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Service Manual of G9180 Grader

SERVICE MANUAL

1 Repair & Maintenance

Service Manual for G9180 Grader

CONTENTS
1 Repair & Maintenance ......................................................................................... 1-1
11 Oil, Coolant and Others ....................................................................................... 1-1
111 Fuel .............................................................................................................. 1-1
112 Coolant......................................................................................................... 1-2
113 Lubricant ...................................................................................................... 1-2
114 Storage of Oil and Fuel................................................................................ 1-3
115 Filters ........................................................................................................... 1-3
12 Selection of Oils .................................................................................................. 1-4
121 Oil Application ............................................................................................ 1-4
122 Notes for Oil Application ............................................................................ 1-5
13 Maintenance......................................................................................................... 1-6
131 Precautions before Maintenance.................................................................. 1-6
132 Periodic Maintenance ................................................................................ 1-10
133 Maintenance & Repair ............................................................................... 1-15

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 The fuel may be frozen at low temperatures (particularly temperatures lower than 5°F (-15°C)). Coolant and Others ATTENTION  Change oil as soon as the oil is deteriorated or is mixed with many impurities. So it may be necessary to change the kind or blend of fuel according to the ambient temperatures.  Always fill up the fuel tank after operating to prevent water. If the fuel mixes with water or dirt.  Strictly choose the fuel type according to recommendations in this manual. 111 Fuel  The fuel pump is a precision instrument. Either too much or too little oil may cause problems.Service Manual for G9180 Grader 1 Repair & Maintenance 11 Oil.  Clean or replace the relevant filters when changing oil.  Add the specified volume of oil. which is condensed by the 1-1 .  Never let impurities or contaminants enter the system when changing fuel filters or adding fuel. Refer to Table 1-1 in this chapter for details. the fuel pump will not work normally.

Refer to Table 1-1 in this chapter for details.  It is required to choose the kind or type of antifreeze according to the ambient temperatures. connecting set) that are not involved in this manual are only for overhauling and not need to add lubricant.  Antifreeze is combustible. from entering the fuel tank.  If the engine is overheating. 112 Coolant  In order to keep sediment from blocking the radiator and affecting the thermal performance. But be sure to fill the lubricant if some parts are difficult to operate after a long time using. . the engine should be cooled down first.  The connectors (pipe joint. stay away from open flame when filling it. 113 Lubricant  Lubricant can help to prevent the wear of fitting surface and noise. use high quality glycol type antifreeze mixed at the proper proportion with distilled water.  If the engine fails to prime with fuel or the filters have been just replaced. if the coolant level is too low. then topped off with coolant  Coolant should be added to the specified level. do not use straight water as coolant.  1-2 Clean the spilled lubricant after filling. purge the air in the fuel inlet system. it will result in engine overheating and corrosion problems of cooling system.Service Manual for G9180 Grader moisture in the air.

dirt. first in .  Never try to clean paper filter elements and use them again. to maintain oil quality during long-term storage.  When replacing the oil filters. They can prevent impurities in the fuel from entering important equipment and causing problems. Always replace them with a new one.  1-3 Always use authentic filters.  Follow the rule.first out. investigate and repair. or other impurities from mixing with the oil. Replace filters at shorter intervals when the machine works in a severe environment.  Never open the packaging of new filters until they are ready to be used. If some metal particles are found.Service Manual for G9180 Grader 114 Storage of Oil and Fuel  Prevent water. 115 Filters  Filters are extremely important safety components. check whether there are some metallic particles adhering to the old filter. .

balance tank.  Fill grease until there is grease squeezing out of the filling point. replace the oil or grease according to the actual situation. such as the drive axle. The fuel tank should be cleaned regularly.  When filling oil or checking the oil level. hydraulic oil. drain the contaminated oil out after operation.  When replacing oil. sludge and debris entering into the oil.  Clean the oiler or container before filling the fuel. Finally. Fill cleaning oil and keep the engine running idly for several minutes to clean all the parts. 1-4 . grease and clean the filling ports to prevent water. put the grader in a horizontal position. And wipe the spilled grease. the oil level should be in the middle part of the oil window. (Refer to Table 1-1).Service Manual for G9180 Grader 12 Selection of Oils 121 Oil Application  Use the oil in strict accordance with the rules about specified brand and quantity.  Except for the grease.  In different seasons. turbine box. Refer to Table 1-1 in this chapter for details. And then fill the new oil and keep the engine running at low speed. use a filter for filling. fill the oil to the specified level. Apart from the oil dipsticks and other pointers.

main causes are: oxidation after wear.Service Manual for G9180 Grader Table 1-1 Oil selection table Kinds of Season Fluids Fuel Recommended Types And Standards Application point Ambient temperature≥4oC 0# common diesel oil GB252 Ambient temperature≥-5oC -10# common diesel oil GB252 Fuel tank Ambient temperature≥-14oC -20# common diesel oil GB252 Ambient temperature≥-29oC -35# common diesel oil GB252 Delo 400 LE Synthetic 15W/40 GB Engine oil pan 11122 Qty. Check whether the fuel tank is contaminated. 1-5 . residual ballast in the cylinder after combustion. and the dust from outside.  The engine oil must be changed regularly because the mechanical impurities in the oil will increase over time. whether there is sediment. 270L Engine oil Full year Hydraulic oil Full year L-HV46 low-temperature hydraulic oil Gear oil Full year Heavy load vehicle gear oil(GL-5) Rear axle and 28+23×2L 85W/90 GB 13895 balancing boxes Transmission oil Full year Diesel engine oil CH-4 15W-40 (Delo Transmission Gold) box Grease November 1~ next 2# common February GB/T7324 28/29 The rest of 3# common the time GB/T7324 Antifreeze Full year -35# ethylene coolant NB/SH/T0521 lithium-base Hydraulic tank oil 16L 132L 28L grease lithium-base grease glycol-based engine All articulated points —— Water tank 24L 122 Notes for Oil Application  Diesel oil in the fuel tank must be added timely to prevent cavitation. and clean the oil filter every mouth.

 Check the cleanliness of hydraulic oil regularly.4~0. 1-6 . 13 Maintenance 131 Precautions before Maintenance Put the machine in maintenance position (refer to Page 10 in Safety & Environment). it proves the oil is polluted and need to be replaced. Replace the oil in hot state. and do not fill the oil directly into the fuel tank. The crude oil must be cleaned when replacing the oil.Service Manual for G9180 Grader  When the impurity content reaches 0. If the paper presents a light yellow circle. physical and chemical index will deteriorate.  Fill the new oil through the oil filter. and the center is black. If the yellow circle on paper is obvious.  Perform the maintenance on hard and level ground.  Lock the front and rear frames with frame locking bars.5%.  Set all control levers/handles to the Neutral position. it proves that the oil can continue to use.  Pull up the parking brake handle to set the loader in the parking brake state.  Wedge the tires with blocks. Method: Take a few drops of oil from the tank and drops the oil on the filter paper (240mesh). Never allow several brands of hydraulic oil mixed to use. oil begins to become black.

If the oil temperatures are lower than this temperature. pipe joints. as this will ensure complete system drainage. or to remove the filters immediately after the engine stops. Use genuine parts It is highly recommended to use only genuine parts specified by the manufacturer. Keep grease fittings. oil level gauges. and fluid fill caps/openings clean to prevent foreign materials from entering these systems. Keep the machine clean Always keep the machine clean. Use clean fluid containers for oils and fuels Keep containers of oils and fuels clean and make certain to use specified oils and fuels. Make sure the engine is cooled down to ambient temperature. Use high quality and premium specification oils and fuels Use oils and fuels specified in this manual and according to local ambient temperatures and machine use conditions. Always drain oils when they are at temperatures of approximately 68~104°F (20~40°C). Inspect the oil and filters After any systems oils are changed or filters are 1-7 . it is recommended to warm it up to this temperature before draining it.Service Manual for G9180 Grader Use warning tags Hang a do-not-start-engine tag near the ignition switch before performing maintenance or repairs to prevent inadvertent engine or machine movements. Pay attention to high-temperature oil and coolant It is very dangerous to drain hot oils or engine coolant.

 Never weld any pipe or take that has fuel or oil in them.  Keep the distance between the grounding cable line and welding area no more than 39in (1m). Keep sparks and cigarette lighters away from them. Inspect the front and rear frames After a long period of operation. 1-8 . and make sure the O-rings and gaskets are in the correct assembly position. and for loose or damaged bolts and nuts. and remove the battery cables from their terminals. Retain the fuel fill strainer Do not remove the fuel strainer while fueling.  Avoid welding near seal rings and bearings. If large amounts of metallic particles or impurities are found. investigate and repair. center joint.  Disconnect all ECU connections. Seals When replacing O-rings or gaskets. check for damage of the undercarriage.Service Manual for G9180 Grader replaced. inspect the oil and filters. Fire prevention When cleaning any parts or components. use non-flammable cleaners or light oil. Practice clean oil changing Change oil in a dust-free place to keep impurities and contaminants out of the oil. and the main battery switch. Welding guide  Turn off the starting switch of the engine. frames. clean the sealing faces first. Precautions to use while washing the machine  Do not wash the machine with a hot or warm engine. Let it cool down.

 Refer to the accompanying Maintenance Manual for Diesel Engine for maintenance and replacement of air filter. Avoid using mixed oil Never use oil mixed from different brands. Environments with airborne contaminants Do the following when the machine works in conditions with airborne dust or chemicals:  Inspect and clean air filter frequently to avoid restricted inlet air. Lubricate and coat anti-rust oil to components. and fill with the new brand oil completely.  Clean and replace fuel filter frequently. especially the starting motor and alternator to avoid accumulation of dust affecting dissipation of heat.  Clean the electric components. Machine cleaning after inclement weather operations Clean the machine immediately after working in rain and snow. 1-9 .  Clean the radiator frequently to avoid blockages and overheating.Service Manual for G9180 Grader  Do not allow water to spray on any electrical components. drain the oil from the machine. If using a different kind of oil from the one previously used.

And you should choose good road for the running-in period. When driving. avoid accelerating suddenly.Service Manual for G9180 Grader 132 Periodic Maintenance Fig.  Avoid emergency brake or using the brake for a long time. do not accelerate to climb the slope. start operation when the water temperature gets to 50oC.  After starting the engine.  1-10 You should properly carry out the maintenance . 1-1  A new machine must have a running-in period of 50h.

1-11 . every 100 hour maintenance. Check whether the connecting bolts between frame and rear axle and hub are loose or broken. every 50 hour maintenance. you should clean the water tank and radiator fins frequently. every 1500 hour maintenance. Every 10 hour maintenance  Clean the grader: Clean the dust and ash on the surface of grader. but the time could not be too long. Fill until there is grease squeezed out of the fitting area. Fix or replace the loose or broken parts.Service Manual for G9180 Grader tasks before. Periodic maintenance is divided into every 10 hour maintenance.  In the first 200 working hours. Important! Check the oil level often. Do not let dirt enter oil filling port and air filter. during and after run-in period. Clean the dust and oil on the surface of parts and hydraulic components. be sure to shorten the maintenance cycle and increase the maintenance times according to real conditions.  Do not operate the grader in full power in the first 50~100h period.  When working in dusty environment. every 200 hour maintenance. every 1000 hour maintenance. you should check the engine oil level twice a day (10h). and every 2000 hour maintenance. inject the grease with low pressure rather than high pressure to avoid too much overflow. It is allowed to operate the grader in full power in the second 50~100h period. every 500 hour maintenance.  When filling the grease to the transmission shaft.  Check the connection and fixing of the parts of grader.

 Check the parking brake system and adjust it if necessary.  Check hydraulic oil level and add specified new oil if necessary. check the wheel nuts (set the torque wrench to 700~800Nm). After the running-in period. Every 100 hour maintenance  Complete the tasks of the 10 hour and 50 hour periodic maintenance indicated above. and ensure the connectors are connected firmly. maintain the machine as per the instruction s below:  Complete the tasks of the 10 hour periodic maintenance indicated above.  Check if there is leakage in the hydraulic system.  Check whether the connection of steering mechanism is loose. remove the problem if so. a running-in period of 50 hour is required. Clean the intake and exhaust pipes if necessary. including nuts of steering 1-12 .Service Manual for G9180 Grader  Check the grader for leaking phenomenon and eliminate the problem.  Check the intake system and exhaust system.  Check hydraulic oil level and fill hydraulic oil to specified level.  Check the tire pressure. and fill hydraulic oil to specified level. Every 50 hour maintenance ATTENTION Before putting a new grader into operation. Follow the instructions in Operation and Maintenance Manual of Diesel Engine to perform the running-in.

200 hour and 500 hour periodic maintenance indicated above. 50 hour 100 hour.  Check whether the clearance of transmission box to rear axle transmission shaft.  Replace the fine filter in transmission box.  Check the oil level of main drive and balancing box.  Check the tension of chain of balancing box. tighten them.Service Manual for G9180 Grader linkage. 50 hour and 100 hour periodic maintenance indicated above.  Tighten the wheel nuts. Repair if damaged. and eliminate the problem if not. 50 hour 100 hour and 200 hour periodic maintenance indicated above. 1-13 . add if necessary. If it is loose. tighten it.  Check the guide clearance of blade and adjust it if necessary. Every 500 hour maintenance  Complete the tasks of the 10 hour. Every 1000 hour maintenance  Complete the tasks of the 10 hour.  Check the guide clearance of rotary frame and adjust it if necessary. Every 200 hour maintenance  Complete the tasks of the 10 hour.  Remove the dust inside the generator with compressed air and check whether the parts are normal.  Check whether the circuits of switches and control monitoring device are normal. engine to working pump transmission shaft and the cardan shaft are oversized.

and adjust front wheel bearing clearance. you need to preheat the engine before starting. 200 hour. 50 hour 100 hour.  Clean the engine oil cooler. Every 2000 hour maintenance  Complete the tasks of the 10 hour. 50 hour 100 hour.  Check the axial clearance of main drive small gear. 500 hour.  Replace the grease in front axle hub. fill grease. 1-14 . 200 hour.  Check whether the bearing of fan transmission shaft and the tension wheel of belt are worn seriously.Service Manual for G9180 Grader  Replace hydraulic oil filter element. adjust if the clearance is greater than 0.  Clean the cooling system. Otherwise. 500 hour and 1000 hour periodic maintenance indicated above. Every 1500 hour maintenance  Complete the tasks of the 10 hour. 1500 hour and 2000 hour periodic maintenance indicated above. Use water as coolant is strictly forbidden.05mm. it is better not to park the grader in an open area.  Engine should be maintained specially if the ambient temperature is lower than 5°C.  Be sure to use antifreeze (coolant) specified by SDLG all year round.  Check the water seal in water pump.  In cold season and areas.  Choose fuel that applicable to winter and pay attention the water content in the fuel in case of blockage of fuel circuit.

coat it with sealant and retighten it. Maintain the diesel engine according to requirements in operation and maintenance manual of diesel engine strictly 133 Maintenance & Repair Draining of transmission box oil 1 3 Overhaul the machine after it is cooled. Clean the oil drain plug. 1-2 1 Oil dipstick 3 Oil filling port 2 Oil drain plug 2. please shorten the maintenance cycle and increase the maintenance times according to the real conditions. Remove the oil drain plug to discharge the transmission oil into a clean vessel. If the working condition is very severe. 1 Fig. 2 Fig.Service Manual for G9180 Grader The maintenance principles listed above are the basic requirements. 1-3 1 Oil drain plug 1-15 . Install the plug after all oil is discharged. 1.

1 Fig. 1-4 1 Oil filling port 2 Oil dipstick 4.Service Manual for G9180 Grader 3. oil level should be between highest scale and middle scale (ZONE HOT). Loosen the oil dipstick clockwise and remove the oil dipstick. When the oil temperature is 176°F (80°C). 1 2 Fig. Clean it. Insert the oil dipstick and tighten it. After filling new oil into the transmission box. When the oil temperature is 104°F (40°C). 1-5 1 Oil dipstick 1-16 . Then take it out to read the oil level (do this at least twice). start engine and let the engine run idly for several minutes (about 1000r/min). oil level should be between bottom scale and middle scale (ZONE COLD). put the transmission lever (gear selector) in the neutral “N” position.

2. Check and ensure the parts are not damaged.Service Manual for G9180 Grader Replacement of transmission oil filter Overhaul the machine after it is cooled. 1 Fig. 2. 1 Fig. 1-7 1 Oil absorption filter screen location 1-17 Reassemble the absorption screen. 1-6 1 Transmission oil filter Clean the oil absorption filter screen of transmission box 1. Install a new gasket between cover and transmission box 3. Remove the cover and clean the internal parts. Install new filter and tighten it according to the instructions described in the related manual. Drain the oil out and then remove the filter. 1. .

Fill new oil into the axle via the oil filling port to specified level. 2. a bit of spilled oil is allowed. Clean the plugs. The oil level can be checked via the oil level hole. 1-8 1 Oil level hole 3 Oil drain plug 2 2 Oil filling port 4 Vent cap Draining and filling of balancing box oil 1. 28L 4. Install and tighten the oil filler plug.Service Manual for G9180 Grader Draining and filling of drive axle oil 2 4 Wear protective equipment to prevent burns caused by uncooled engine oil. 3. 1. The lower limit is about 8mm to the edge of the hole. 1 Fig. Axle oil: approx. Screw off the oil drain plugs on bottom of the balancing box (each balancing box has two oil drain plugs) 2. and install each plug with new seal ring. 1-9 1 Oil drain plug 1-18 . Clean the oil drain plug and retighten it. Tighten the plugs. Remove the oil drain plug to discharge the transmission oil into a clean vessel. 1 Fig.

The volume of each balancing box is about 23L. 1-11 1 Cover plate 2. Keep the axle in horizontal position when filling. Remove the vent cap and fill new oil into the balancing box via the oil filling port to the bottom edge of the oil level hole (the oil is about to overflow from the hole).Service Manual for G9180 Grader 12 3. Install and tighten the vent cap. 5. 1 Fig. 3 Fig. 1-12 1 Balancing box 1-19 . 1-10 1 Oil filling port 3 Oil level hole 2 Vent cap Tensioning of balancing box chain 1. Lift up the balancing box assembly and support it. Remove the two cover plates. 4. 1 Fig.

Tensioning of the chain is realized by rotating the eccentric bearing cap.Service Manual for G9180 Grader 3. its elongation will increase. ATTENTION There are two chains in each balancing box. Tensioning of the chains can only Fig. 1-13 be performed by professionals. 1-15 1 Rear wheel 1-20 . 1 Fig. When the train is pulled. 1-14 1 Oil drain plug 3. Empty the balancing box.2 Remove the rear wheel.1 Support the balancing box assembly to keep the wheels off ground. If the sag of the loose side of chain is greater than 18mm. the two chains need to be inspected together. As per the steps below: 3. the chain needs to be re-tensioned. 1 Fig.

5 Remove the fixing bolts of the connecting plate. 1-16 1 Drum brake 3. screw the bolt into the hole for about 5~8 circles. and install a M10 bolt to the hole instead.3 Remove the drum brake.4 Remove the oil cup. 1 Fig. ATTENTION The bolt is used to prevent the chain wheel and shaft module from slipping away from the tapered roller bearing. 1-18 1 Connecting plate 1-21 . 1 Fig.Service Manual for G9180 Grader 3. 1-17 1 Oil cup 3. 1 Fig.

be careful to avoid Fig. Lower the shovel blades to the ground and raise the front bulldozing plate to the highest position. you should mark their positions. Replacement of hydraulic oil 1. ATTENTION Before disassembling the connecting plate and bearing seat.8 After the adjusting. Fig. Shut down the engine. During rotating the connecting 1 plate and bearing seat.7 Rotate the connecting plate and bearing seat in the same direction for the same angle until the sag of the loose side is about 11. and operate the control handle to lower the front bulldozing plate to the ground. 3. install the removed parts orderly. 3. 1-21 1-22 . 1-19 1 Bearing seat damaging the O-rings.5mm.10 Adjust and deflate the brake system. 1-20 1 Front bulldozing plate 2.9 Fill oil into the balancing box and reassemble the cover plates. 3.6 Remove the fixing bolts of the bearing seat.Service Manual for G9180 Grader 3. 1 Fig. 3.

Open the return oil filter cap and fill specified hydraulic oil into the tank until the oil level pointer points at the middle position. shut down the engine and deflate the hydraulic oil 2 tank. during repairing 1 2 Fig. 1-22 1 Return oil filter 3 Oil drain valve 2 Oil level pointer 4 Air filter 8. Hydraulic oil: 132L ATTENTION Special attention should be paid to the sealing of the filter mouth. if an obvious black spot appears a few hours later. and the seal ring should be replaced when necessary. 1-23 1 Oil return flange 2 Oil absorption flange or working in dusty environment. Additionally. then the oil must be replaced to avoid damaging the hydraulic system. let one drop of the hydraulic oil fall on a filter paper or blotting paper. be careful when installing the cap. 3 Fig. 6. Install the filter cap. Open the drain valve to discharge the hydraulic oil into the container. Start the engine and operate the control handles repeatedly to fill the hydraulic system with oil and bleed the air out 7. To prevent damaging the fine thread on filter cap. 4. Check the oil level via a round oil level pointer and add when necessary. Close the valve after all oil is discharged. Lower all working devices to the ground. Place an oil collection container under the 4 drain valve. 5.Service Manual for G9180 Grader 1 3. The hydraulic oil should be replaced periodically. 1-23 .

1-24 Replacement of return oil filter element 1. 2. 2. ATTENTION When installing the filter assembly. Close the oil drain valve and fill hydraulic oil to specified level after the replacement or repair. 1-25 1 Return oil filter cap must be careful to avoid damaging the seal ring. Remove the filter cap. 1-24 . Replace or repair the working/steering pump. you 1 Fig. 3. Take out the entire filter element. Open the oil drain valve on bottom of hydraulic oil tank to discharge the oil. Fig. 3.Service Manual for G9180 Grader Replacement or repair of working/steering pump 1. Replace the filter element with a new one and assemble it. Tighten the filter cap slowly and carefully.

4. 1-26 1 Oil drain plug The fuel tank should be cleaned with specified volume of kerosene (about a quarter of the fuel tank volume). be sure to fill up the fuel tank. 2. ATTENTION 1 Fig. Retighten the plug after the draining. Loosen the oil drain plug on the bottom of fuel tank to discharge the kerosene into a container. you should keep the grader running for a while to let the sediments in the fuel tank gather. Fuel filling 1. 3. There should be no smoking or open flame near the fueling site.Service Manual for G9180 Grader Cleaning of fuel tank 1. 1 Fig. To avoid condensation of water vapor in the air. Remove the filler cap. Before the cleaning. 2. Install the filler cap immediately after the filling to prevent contamination. 1-27 1 Fuel filler 2 2 Fuel filter assembly 1-25 . Use kerosene to clean the fuel tank caps and filter screens carefully. and the engine must be stopped. and pay attention to check whether the seal is normal.

2. Place the empty container under the engine and remove the oil drain plug.Service Manual for G9180 Grader Engine oil draining 1. 1 2 3 Fig. Replacement of fuel filters Do the maintenance after the machine is cooled. And tighten them according to the requirements described in the filter manual. Do the maintenance after the machine is cooled. 2. 1-28 1 Oil drain plug Replacement of fuel filters 1. 1 Fig. Replace the engine oil filter. Deflate fuel system after the replacement. Apply new engine oil to the seals of the new filter. 2. 3. Coat the new filter seals with new engine oil. 1-29 1 Coarse fuel filter (pre-filter) 2 Engine oil filter 3 Fine fuel filter 1. Tighten the filter according requirements described in the manual. 1-26 to the . Remove the filters with filter wrench.

1-31 1 Engine oil filling pipe 1 Fig. it is not necessary to remove the safety filter element. Oil level should be between “MAX” mark and “MIN” mark on the oil dipstick. because the safety filter element is maintenance-free. 1-30 1 Air filter safety filter element should be replaced at the same time. 1-32 1 Engine oil dipstick 1-27 . Engine oil: 16L 1 2 Fig. 2. When maintaining the main filter element. If the main filter element has been maintained 3 times or the alarm indicator is still on after 1 the maintaining.Service Manual for G9180 Grader Replacement of engine air filter 1. 3. the main filter element and Fig. Maintain or replace the main filter when the filter is blocked and the alarm is triggered. Engine oil filling Fill the engine oil to the specified level.

Use a gauge to check tensioning condition of belt. Separate the brake bar and the fork. 3. Then tighten the back nut again until deflection of the 1-28 . Tighten the back nut. 2. and make sure no brake force is produced when assembling. Connect the brake bar and the fork with pin. pull the brake handle to the extreme position to obtain the maximum braking force. and replace it if necessary. 1 Fig. 5. Then pull and push the brake handle between middle position and original position for three times. Then tighten the back nut until deflection of the flexible shaft is small than 3mm under the action of 30N forces. 6. 1-34 1 Adjusting nut 3 Connecting pin 3 2 Brake bar 4. Loosen the adjusting nut for a few circles. 1-33 1 Belt Adjustment of parking brake 1 ATTENTION When adjusting the parking brake. Remove the connecting pin of brake bar and the fork. You need to adjust the flexible shaft to critical tensioned state. 2 Fig. 2. Check whether the belt is worn.Service Manual for G9180 Grader Transmission belt checking 1. 1. Turn the fork for a few circles to adjust.

Remove the inside hexagonal bolts. 1-36 1 Inside hexagonal bolt 3. 1 Fig. 1-37 1-29 . Jack up the front axle and remove the front wheel(s). Take down the end cover. Fig.Service Manual for G9180 Grader flexible shaft is small than 3mm under the action of 30N forces. Lubrication and adjustment of front wheel bearing 1. 1-35 1 The front wheel is removed 2. 1 Fig.

Service Manual for G9180 Grader 4. ATTENTION Maintaining of the front wheel bearing can only be performed by professionals. 1 2 Fig. 1-39 1 V-shape seal ring 2 Seal ring 8. front wheel spindle. replace the seal rings with new ones. bearing and end cover. Fill lubricating grease. tighten the inside hexagon bolts orderly and crosswise. Check and make sure that the hub can rotate freely and smoothly. 6. 1-38 1 Puller 2 2 Hub 5. 1 Fig. install the hub and check the bearing clearance. Lubricating grease: about 280g for each wheel Lubricating grease: common lubricating grease EP2 GB 7324 1-30 lithium . Install the end cover fixing bolts. Rinse the hub. 7. without runout and vibration. Use a puller to remove the hub.

and tighten the cover plate. A file can be used to flat the rail. then the wear-resisting plate and lining should be replaced together. 1 Fig. 1.  Replace the wear-resisting plate with a new one.  Screw off the fastening bolts. Replacement of the lining  Place the shovel blade on two wood blocks. 1-41 1 Wearing-resisting plate 1-31 . the wear degree can be reduced greatly. Besides.  Install the new lining. and then tighten the fastening bolts. if you pay attention to flat the guide rail during normal use.Service Manual for G9180 Grader Adjusting of shovel blade If the shovel blade vibrates a lot during working. 1 2 Fig. 1-40 1 Cover plate 2 Lining 2.  Remove the lining. Replacement of the wear-resisting plate  Place the shovel blade on two wood blocks.  Remove the cover plate.

and tighten the lock nuts. Radial adjustment of rotary frame  Loosen the nuts and bolts to adjust the guide plate. 2 Guide plate  Tighten the fixing nuts to 755±45Nm. 2. 1 Fig.  Change the number of adjusting gaskets and use a feeler gauge to ensure the axial clearance between the bottom of rotary 1 Fig. and make sure the rotary ring can turn 360 degrees freely.Service Manual for G9180 Grader Adjusting of shovel blade rotary gear ring 1.  Tighten the nuts to 755±45Nm. Axial adjustment of rotary frame  Loosen the lock nuts and fixing nuts on bottom of clamp plate. 1-42 1 Clamp plate frame and wear-resisting nylon is within 2 1~2mm. 1-43 1 Guide plate 1-32 .  Perform turning trial.  Assemble the guide plate. Take down the rotary gear ring guide plate.

Operate the control handle keep the shovel blade close to the to-be removed wheel. and remove all foreign matters immediately. Put the machine in maintenance position. 4. crack and penetration of sharps things. Leaking valve elements should be replaced with new ones. 5. too high or too low pressure will cause severe wear or unilateral wear. 1-44 1 Grader side to jack up the grader. 3.Service Manual for G9180 Grader Maintenance of tires 1. while that for rear tire is 0. 4. Prevent the tires from being corroded by fuel. 5. engine oil and lubricating grease. Inflation pressure for front tire is 0.01MPa. 6. Before removing the wheel.21±0. Check the tire pressure periodically. Check the tires daily for cut. 2. Pull up the parking brake handle. 3. you must support the grader stably. Then 1 operate the blade lifting cylinder on the same Fig.01MPa. Replacement of wheels 1. Use the front bulldozing plate or shovel blade to jack up the front wheel. Refer to Page 10 in Safety & Environment. 2.25±0. The inflation valve must be installed with mesh cap to avoid intrusion of impurities. 1-33 .

When assembling the tires. We suggest you install the rear drive tires in the way illustrated in the Fig. Tighten the wheel nuts crosswise and diagonally when installing the wheel. 1 Fig. 1-46. ATTENTION Do not damage the thread when removing the nuts. Texture direction of tires 1. 1 Fig. Use pneumatic impact wrench to remove wheel nuts. 1-46 1 Rear tire texture 2. as shown in Fig. pay attention to the texture direction. to obtain maximum traction force. The front tires should be installed in the opposite direction. 1-45 1 Rear wheel 100 working hours.Service Manual for G9180 Grader 6. 1-47. 1-47 1 Front tire texture 1-34 . Check and retighten the wheel nuts after 1 Fig.

You should also check the fixation state of the batteries constantly to prevent looseness. Disassembly and assembly of storage battery  When negative disassembling. 2. and the then disconnect the positive wire (+).  The battery must be fixed on the grader firmly. then there might be bubbles in “battery eye”. If the “battery eye” still indicates “white” after waggling. it means the battery is fully charged. and then connect the negative wire (-). if the “battery eye” indicates green.  When assembling. if the “battery eye” indicates black. then the battery power is low. then the battery should be replaced. Inspection of battery electric quantity  The “battery eye” can be used to determine the battery electric quantity: Check the color of “battery eye”.Service Manual for G9180 Grader Maintenance of storage battery G9180 grader is equipped with two 6-QW-70B maintenance-free storage batteries. and connected to electrical system 1-35 . 1 Fig. 1-49 1 Battery eye If the “battery eye” turn white. 1  Fig. You must check the electric quantity of the battery after long-term storage (more than 6 months). connect the positive wire (+) first. waggle the battery gently to drive the bubble away. wire (-) disconnect first. the two batteries are connected in series. 1-48 1 Storage battery 1.

and you must check the tire pressure regularly. and warp them up as far as possible. Run the grader every other week to warm it up. balancing box oil and engine oil 1-36 . to prevent the tires from exposing to strong sun light and moisture. If the grader is going to be stored for long time. Long-term storage of the grader 1. you should clean and lubricate it thoroughly. and charge them every month. transmission box oil. and then reduce the tire pressure by half. if possible. Coat the terminals with some Vaseline to prevent electric erosion. you should remove the batteries and put them in dry and warm place. cover the tires to avoid direct sun light exposure. If the grader is going to be parked the in open air or on uneven ground. jack the machine up to engage the transmission gears. If the grader is going to be stored for more than four weeks. 4. 6. It is reasonable to run the grader periodically. To avoid corrosion. 5. you should replace the hydraulic oil. 3. Reset the grader back to working state If the grader is out of work for about a year. 2. it is better to jack up the machine with wood block to deload the tires. axle oil. the fuel tank should be filled up with fuel.Service Manual for G9180 Grader correctly. It is better to park the grader in a shed or house. Coat the fine finished surfaces with lubricating grease and coat the piston rods with a thick layer of Vaseline. add preservative (10% of the total fuel quantity) if the conditions permit. In the meantime.

add more hydraulic oil into the hydraulic oil tank. And speed up the engine to 1800rpm until the engine and transmission box reaches working temperature 50~90oC (122~194oF). Transmission oil level checking When the machine is at working temperature and the engine runs at idle status. 1-50 1 Oil dipstick 1-37 . Recover the machine in the maintenance position.  Before you continue to preheat the machine. Check the display screen for any warnings regarding low oil level. Check the battery electrolyte level and tire pressure. 3. and inject all grease cups with lubricating grease. 5. 1 Fig. Preheat and start the engine. Walk around the machine to make sure that there is no leakage. the oil level of transmission oil should be in the rated range marked on the oil dipstick.Service Manual for G9180 Grader before putting it into operation again. 1. 6. 4. Rinse the piston rods thoroughly.  Preheat the grader and check the display screen for any warnings regarding low oil level. 2.

and fill more water if the level is below the baffle plate. 1-38 . it takes about 20min to fill up the water tank for the first time. Fill water through the coolant filling port. 1 Fig. 1-52 1 Engine oil dipstick Coolant level checking 1. the water will flow into the water tank through the refill pipe. check the water level through the water filling port. 1 2 Fig. 1-51 1 Round oil level pointer Engine oil level checking Oil level should be between “MAX” mark and “MIN” mark on the oil dipstick. 1 Fig. start the engine and run it idly.Service Manual for G9180 Grader Hydraulic oil level checking Check the hydraulic oil level through the round oil level pointer on hydraulic oil tank. 1-53 1 Expansion water tank 2 Coolant filling port 3. 2. Do not fill the water too fast. When expansion water tank is filled up with water.

It forbidden to start the engine without filing up the water tank. and green color means normal. WARNING It is forbidden to open the filler cap when the system is not cooled to avoid human injury caused by high-pressure steam. 2. 1 Fig. (See Fig. 1-55 1 Radiator 1-39 . 1-54 1 Storage battery such as Vaseline. Install the grid shield device. Cleaning of radiator 1. 1 Fig. Wear protective gloves. and coat the external surface with grease as anticorrosion. goggle and clothes when maintaining the battery.  Open the battery covers. the fins of radiator may get damaged. Clean the fins of radiator and condenser with compressed air along the moving direction of the machine. ATTENTION If not being dealt properly.Service Manual for G9180 Grader 4. Open the engine hood and remove the grille shield device. Checking of battery. 1-54)  Check the liquid level. Open one each time.  Check and clean the connectors of cable and terminals and bolts of battery. cable and connector Touching the liquid of battery will cause severe chemical burning. 3.

Service Manual for G9180 Grader Cleaning of condenser 1. . If the grader is installed with A/C. 2. Remove the cover hood. 3. 1 Fig. and clean the condenser with compressed air from outside. 1-56 1 Condenser 1-40 Install the cover hood.