oil tank, enters the diesel primary filter through the oil tubes, then runs into the fine filter through oil conveying pump and finally into the oil chamber of the single bump.

(III) Troubleshooting First, the tubes and adapters of the oil circuits should be checked to see that whether they are broken or leak air. Then examine the primary and fine filters to see whether they are blocked and whether the seal gasket is flat or leaks air or oil after the cleaner is replaced. If the above problems are excluded, then examine the diesel-conveying pump and the pressure-limiting valve.

(IV) Case When a Deutz diesel engine was started, the above malfunction appeared. Examinations were done by following the above measures, finding that the pressure for oil conveying of the oil conveying pump was low. Through disassembling the oil conveying pump, we found the inclined abrasion of the pressure-limiting valve seat that leads to the low pressure, thus the diesel engine can’t be started. The diesel engine then worked properly after the oil pump was replaced and the air was drained out.

IV. Diesel Engine Can’t be Started (Part 3) (I) Malfunction Close the power supply, rotate the ignition key, and start the diesel engine. If feel the diesel engine is started while it stops when releasing the ignition key, carefully observe it, the moment when releasing the ignition key, brake electromagnetic valve will be switched off simultaneously (demagnetized), and returns to the parking position.

(II) Analysis on Reasons If the diesel engine could be ignited, it indicates that its fuel oil system is sound, consequently, it could determine that maybe its electrical system is broken, The working principles of the brake electromagnetic valve of the diesel engine (Deutz) are if power is switched on, oil will be supplied, and if power is switched off, oil will be cut off. As the wire end is loose, the moment when the ignition button is released, the brake electromagnetic valve will be switched off simultaneously.

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(III) Troubleshooting Arrange and screw down the loose wire end to make it have a sound contact V. Diesel Engine Can’t be Started (Part 4) (I) Malfunction Close the power supply, rotate the ignition key, and start the diesel engine. If feel the motor of the diesel engine works normally, while the diesel engine could not be ignited and started, and no fume appears in the exhaust tube.

(II) Analysis on Reasons The motor of the diesel engine works well, while it could not be ignited and no fume appears in the exhaust tube, it indicates that the diesel engine does not supply oil fundamentally. If power of the brake electromagnetic valve of the diesel engine is switched on, oil will be supplied, and if power is switched off, oil will be cut off. As the brake electromagnetic valve is in the break status of power and oil constantly, it could not be started.

If in winter, oil maybe could not be normally supplied due to too high diesel grade, therefore, the diesel engine could not be started. Accordingly, check if wax bleeding of diesel appears due to too low temperature and if the fuel oil system is blocked. If serious, part spare parts of the fuel oil system would be damaged. Accordingly, the diesel grade should be selected based on the local temperature.

(III) Troubleshooting Arrange lines of the brake electromagnetic valve.

VI. Ignition Motor of Diesel Engine is Broken (I) Malfunction 1.

If motor does not rotate during start, check if the circuit is normal. If carry out the shortcircuit on the motor directly while the motor does not rotate, it could be confirmed that the motor is damaged;

2.

When starting the diesel engine only hear loose sound of the motor, while the diesel engine could not be started, check if power supply and all parts are normal. While start diesel engine after rotating the flywheel of the diesel engine to one direction, it could be started, it shows that maybe one or several gears of the ignition motor are broken;

(II) Analysis on Reasons 1.

Reasons which damage the ignition motor are as follows:

(1) Main contact burning loss contact is bad; (2) Electromagnetic loop is burnt; (3) Carbon brush is burnt.

2.

Reasons leading malfunction are as follows: 159

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(1) Do not release the ignition button rapidly after start, if pressing the ignition button for a long time the ignition motor will be burnt; (2) If the ignition motor has been used for a long time, the contact of the main contact will become bad.

3.

The reasons leading broken gears of the ignition motor are as follows: during consecutive start, no interval is reserved, and the second start is conducted when the motor does not stop completely, consequently, the engagement among gears has not been carried out thoroughly and the gear is broken.

(III) Troubleshooting 1.

Replace the motor;

2.

Replace the motor gear.

VII. Pressure of Engine Oil is a Little Low (I) Malfunction When the diesel engine is normally started, the pressure of engine oil shows a little low during operation with high and low idle speed, and the pressure of engine oil shows a little low and alarms during operation with low idle speed.

(II) Analysis on Reasons Factors leading low pressure of engine oil of the diesel engine are as follows: 1.

Engine oil level is a little low;

2.

Engine oil cleaner is blocked;

3.

Engine oil grade is too low, and the viscosity is incorrect;

4.

Engine oil pump is damaged;

5.

Oil pressure gauge or oil pressure sensor is damaged.

(III) Troubleshooting 1.

Supply the engine oil to the standard oil level (oil level should be between the first scale line and the second scale line of the engine oil surveying rod);

2.

Replace the engine oil filter core;

3.

Replace qualified engine oil in terms of standards;

4.

Overhaul and replace the engine oil pump;

5.

Overhaul and replace the oil pressure gauge or oil pressure sensor

VIII. Pressure of Engine Oil is a Little High (I) Malfunction When the diesel engine is normally started, the pressure of engine oil shows a little high during operation with high idle speed and exceeds the scale displayed by the engine oil pressure gauge.

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(II) Analysis on Reasons If operating the diesel engine with high speed directly after start, the engine oil pressure will become too high due to low temperature of the engine oil and large viscosity, which will become more distinct in winter, it is better to operate with high speed or work with large load after water temperature rises.

Relevant parameters: BF6M1013E and BF6M1013EC engine oil pressure in the Deutz engine 1.

Min. engine oil pressure during low idle speed of the heat engine (when water temperature is above 85℃) is 0.5bar;

2.

Min. engine oil pressure during high idle speed of the heat engine (when water temperature is above 85℃) is 2.0bar;

3.

Max. engine oil pressure during high idle speed of the heat engine (when water temperature is above 85℃) is 5.0bar generally, and it is allowed to reach 7.0bar is short time. The pressure relief valve to control the system pressure is installed in the main oil circuit within the lubrication system, so as to protect the system.

(III) Troubleshooting After operating with middle speed for a certain time and water temperature rises, the engine oil pressure will become normal.

IX. Consumption of Engine Oil is a Little High (I) Malfunction During working of the diesel engine, oil consumption of certain stage increases compared with that of other workdays.

(II) Analysis on Reasons Factors leading high consumption of engine oil of the diesel engine are as follows: 1.

High engine oil level;

2.

Too low engine oil grade and incorrect viscosity;

3.

Leaked engine oil;

4.

Long inclined working time of the motor grader.

(III) Troubleshooting 1.

Adjust the engine oil to the oil level;

2.

Replace engine oil in terms of the standard;

3.

Overhaul all combined faces, oil tubes, and oil seals (if necessary, replace it);

4.

Reduce the inclined working time.

Relevant parameters: Engine oil consumption rate of the Deutz engine The max. engine oil consumption rate of the diesel engine BF6M1013E matched withPQ190II/IIA 161

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and the diesel engine BF6M1013EC matched with PQ190II/IIAG is 97g/h and 110g/h respectively.

X. Temperature of Cooling Water is Too High (I) Malfunction During working of the diesel engine, if water temperature is too high and working with full load for a long time, water temperature will become too high and alarm.

(II) Analysis on Reasons Factors leading too high water temperature of the diesel engine are as follows: 1.

The water tank is short of coolant;

2.

The fan belt is loose or broken;

3.

The fan is damaged;

4.

The water pump is damaged, and the coolant is un-circular;

5.

The thermostat is ineffective;

6.

The radiator sheet out of the water tank is blocked;

7.

The water tank inside is blocked or calcified.

(III) Troubleshooting 1.

Add coolant, and check the leaking points;

2.

Strain or replace the belt;

3.

Replace the fan;

4.

Check the water pump, if necessary, replace it;

5.

Replace the thermostat;

6.

Clear dust among radiator sheets;

7.

Replace the water tank.

(IV) Maintenance Suggestions 1.

Check amount of coolant in the water tank frequently and annihilate leakage of cooling system, in addition, the coolant quality should be ensured, and reduce fouling possibility of the water tank;

2.

It is forbidden to use untreated water from rivers and lakes and heavy water to replace the coolant, the distilled water and soft water could be used to replace the coolant in special cases.

XI. Diesel Engine Fails to Accelerate Seriously (I) Malfunction The diesel engine starts normally, works normally during high and low idle speed, while during acceleration, the motor grader fails to accelerate, the rotation speed falls to about 1400rpm~1600rpm, the speed is a little low, while it becomes normal after having worked for a short time.

(II) Analysis on Reasons 162

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If the diesel engine starts normally and works normally with high and low idle speed, it indicates that the electrical parts of the diesel engine are normal, while the fuel oil system is in trouble. The blockage of the fuel oil system pipelines and cleaner will affect normal oil supply of the diesel engine, and establish a slow pressure of the low pressure oil circuit, therefore, the oil supply of the cylinder will become few, the oil supply pressure will become low, the atomization will be bad, and the power of the diesel engine will be low. Generally, it will become normal after solving blockages of the fuel oil system pipelines and cleaner. In addition, the blockage of the oil conveying pump will lead the same problem. By checking the pressure (＞5bar) and flow (＞8L) of the diesel circuit could judge if the oil conveying pump is normal.

(III) Troubleshooting Check pressure and flow of the fuel oil system, if finding the pressure and flow is a little low, check foreign matters in the fuel oil system pipelines, cleaner, and hand oil pump, and it will become normal after having been cleared.

(IV) Suggestions If the diesel engine has been parked for a long time, when it is started, a certain time is required due to pressure establishment of the low pressure oil circuit, if working with large load immediately, the output power will be a little low. It is suggested that the motor grader should start work after it has been operated empty in the middle-speed area for about 20s.

XII. Oil Atomizer of Diesel Engine is in Trouble (I) Malfunction When the diesel engine is operated with low speed, white fume will appear; when load is increased, black fume will appear, the power of the engine is insufficient obviously, and the rotation speed will fall as well.

(II) Analysis on Reasons The above phenomena are caused by bad fuel oil atomization of the oil nozzle mostly, and the main reasons are that unclean fuel oil is used. In the case that the fuel oil could not be filtered by damaged diesel filter core completely, the coupling of the oil nozzle will be blocked, or the start pressure of the oil nozzle will be a little low.

(III) Troubleshooting Release the adaptor of the high-pressure oil tube of each cylinder in turn, when the sound of the diesel engine doesn’t change obviously after disconnecting certain cylinder, or the rotation speed doesn’t change largely, it could be confirmed that the oil atomizer of the cylinder is in trouble. Then, disassemble the oil atomizer of the cylinder and put it on the inspection table for pressure test, the malfunction reason could be found out. If the oil nozzle coupling is blocked, it will become normal 163

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after having replaced a new coupling and adjust the pressure; if the difference between rotation speed of the diesel engines of the cylinders after having been stopped, the diesel filter core should be inspected to see if it is damaged.

XIII. Individual Cylinders of Diesel Engine Don’t Work The main reason, which causes individual cylinders of the diesel engine don’t work, is that individual oil atomizers work abnormally.

(I) Malfunction 1.

When the engine works, acoustical damper sends out the rhythmical noise, black fume appears, and the power falls down. At this time, change the throttle opening, the acoustical damper sends out the rhythmical noise no matter the engine is under whatever rotation speed, during operation with idle speed, if rotation speed is increased slightly, the sound becomes more distinct; based on the above phenomena, it could be confirmed that individual cylinders of the engine don’t work.

2.

How to judge which cylinder doesn’t work Cutoff method: Loosen the high-pressure oil tube with spanner and observe it, if the rotation speed of the engine doesn’t change or changes little, it indicates that the cylinder doesn’t work or works bad, if the rotation speed of the engine changes obviously, it shows that the cylinder works well.

(II) Analysis on Reasons The broken fuel oil system will cause individual cylinders don’t work. If water and impurities mix into the diesel, or the rust proof oil is not cleaned thoroughly when replacing the coupling, the needle valve of the oil atomizer would be blocked, and oil mist could not be formed, thus, the cylinder could not work normally; in addition, the worn and broken oil valve coupling pumped out by the high-pressure oil, decreased start pressure of the oil nozzle coupling will cause that the oil nozzle can’t work normally or the engine works abnormally probably.

(III) Troubleshooting 1.

Take off the faulted oil atomizer, install the oil atomizer on the inspection table, press the compression bar of hand pump on the inspection table to make the oil atomizer spray oil, and check whether the initiation pressure of oil atomizer meets the requirement;

2.

Change the pretightening force of pressure regulating spring by adding or removing the pressure regulating shims in the oil atomizer, and hence adjust the initiation pressure of oil atomizer; repeat the adjustment to make the reading of pressure gauge reaches the specified initiation pressure of oil atomizer, and to achieve favorable, fine and uniform atomization of diesel oil; ;

3.

If the oil nozzle is severely worn, the pressure can’t be adjusted, and the atomization is poor, replace the valve core of oil atomizer, so as to guarantee its pressure and atomization result;

4.

If the oil atomizer has no malfunction, check whether the coupling and spring of oil-out value of oil 164

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pump are broken; In the process of oil atomizer installment, clean the mounting hole of oil atomizer on the cylinder cover, keep it free of foreign substances, and place the copper spacer according to technical requirement. Make sure no air leakage after installation.

(IV) Relevant parameters: the initiation pressure of oil atomizers of DEUTZ engine BF6M1013E and BF6M1013EC is 250bar.

XIV. Unstable Rotary Speed of Diesel Engine (I) Malfunction During running of motor grader, the rotary speed of diesel engine is unstable and rapid in speed reduction.

(II) Analysis on Reasons 1.

Oil-in and oil-return pipeline leaks oil and air;

2.

Diesel filter core is jammed;

3.

Insufficient oil supply and inferior diesel.

(III) Troubleshooting 1. Check malfunction points with leakage; 2. Rinse the core of coarse filter for diesel oil, and replace with a secondary filter for diesel; 3. Tension the belt of oil conveying pump, check the pressure and oil-return volume of diesel circuit under rapid idling speed, and replace the oil conveying pump in case the pressure below 5bar and the oil-return volume below 8L/min.

(IV) Maintenance Suggestions 1. Guarantee the quality and sufficient amount of diesel; 2. Periodically drain the water and pollutants in diesel in the oil tank; 3. Strictly fulfill the maintenance regulation for diesel engine, replace the secondary filter for diesel in specified period, and rinse the coarse filter; 4. Often check the moving parts of diesel engine, especially check the tightness of belts of diesel conveying pump, fan, dynamotor, and water pump belt of diesel engine.

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PQ190IIIA Full Hydraulic Motor Grader User’s Guide Chapter III Malfunctions for the Hydraulic and Air-conditioning Parts

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Common Malfunctions of the Hydraulic System and Troubleshooting Malfunction

Possible Cause

Troubleshooting

a. Air is mixed in the system Exhaust it b. Oil level is too low, and air is absorbed Fill oil liquid and exhaust air 1

System vibrates, noisy

2

Oil pump vibrates, noisy

Motor grader can only travel forward, and fail to travel 3 backward; or, on the contrary, it can travel backward while fail to travel forward.

Even the gear has shifted, 4 the traveling speed does not change much

5

The gear is in neutral position, and the motor grader brakes

6 Oil cylinder piston rod crawls

7

Multi-port valve operating rod cannot restore to its original place automatically

Operate the multi-port valve, 8 executive element doesn’t move

Replace hydraulic pressure oil in the oil pump. c. Hydraulic pressure oil becomes Repair oil suction pipe, and exhaust foamlization. d. Air leakage in oil suction pipe of oil pump; air is absorbed in oil pump.

The same as b, c, and d in 1 a. The same as the b, c, and d in 2.1 Screw down the bolt b. Loose erection bolt of oil pump Start the diesel engine in place, warm c. Too low oil temperature up the oil via steering system; If it frequently happens, check oil pressure to see if it is up to the requirements a. A certain high-pressure overflow valve of Clean or replace the high pressure the traveling pump is blocked or overflow valve Replace the electromagnet of damaged. b. Electromagnet of the reversing valve on reversing valve Check and debug the PLC program traveling pump is damaged c. Reversing valve’s electromagnet hasn’t and repair the relevant circuit. received the electrical signal. a. Wrong input signal of motor proportion Check and debug the PLC program electromagnet and repair the relevant circuit b. Motor proportion electromagnet is Replace or repair motor proportion damaged electromagnet c. Speed measurement sensors are Replace the sensors damaged a. Cartridge inserted valve reversing valve Wash or replace the reversing is damaged or the valve core is blocked. electromagnetic valve b. Cartridge inserted valve reversing valve Replace the electromagnet Wash or replace the cartridge inserted electromagnet is damaged c. Cartridge inserted valve is damaged or valve the valve core is blocked. Cartridge Check and adjust the PLC program inserted valve reversing valve magnet and repair the relevant circuit has not received any signal. a. Air enters the system Exhaust b. Oil cylinder guiding ring, seal ring is too Replace the oil cylinder tight, and oil temperature rising cause the piston rod seizure a. Vertical connecting rod is too tightly Eliminate the reasons for too tightly clamped. clamped b. Dirty matters blocked the multi-port valve Wash the multi-port valve, repair or core replace the damaged one Replace the return spring c. Returning spring is too soft or broken a. Multi-port valve or main overflow valve Replace or wash the main overflow broken or dirty matters make the valve valve Replace or repair the oil pump core cannot shut completely 167

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10

11

12

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Malfunction

Possible Cause Troubleshooting b. Oil pump is broken Wash or repair the multi-port valve c. Multi-port valve core is blocked a. Multi-port valve or the Re-adjust the pressure and lock up pressure-adjustment component on hydraulic pump is loose, Replace or wash overflow valve Executive component moves pressure-regulating level is floating. slowly, or executive b. Overflow valve broken or dirty matters Repair or replace oil pump component actions are causes the valve core cannot completely Replace the sealing element feeble. shut up. c. Oil pump is damaged. d. Executive component sealing is broken, and interior leakage is caused. a. Cooler radiator is too dirty or blower go Wash radiator blade or repair blower wrong b. Oil way to the radiator is blocked, Oil way running through the radiator hydraulic oil goes back to oil tank via shall be expedite Oil temperature rises rapidly, bypass without carrying off the heat and keeps high c. Throttle loss failures exist in the system Eliminate the loss of throttling oil way d. Hydraulic oil viscosity is not conform to Replace the hydraulic oil the standards Oil leaks a. Sealing element is damaged Replace sealing element b. The joint becomes flexible screw down the joint Operating device cannot a. Balanced valve is damaged or valve core Wash or replace the balanced valve keep in the selected position is blocked b. Sealing element of piston in oil cylinder is Replace the oil cylinder sealing damaged element Frequent malfunctions of the Hydraulic oil is too dirty Examine the cleanliness of hydraulic hydraulic system oil; replace the hydraulic oil a. Air inputs to the brake system Deflate the brake system b. Oil filtered on braking pipe joint Screw down the joint and replace the Traveling crane brake doesn’t c. Oil cylinder sealing element is damaged sealing element work d. Wheel brake clearance is too wide, brake Replace the sealing element liner is damaged or worn Adjust the clearance, or replace the entire brake or liner a. Brake friction disc is damaged Replace friction disc b. Brake spring is feeble or damaged Replace spring Brake doesn’t work c. Steering valve damaged or blocked valve Wash or replace reversing solenoid core valve a. Braking pipeline joint leaks oil Screw down the joint to replace the b. Brake oil cylinder sealing element sealing element Replace sealing element damaged During the traveling, the c. Reversing valve is damaged or the valve Wash or replace reversing solenoid brake friction disc is not core is blocked. valve completely separated. d. Reversing valve electromagnet is Replace electromagnet Examine and repair (replace) damaged e. Oil refilling pressure is insufficient oil-refilling overflow valve or oil-refilling pump 168

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II. Air-conditioning System No.

Malfunction

1

No rotation of the blower fan

2

Normal rotation of the blower fan, but with little wind

3

4

No or difficult running of the compressor

Insufficient coolant

The readings of the high and low-pressure gauges under normal work The low-pressure gauge with too high pressure

The low-pressure gauge with frost stuck on the surface

The low-pressure gauge with too low pressure

Both of the readings of the high and low-pressure gauges lower than the normal value The low-pressure gauge with negative pressure value

5

Possible Cause 1. The electrical connectors with bad contact; 2. The wind switch, relay or temperature controlled switch damaged; 3. The fuse broken or the batteries with too low voltage 1. The air suction side with obstacles; 2. The fin of the evaporator or condenser blocked; 3. Unsmooth radiation; 4. One impeller of the blower fan blocked or damaged 1. The wires broken or with bad contact, resulting in no attracting of the clutch of the compressor; 2. The belt of the compressor tensioned insufficiently or too loosely; 3. The coil of the compressor’s clutch broken, resulting in failure; 4. The high and low-pressure switch of the liquid receiver functions.

Troubleshooting

Repair or replace it.

Clean it.

1. Repair it.

2. Tension it.

3. Replace the coil of the clutch.

4. Too much or little coolant.

1. Eliminate the leakage point; 1. Leakage of the coolant; 2.

Fill appropriate 2. The too little coolant filled; coolant.

Under the ambient temperature of 30℃~50℃, the high-pressure gauge has a reading of 1.47 MPa~1.67MPa (15 Kgf/cm~17Kgf/cm), and the high-pressure gauge has a reading of 0.13~0.20MPa(1.4 Kgf/cm~2.11Kgf/cm).

1. The expansion valve widely 1. Replace the expansion valve; opened; Correctly install the 2. The temperature sensing pack 2. of the expansion valve with bad temperature sensing pack; 3. Let out some coolant till the contact; specified amount.

3. The excessive coolant in the system.

Insufficient coolant

The low-pressure rubber hose blocked, the expansion valve blocked by ice or dirt 169

Fill the coolant till the specified amount.

Repair the system, if it is blocked by ice, replace the liquid receiver.

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Malfunction sometimes The evaporator frozen The outlet side of the expansion valve being cool and with frost The outlet side of the expansion valve not cool, and the low-pressure gauge with negative pressure value sometimes Both of the high and low-pressure gauges with high The high-pressure pressure gauge with The condenser too high blocked by dust pressure or foreign substance or damaged Both of the high and low-pressure gauges with too low pressure The values, the high-pressure low-pressure gauge with gauge with too low negative pressure pressure value sometimes, and the compressor with malfunction

Possible Cause

Troubleshooting

1. Insufficient coolant; 2. The low-pressure pipeline blocked or damaged; 3. The compressor with malfunction inside; 4. The compressor and the high-pressure tube with high temperature.

1.Repair it and fill the coolant; 2.Clean or replace the malfunction part; 3. Replace the compressor.

The hot water valve not closed due to damage

The warm wind offsets the cooling effect, so the cooling effect is bad.

Close and replace the hot water electromagnetic valve.

The failure of the temperature controller

Replace the temperature controller.

The expansion valve blocked

Wash or replace the expansion valve.

Leakage of the temperature sensing tube or pack of the expansion valve

Replace the expansion valve.

1. The cycling system mixed with air; 2. The coolant filled excessively

1. Exhaust it, re-pump vacuum and fill the coolant; 2. Let out the redundant coolant.

The condenser condensing

Wash the condenser, eliminate the blockage, check and replace the condensing fan.

with

bad

III. Common Malfunctions Conditions: the ambient temperature is 30℃~50℃, and the compressor can rotate normally.

(I) The system with insufficient refrigeration 1.

Malfunction (1) The air-conditioner works normally but has little refrigeration.; 170

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(2) The high-pressure gauge has the indication of 8kgf/cm2~10kgf/cm2, while the low-pressure gauge has the indication of less than 1kgf/cm2; (3) There are successive bubbles viewing from the liquid sight glass.

2.

Analysis on causes The coolant is insufficient resulted from a little leakage.

3.

Troubleshooting Find out the leakage point with leak detector, eliminate leakage points, and re-fill the coolant till the specified value.

(II) The system with much coolant 1.

Malfunction (1) The air-conditioner works normally but has little refrigeration.; (2) The high-pressure gauge has the indication of 18kgf/cm2~25kgf/cm2, while the low-pressure gauge has the indication of 2.5kgf/cm2~3kgf/cm2;

2.

Analysis on causes Resulted from the coolant excessively filled, exceeding the specified value or the condenser with insufficient cooling;

3.

Troubleshooting (1) Let out the redundant coolant by the high and low pressure gauge till the specified amount; (2) Wash the surface of the condenser, check the condensing fan for damage or ventilation.

(III) The system mixed with air 1.

Malfunction (1) The air-conditioner works normally but has little refrigeration.; (2) The high-pressure gauge has the indication of 20kgf/cm2~25kgf/cm2, while the low-pressure gauge has the indication of 2.5kgf/cm2~3.5kgf/cm2; (3) The piping at the side of the low pressure is not cool, and the compressor heats.

2.

Analysis on causes The vacuum has not been pumped completely, and the refrigeration system is mixed with air.

3.

Troubleshooting Let out the coolant, replace the liquid receiver, re-pump vacuum and fill the coolant.

(IV) The system mixed with moisture 1.

Malfunction (1) Refrigeration sometimes and no refrigeration sometimes; (2) The high-pressure gauge has the indication of 6kgf/cm2~18kgf/cm2, while the low-pressure gauge has the indication of - kgf/cm2; 171

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2.

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Analysis on causes In the cycling of refrigeration, the moisture freezes at the expansion valve; the ice melts after the refrigeration cycling stops and the normal refrigeration is restored.

3.

Troubleshooting Let out the coolant, replace the expansion valve and liquid receiver, fill the freeze oil, re-pump vacuum and fill the coolant till the specified value.

(V) The system blocked by dirt 1.

Malfunction (1) All are normal except no refrigeration; (2) The high-pressure gauge has the indication of 5kgf/cm2~6kgf/cm2, while the low-pressure gauge has the indication of -1kgf/cm2; (3) There are frost and dew on the liquid receiver, expansion valve, the front and rear pipings, and the condenser doesn’t heat; (4) The liquid sight glass has no flowing coolant.

2.

Analysis on causes The system is blocked by dirt.

3.

Troubleshooting Let out the coolant, check for the blockage resulted from dust or foreign substances, replace the liquid receiver, expansion valve, condenser and rubber hose, re-fill the freeze oil and coolant (had better replace all).

(VI) The expansion valve works abnormally.

1.

Malfunction (1) The wind is not cool and insufficient refrigeration; (2) The high-pressure gauge has the indication of 22kgf/cm2~23kgf/cm2, while the low-pressure gauge has the indication of less than 2.5kgf/cm2; (3) There are frost and dew on the expansion valve.

2.

Analysis on causes The expansion valve cannot be ignited normally and cannot reduce pressure normally.

3.

Troubleshooting Replace the expansion valve, re-fill the freeze oil and coolant.; or adjust the temperature sensing pack.

(VII) The compressor works abnormally.

1.

Malfunction (1) The wind is not cool, insufficient or no refrigeration; 172

PQ190IIIA Full Hydraulic Motor Grader User’s Guide

Sany Heavy Industry Co., Ltd.

(2) The high-pressure gauge has the indication of 7kgf/cm2~11kgf/cm2, while the low-pressure gauge has the indication of less than 4kgf/cm2~6kgf/cm2; (3) There are frost and dew on the expansion valve.

2.

Analysis on causes The compressor’s chambers are mixed.

3.

Troubleshooting Replace the compressor, and re-fill the freeze oil and coolant.

173

Due to the principle of constantly perfecting product’s performance, It may be difficult for SANY to timely inform you of the partial alteration of our products.

Add: SANY Industry Town, Changsha Economy Development District, China.

Tel: 0086-731-4031642 Fax:0086-731-4031527 Customer service Telephone: 0086-731-4031000 Sales Email:syin@sany.com.cn Customer service Email:sanyservice@sany.com.cn Code Postal: 410100 http://www.sany.com.cn

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