Service

Service Manual
Manual

0 0Overview
Overview
 Service Manual of G9190 Grader

Contents
0 Overview .......................................................................................................... 0-1
01 Product Introduction ........................................................................................ 0-1
011 Overall Exterior and Names of Parts ........................................................ 0-1
012 Diagram of Overall Dimensions ............................................................... 0-2
013 Composition and Meaning of Product Model .......................................... 0-2
014 Nameplate ................................................................................................. 0-2
015 Application ................................................................................................ 0-3
016 Technical Characteristics .......................................................................... 0-3
017 Main Technical Specifications .................................................................. 0-6
02 Specification .................................................................................................. 0-10
03 Tools .............................................................................................................. 0-15
04 Marking ......................................................................................................... 0-16
05 Judgment Criterion of Repair ........................................................................ 0-17
051 Judgment by Visual Examination or Hand Touch .................................. 0-17
052 Measurement by Measure ....................................................................... 0-19

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 Service Manual of G9190 Grader

0 Overview
01 Product Introduction
011 Overall Exterior and Names of
Parts

1 2 3 4 5 6 7 8 9 10 11 12 13

Figure 1
1. Front axle assembly The G9190 grader is mainly composed of engine
2. Front frame assembly system, working device system, frame system,
3. Working device assembly
4. Swing frame assembly torque converter - transmission system, rear
5. Blade assembly
drive axle assembly, front axle system, operating
6. Multi-way valve assembly
7. Operating board assembly system, A/C system, electric system, and
8. Cab assembly
9. Articulation assembly covering system.
10. Covering assembly
11. Rear axle assembly
12. Rear frame assembly
13. Fuel tank assembly

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 Service Manual of G9190 Grader

012 Diagram of Overall Dimensions

Figure 2

013 Composition and Meaning of

Product Model
G 9 190

Engine rated power at 190ps

Hydro-mechanical driven

Grader

014 Nameplate
The nameplate of this machine is affixed on the

left rear portion of the front frame, indicating the

vehicle type, product identification code,

manufacturing year, and manufacturer.

Figure 3

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The cab nameplate is located on the lower left

front portion of the cab.

Figure 4

015 Application
This machine is mainly applied for the leveling of large

area ground (such as roads, airports, and farmlands) and

excavation of roadbeds to realize the functions such as

earth and aggregate mixture moving, excavation of side

ditches, scraping of side slope, and removal of snow

and obstacle. It’s one necessary construction machinery

for building construction, water conservancy

construction, and farmland improvement, including the

national defense construction, mine construction, and

urban and rural roads.

016 Technical Characteristics

1. It’s equipped with Dalian Deutz inline,

water-cooled, four-stroke, electronic direct

injection diesel engine. This engine features

three power curves and its emission

conforms to the requirements of EC Stage II

& EPA Tier II.

2. The overall weight of the machine is

sufficiently utilized to reasonably distribute

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Service Manual of G9190 Grader

the loads and optimize the overall layout. It

features powerful traction force and best

downward blade pressure.

3. The tray type working device driven by

double cylinders is capable of loaded

rotation, featuring accurate positioning and

high reliability.

4. The blade part adopts single cylinder

structure to prevent the bending of blade due

to redundant positioning under the

application of force.

5. The three-segment rear drive axle fitted with

no-spin differential is adopted. The front

drive axle adopts heavy load design,

featuring high ground clearance, less

quantity of parts, guarantee of long service

life and log maintenance needs, and

realization of sudden turn under low turning

radius.

6. The fixed displacement hydraulic system

with high pressure gear pump + multi-way

valve is adopted, with hydraulic system

pressure at 21MPa. The service brake

system adopts dual-circuit fully hydraulic

brake system, featuring stable braking and

high safety and reliability.

7. The front arrangement of multi-way valve

and the optimization design of operating

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Service Manual of G9190 Grader

mechanism feature light and flexible

operations.

8. The front and rear frames applicable for

harsh conditions, the fast assembly design of

parts, and lubrication-free design of working

device bearings achieve high reliability and

maintenance-free.

9. FOPS/ROPS cab newly designed as per the

ergonomic principles is arranged at the rear

portion of the front frame.

10. The electro-hydraulic controlled swing

frame pin cylinder and 7-hole connecting

rod can rapidly achieve the most extensive

positioning of blade.

11. The optimized blade curvature enables the

materials to have good throughput capacity

and flow capacity, promoting the labor

efficiency.

12. The multiple optional attachments can meet

the customers’ needs under different

working conditions.

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 Service Manual of G9190 Grader

017 Main Technical Specifications

Table 0-1 Overall Performance Parameters
Item Parameter Item Parameter
Overall weight (kg) 15800 Min turning radius (m) 7.6
Front axle load Ground clearance of blade
4700 445
distribution (kg) (mm)
Rear axle load
11100 Cutting depth of blade 787
distribution (kg)
Maximum tilting angle Tilting angle of blade
±18 47
of front wheel (º) (Forward, º)
Maximum swing angle Tilting angle of blade
±16 5
of front axle (Backward, º)
Maximum swing angle
±50 Titling angle of blade (º) 90
of front wheel (º)
Articulated steering 673 for both left and
±23 Slide range of blade (mm)
angle of frame (º) right
Maximum traction force (KN)
Cutter diameter (mm) 1626 82
(f=0.75)
Blade specification
3962×635×22 Blade swing angle (º) 360
(mm)
Gear I II III IV V VI
Forward
Traveling 4.8 8.4 11 18.6 23 38
(km/h)
speed
Reversing
4.8 11 23
(km/h)

Table 0-2 Main Dimensions

Item Parameter Item Parameter
Length (mm) 8975 Wheeltread (mm) 2260
Wheeltread
Height (mm) 3240 6480
(Front/rear) (mm)
Width (mm) 2710 Rear axle wheelbase 1538
Minimum ground clearance of Ground clearance of
610 430
front axle (mm) rear axle

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Table 0-3 Engine

Item Parameter Item Parameter
Model BF6M1013EC Number of cylinders 6
Inline, water-cooling,
Type 4-stroke, and direct Cylinder bore/Stroke (mm) 108/130
injection
Rated power Minimum fuel consumption
146 210
(kW) (g/kw.h)
Rated speed Top torque (N.m)/Speed
2200 710/1500
(r/min) (r/min)
EC Stage II
Displacement
7146 Emission standard &EPA Tier II
(ml)
compliant

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Table 0-4 Drive System

Item Parameter/description
Model ZFW320
Single-stage, single-phase, and
Type three-element, integrated with
transmission
Hydraulic Diameter of circulation circuit 320
torque Torque ratio at stalling 1.94
converter Mbgo 133.3N·m
Torque converter inlet pressure -
0.25~1.0MPa
MPa
Torque converter outlet pressure -
0.25~0.4MPa
MPa
Model 6WG180/200
Type Fixed shaft power shift
Control model Electro-hydraulic control
Gearshift control oil pressure - MPa 1.3~1.8MPa
Drive gear I 5.986
Drive gear II 3.42
Transmission Drive gear III 2.594
Drive gear IV 1.48
Drive gear V 1.178
Drive gear VI 0.672
Reverse gear I 5.986
Reverse gear II 2.594
Reverse gear III 1.178
Three-segment grader drive axle, no-spin limited slip differential, swing type
balance box, ±15ºswing angle, heavy roller chain drive, and wheel drum brake
Total reduction ratio 17.779
Drive axle and
Main reduction ratio 3.7
balance box Drive axle
Wheel reduction ratio 3.26
Balance Balance box reduction
1.474
box ratio
Tire specification Tire 17.5-25-16PR
Tire Wheel rim 14.00/1.5-25
specification Front axle tire pressure (MPa) 0.2
Rear axle tire pressure (MPa) 0.25
Brake system Service braking pressure (MPa) 10.3±0.5

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Table 0-5 Hydraulic System

Item Parameter/description
Type Open-type system
Main pump Gear pump (Jinan)
System pressure (MPa) 21
Pressure setting of safety 21.4±0.35
Husco multi-way valve (MPa)
valve Pressure setting of 23.4
overload valve (MPa)
Nominal flow (L/min) 65
Rotary valve Mico rotary valve
Front wheel tilting cylinder Ø100×Ø50-169-473
Front wheel steering cylinder Ø63×Ø45-340-577
Tightening cylinder Ø80×Ø60-63.5-38
Swing cylinder Ø80×Ø35-279.5-507
Blade extraction cylinder Ø90×Ø50-1346-1794
Blade swing cylinder Ø90×Ø50-693.5-955.5
Blade lifting cylinder Ø90×Ø50-1379.5-493.5
Articulated steering cylinder Ø110×Ø50-303-610
Blade angle changing cylinder Ø100×Ø50-260.5-562

Table 0-6 Fuel/Oil Capacity

Item Parameter Item Parameter
Fuel Approximate 250L Rear axle and balance Approximate
box oil 28+23×2
Hydraulic oil Approximate 160L Transmission Approximate 28L
lubricating oil
Engine oil Approximate 22L

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 Service Manual of G9190 Grader

02 Specification
Standard tightening torque (See table below)

Table 0-7 Tightening Torque for Common Bolts

Bolt Yield Nominal Diameter of Bolt (mm)
Strength strength 6 8 10 12 14
Grade N/mm2 Tightening Torque N.m
4.6 240 4～5 10～12 20～25 36～45 55～70
5.6 300 5～7 12～15 25～32 45～55 70～90
6.8 480 7～9 17～23 33～45 58～78 93～124
8.8 640 9～12 22～30 45～59 78～104 124～165
10.9 900 13～16 30～36 65～78 110～130 180～210
12.9 1080 16～21 38～51 75～100 131～175 209～278
Bolt Yield Nominal Diameter of Bolt (mm)
Strength strength 16 18 20 22 24
Grade N/mm2 Tightening Torque N.m
4.6 240 90～110 120～150 170～210 230～290 300～377
5.6 300 110～140 150～190 210～270 290～350 370～450
6.8 480 145～193 199～264 282～376 384～512 488～650
8.8 640 193～257 264～354 376～502 521～683 651～868
10.9 900 280～330 380～450 540～650 740～880 940～1120
12.9 1080 326～434 448～597 635～847 864～1152 1098～1464
Bolt Yield Nominal Diameter of Bolt (mm)
Strength strength 27 30 33 36 39
Grade N/mm2 Tightening Torque N.m
4.6 240 450～530 540～680 670～880 900～1100 928～1237
5.6 300 550～700 680～850 825～1100 1120～1400 1160～1546
6.8 480 714～952 969～1293 1319～1759 1694～2259 1559～2079
8.8 640 952～1269 1293～1723 1759～2345 2259～3012 2923～3898
1400～
10.9 900 1700～2000 2473～3298 2800～3350 4111～5481
1650
1606～
12.9 1080 2181～2908 2968～3958 3812～5082 4933～6577
2142

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Table 0-8 Table of Tightening Torques for Bolts for Cast Iron and Aluminum Connections
Bolt grade 8.8 10.9
and torque Torque (N.m) Torque (N.m)

Bolt specification Cast iron Aluminum Cast iron Aluminum

M8 20～25 15～20 28~33 15~20
M10 45～50 25～30 55~60 25~30
M12 70～80 50～55 100~105 50~55
M14 110～125 80～90 150~165 80~90
M16 160～180 120～140 220~240 120~140
M18 205～230 165～180 295~320 165~180
Table 0-9 Tightening Torque for Connectors
Connectors sealed with copper washer or taper thread Connectors sealed with O-ring
Connector Connector Tightening Torque
Tightening Torque N.m
specification specification N.m
M14, G1/4 34±5 M12×1.5 35±3.5
M18, G3/8 73±10 M14×1.5 45±4.5
M20, G1/2 93±10 M16×1.5 55±5.5
M24 142±20 M18×1.5 70±7.0
M27, G3/4 205±30 M20×1.5 80±8.0
M33, G1 421±49 M22×1.5 110±10
M42 872±98 M27×2.0 170±17
M30 320±40 M33×2.0 310±31
M36×2.0 310±31
Table 0-10 Tightening Torque for Fasteners Sealed with 24ºTaper Thread
Tightening torque for connecting nuts sealed with 24ºtaper thread
Specification Tightening Torque N.m
M12×1.5 20±5
M14×1.5 30±5
M16×1.5 35±5
M18×1.5 45±5
M20×1.5 50±5
M22×1.5 65±10
M24×1.5 70±10
M26×1.5 85±10
M30×2 115±15
M36×2 145±15
M42×2 210±20

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Table 0-11 Tightening Torque for Articulated Bolts

Thread specification Tightening torque (N.m)
M10×1 25～35
M12×1.5 60～75
M14×1.5 80～100
M16×1.5 105～115
M18×1.5 20～130
M22×1.5 140～155
M24×1.5 160～180
M27×2 190～230
M33×2 270～320

Unit Conversion Table

Table 0-12 Length
Unit Centimeter Meter Kilometer Inch Foot Yard Mild
Centimeter 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
Meter 100 1 0.001 39.37 3.2808 1.0936 0.00062
Kilometer 100000 1000 1 39370.7 3280.8 1093.6 0.62137
Inch 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
Foot 30.48 0.3048 0.000304 12 1 0.3333 0.000189
Yard 91.44 0.9144 0.000914 36 3 1 0.000568
Mild 160930 1609.3 1.6093 63360 5280 1760 1
1 millimeter = 0.1 centimeter 1 micrometer = 0.001 millimeter

Table 0-13 Area

Unit Centimeter2 Meter2 Kilometer2 Are Foot2 Yard2 Inch2
Centimeter2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
Meter2 10000 1 0.000001 0.01 10.764 1.1958 -
Kilometer2 - 1000000 1 10000 1076400 1195800 -
Are 0.01 100 0.0001 1 1076.4 119.58 -
2
Foot - 0.092903 - 0.000929 1 0.1111 144.000
2
Yard - 0.83613 - 0.008361 9 1 1296.00
Inch2 6.4516 0.000645 - - 0.006943 0.000771 1
1 Hectare=100 Ares 1 Mile2=259 Hectare=2.59 Kilometer2

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 Service Manual of G9190 Grader

Table 0-14 Capacity/Volume

Unit Centimeter3 Meter3 Decimeter3 Inch3 Foot3 Yard3
Milliliter 1 0.000001 0.001 0.061024 0.000035 0.000001
Kiloliter 1000000 1 1000 61024 35.315 1.30796
Liter 1000 0.001 1 61.024 0.035315 0.001308
Inch3 16.387 0.000016 0.01638 1 0.000578 0.000021
Foot3 28316.8 0.028317 28.317 1728 1 0.03704
Yard3 764529.8 0.76453 764.53 46656 27 1
1 Gallon (American) =3785.41 Centimeter3=231 Inch3=0.83267 Gallon (British)
Table 0-15 Weight
Unit Gram Kilogram Ton Ounce lb. (Pound)
Gram 1 0.001 0.000001 0.03527 0.0022
Kilogram 1000 1 0.001 35.273 2.20459
Metric Ton 1000000 1000 1 35273 2204.59
Ounce 28.3495 0.02835 0.000028 1 0.0625
lb (Pound) 453.592 0.45359 0.000454 16 1
1 Ton (Metric) =1.1023 Ton (American) =0.9842 Ton (British)
Table 0-16 Pressure
Pascal =
Kilopound/ Kilo Pound-force/ Pound-force/
Unit Bar Newton/
Centimeter2 pascal Inch2 Foot2
Meter2
Kilopound/
1 0.98067 98066.5 98.0665 14.2233 2048.16
Centimeter2
Bar 1.01972 1 100000 0.001 0.00015 0.02086
Pascal =
Newton/ 0.00001 0.001 1 0.001 0.00015 0.02086
Meter2
Kilopascal 0.01020 0.01 1000 1 0.14504 20.886
Pound-force/
0.07032 0.0689 6894.76 6.89476 1 144
Inch2
Pound-force/
0.00047 0.00047 47.88028 0.04788 0.00694 1
Foot2
Kilogram/Centimeter2= 735.56 Dry Measure (mmHg) =0.96784 Barometric Pressure

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Table 0-17 Description of Units

Unit Acronyms
Newton metre N·m
Kilopound meter kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kj
British Thermal Unit Btu
Calorie ca

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 Service Manual of G9190 Grader

03 Tools
Table 0-18

Common tools Specification Quantity Application

Choose different
Pneumatic BQ8, BQ10, BQ16, BQ30,
1 set specification depending on
wrench MI-17HE
size of assembling bolt
Choose different
Socket 10, 13, 15, 16, 18, 21, 24, 36, 46 1 set specification depending on
size of assembling bolt
Use for light hammering
Soft hammer 1 while assembling parts with
interference fit
5.5×7, 8×10, 10×13, 11×13,
12×14, 13×15, 13×16, 14×16, Choose different
Solid wrench 16×17, 16×18, 17×19, 18×24, 1 set specification depending on
18×21, 22×24, 24×27, 24×30, size of assembling bolt
27×32, 30×34, 36×41, 41×46
Use for light hammering
Copper bar 1 while assembling parts with
interference fit
Measure the gap adjustment
Feeler gauge 1 set
portions
Flathead
1 For slotted head screw
screwdriver
Philips
1 For Philips head screw
screwdriver

Pliers 1

Adjustable
1
wrench

Crowbar 1

Special tool Specification Quantity Application

Disassemble and assemble

Prepare disassembling platform if
Bracket 2 types working device and axle
unavailable
assembly
Disassemble and assemble
Trolley 1
axle assembly
Fix the complete machine
Wood wedge 12
during repair

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 Service Manual of G9190 Grader

04 Marking
To highlight the importance in terms of safety

and quality more vividly, the following symbols

are fabricated for markings.

Table 0-19
Marking Item Note

Pay special attention to safety during operations.

Safety
Pay special attention to the safety during operations, as it
contains internal pressure.
Pay special attention to the technical requirements
Caution during operations to ensure that the operation quality
meets the specification.
Weight and disassembly/installation method of part or
Weight device. Pay attention to the selection of slings and the
operating posture.
Tightening Pay attention to the tightening torques of parts during
torque assembly.
Application
of The application of sealant or grease is required.
sealant/grease

Fuel/oil/water Add a certain amount of oil, water, or fuel

Drainage The place to drain oil or water and drainage amount.

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05 Judgment Criterion of Repair

051 Judgment by Visual Examination or

Hand Touch

1. It’s disallowed to further use the parts that

are ever seriously knocked, cracked, broken,

or functionally failed.

2. The oil seals, dust rings, O-rings, and seal

gaskets that are ever disassembled for

leakage cause are disallowed for further use

due to poor reliability and short service life.

3. The bolts, nuts, washers, screw plugs, and

pipe connectors that get seriously rusted,

fail for normal tightening in the thread part,

have knocking damage in thread part, or

have excessive wear or thread failure are

disallowed for further use.

4. The lock wire in the bolt connections is

disallowed for further use once being

disassembled.

5. The bearings in stagnated manual rotation or

with cracked parts, seriously worn raceway,

or damaged balls are disallowed for further

use.

6. The gears or splines with cracking, flaking,

knocking damage, excessive wear in the

tooth portion are disallowed for further use.

7. The housing with cracking, or cracking,

wear, oval shape, or flaking in bearing

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Service Manual of G9190 Grader

mounting bore, or tightening failure of

thread due to damage is disallowed for

further use.

8. The bearing blocks and oil seal seats with

cracking, wear, overall shape, knocking

damage, or flaking at the fitting surface/stop

opening are disallowed for further use.

9. The pins with serious wear or knocking

cracking are disallowed for further use.

10. Conduct the initial judgment by visual

examination or smelling method. The

hydraulic oil shall be replaced upon

detection of following conditions during

checking: Emergence of milk white, acid

smell, yellowing color, or muddy oil.

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 Service Manual of G9190 Grader

052 Measurement by Measure

The measure measurement can be used if it’s

difficult to judge by visual examination or hand

touch.

Table 0-20
Judgment criterion
Type of Measure against
Inspection item Dimension
parts Permissible limit out-of-tolerance
(tolerance)
Inside diameter Approximate
+0.02
tolerance 0~-0.02
Bearing Replace
Outside diameter Approximate
－0.04
tolerance 0~-0.02
12％ of tooth
thickness at reference
Tooth thickness Approximate
Gears circle Replace
wear 0~-0.10
(generally taken as
1.2~1.4)
Recommendation:
Outside diameter The tolerance is
Less than lower limit
for common fit taken as T
Common by 0.3T
Replace
parts Recommendation:
Inside diameter The tolerance is
Higher than upper
for common fit taken as T
limit by 0.3T
Fit gap between
Multi-way
valve core and >0.02 Replace
valve
valve bore
Fit gap between
Steering valve core and >0.02 Replace
gear valve sleeve
Stator and rotor >0.08 Replace
Single Fit gap between
stabilizer valve core and >0.02 Replace
valve valve body
Fit gap between
Priority
valve core and >0.02 Replace
valve
valve body

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